Search NASA⌕ Search

SEARCH · Search NASA

Results for “flake”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

NSTAR Extended Life Test Discharge Chamber Flake Analysis

The Extended Life Test (ELT) of the NASA Solar Electric Propulsion Technology Readiness (NSTAR) ion thruster was concluded after 30,352 hours of operation. The ELT was conducted using the Deep Space 1 (DS1) back-up flight engine, a 30 cm diameter xenon ion thruster. Post-test inspection of the ELT engine revealed numerous contaminant flakes distributed over the bottom of the cylindrical section of the anode within the discharge chamber (DC). Extensive analyses were conducted to determine the source of the particles, which is critical to the understanding of degradation mechanisms of long life ion thruster operation. Analyses included: optical microscopy (OM) and particle length histograms, field emission scanning electron microscopy (FESEM) combined with energy dispersive spectroscopy (EDS), and atomic oxygen plasma exposure tests. Analyses of the particles indicate that the majority of the DC flakes consist of a layered structure, typically with either two or three layers. The flakes comprising two layers were typically found to have a molybdenum-rich (Mo-rich) layer on one side and a carbon-rich (C-rich) layer on the other side. The flakes comprising three layers were found to be sandwich-like structures with Mo-rich exterior layers and a C-rich interior layer. The presence of the C-rich layers indicates that these particles were produced by sputter deposition build-up on a surface external to the discharge chamber from ion sputter erosion of the graphite target in the test chamber. This contaminant layer became thick enough that particles spalled off, and then were electro-statically attracted into the ion thruster interior, where they were coated with Mo from internal sputter erosion of the screen grid and cathode components. Atomic oxygen tests provided evidence that the DC chamber flakes are composed of a significant fraction of carbon. Particle size histograms further indicated that the source of the particles was spalling of carbon flakes from downstream surfaces. Analyses of flakes taken from the downstream surface of the accelerator grid provided additional supportive information. The production of the downstream carbon flakes, and hence the potential problems associated with the flake particles in the ELT ion thruster engine is a facility induced effect and would not occur in the space environment.

deGroh, Kim K.↗
NASA NTRS1973

On the manganese content of cosmic flakes from deep-sea sediments

Cosmic flakes belong to the category of cosmic microparticles. They occur together with cosmic spherules in sediments. These flakes appear to represent ablation products of iron meteorites burnt away during the passage of a meteorite through the atmosphere by friction against air molecules. Microprobe analyses of flakes from deep sea deposits proved the particles to consist of magnetite which in most cases had been altered into maghemite in the outer zones. This is in agreement with the assumption that they represent fragments of fusion crust of iron meteorites. Most of the flakes, however, contained a small percentage of manganese. This element is not a common constituent of iron meteorites. An attempt is made to explain the presence of manganese in flakes and its absence in cosmic spherules.

Utech, K.↗
NASA NTRS1986

Apparatus for producing diamond-like carbon flakes

A vacuum arc from a spot at the face of a graphite cathode to a graphite anode produces a beam of carbon ions and atoms. A carbon coating from this beam is deposited on an ion beam sputtered target to produce diamond-like carbon flakes. A graphite tube encloses the cathode, and electrical isolation is provided by an insulating sleeve. The tube forces the vacuum arc spot to be confined to the surface on the outermost end of the cathode. Without the tube the arc spot will wander to the side of the cathode. This spot movement results in low rates of carbon deposition, and the properties of the deposited flakes are more graphite-like than diamond-like.

Banks, Bruce A.↗
NASA NTRS1984

Diamondlike flake composites

A carbon coating is vacuum arc deposited on a smooth surface of a target which is simultaneously ion beam sputtered. The bombarding ions have sufficient energy to create diamond bonds. Spalling occurs as the carbon deposit thickens. The resulting diamond-like carbon flakes are mixed with a binder or matrix material to form a composite material having improved thermal, electrical, mechanical, and tribological properties when used in aerospace structures and components.

Banks, B. A.↗
NASA NTRS1984

Directional solidification of flake and nodular cast iron during KC-135 low-g maneuvers

Alloys solidified in a low-gravity environment can, due to the elimination of sedimentation and convection, form unique and often desirable microstructures. One method of studying the effects of low-gravity (low-g) on alloy solidification was the use of the NASA KC-135 aircraft flying repetitive low-g maneuvers. Each maneuver gives from 20 to 30 seconds of low-g which is between about 0.1 and 0.001 gravity. A directional solidification furnace was used to study the behavior of off eutectic composition case irons in a low-g environment. The solidification interface of hypereutectic flake and spheroidal graphite case irons was slowly advanced through a rod sample, 5 mm in diameter. Controlled solidification was continued through a number of aircraft parabolas. The known solidification rate of the sample was then correlated with accelerometer data to determine the gravity level during solidification for any location of the sample. The thermal gradient and solidification rate were controlled independently. Samples run on the KC-135 aircraft exhibited bands of coarser graphite or of larger nodules usually corresponding to the regions solidified under low-g. Samples containing high phosphorous (used in order to determine the eutectic cell) exhibited larger eutectic cells in the low-g zone, followed by a band of coarser graphite.

Curreri, P. A.↗
NASA NTRS1985

Diamondlike flakes

A carbon coating was vacuum arc deposited on a smooth surface of a target which was simultaneously ion beam sputtered. The bombarding ions have sufficient energy to create diamond bonds. Spalling occurs as the carbon deposit thickens. The resulting diamond like carbon flakes improve thermal, electrical, mechanical, and tribological properties when used in aerospace structures and components.

Banks, B. A.↗
NASA NTRS1987

Directional solidification of flake and spheroidal graphite cast iron in low and normal gravity environment

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.

Hendrix, J. C.↗
NASA NTRS1985

Study on effects of powder and flake chemistry and morphology on the properties of Al-Cu-Mg-X-X-X powder metallurgy advanced aluminum alloys

The effects of alloy chemistry and particulate morphology on consolidation behavior and consolidated product properties in rapid solidification processed, powder-metallurgical Al-3Li-1.5Cu-1Mg-0.5Co-0.2Zr and Al-4.4Cu-1.5Mg-Fe-Ni-0.2Zr extrusions and forgings were studied. Microstructures and mechanical properties of both alloys are largely unaffected by particulate production method (vacuum atomization, ultrasonic atomization, or twin-roller quenching) and by particulate solidification rates between 1000 and 100,000 K/s. Consolidation processing by canning, cold compaction, degassing, and hot extrusion is sufficient to yield mechanical properties in the non-Li-containing alloy extrusions which are similar to those of 7075-Al, but ductilities and fracture toughnesses are inferior owing to poor interparticle bonding caused by lack of a vacuum-hot-pressing step during consolidation. Mechanical properties of extrusions are superior to those of forgings owing to the stronger textures produced by the more severe hot working during extrusion. The effects on mechanical properties of dispersoid size and volume fraction, substructural refinement, solid solution strengthening by Mg, and precipitate size and distribution are elucidated for both alloy types.

Meschter, P. J.↗
NASA NTRS1986

Study on effects of powder and flake chemistry and morphology on the properties of Al-Cu-Mg-X-X-X powder metallurgy advanced aluminum alloys

A study was conducted: (1) to develop rapid solidification processed (RSP) dispersoid-containing Al-3Cu-2Li-1Mg-0.2Zr alloys as substitutes for titanium alloys and commercial 2XXX aluminum alloys for service to at least 150 C; and (2) to develop RSP Al-4Li-Cu-Mg-Zr alloys as substitutes for high-strength commercial 7XXX alloys in ambient-temperature applications. RSP Al-3Cu-2Li-1Mg-0.2Zr alloys have density-normalized yield stresses at 150 C up to 52% larger than that of 2124-T851 and up to 30% larger than that of Ti-6Al-4V. Strength at 150 C in these alloys is provided by thermally stable delta' (Al3Li), T1 (Al2LiCu), and S' (Al2CuMg) precipitates. Density-normalized yield stresses of RSP Al-3Cu-2Li-1Mg-0.2Zr alloys are up to 100% larger than that of 2124-T851 and equivalent to that of Al-8Fe-4Ce at 260 C. Strength in the RSP alloys at 260 C is provided by incoherent dispersoids and subboundary constituent particles such as T1 and S. The RSP alloys are attractive substitutes in less than or = 100-h exposures for 2xxx and Al-4Fe-Ce alloys up to 260 C and for titanium alloys up to 150 C. RSP Al-4Li-Cu-Mg-Zr alloys have ambient-temperature yield and ultimate tensile stresses similar to that of 7050-T7651, and are 14% less dense. RSP Al-4Li-0.5Cu-1.5Mg-0.2Zr has a 20% higher specific yield stress, 40% higher specific elastic modulus, and superior corrosion resistance compared to the properties of 7050-T7651. Strength in the Al-4Li-Cu-Mg-Zr alloy class is primarily provided by the substructure and delta' precipitates and is independent of Cu:Mg ratio. Improvements in fracture toughness and transverse-orientation properties in both alloy classes depend on improved melt practices to eliminate oxide inclusions which are incorporated into the consolidated forms.

Meschter, P. J.↗
NASA NTRS2013

Carbon Nanotube Microarrays Grown on Nanoflake Substrates

This innovation consists of a new composition of matter where single-walled carbon nanotubes (SWNTs) are grown in aligned arrays from nanostructured flakes that are coated in Fe catalyst. This method of growth of aligned SWNTs, which can yield well over 400 percent SWNT mass per unit substrate mass, exceeds current yields for entangled SWNT growth. In addition, processing can be performed with minimal wet etching treatments, leaving aligned SWNTs with superior properties over those that exist in entangled mats. The alignment of the nanotubes is similar to that achieved in vertically aligned nanotubes, which are called "carpets. " Because these flakes are grown in a state where they are airborne in a reactor, these flakes, after growing SWNTs, are termed "flying carpets. " These flakes are created in a roll-to-roll evaporator system, where three subsequent evaporations are performed on a 100-ft (approx. =30-m) roll of Mylar. The first layer is composed of a water-soluble "release layer, " which can be a material such as NaCl. After depositing NaCl, the second layer involves 40 nm of supporting layer material . either Al2O3 or MgO. The thickness of the layer can be tuned to synthesize flakes that are larger or smaller than those obtained with a 40-nm deposition. Finally, the third layer consists of a thin Fe catalyst layer with a thickness of 0.5 nm. The thickness of this layer ultimately determines the diameter of SWNT growth, and a layer that is too thick will result in the growth of multiwalled carbon nanotubes instead of single-wall nanotubes. However, between a thickness of 0.5 nm to 1 nm, single-walled carbon nanotubes are known to be the primary constituent. After this three-layer deposition process, the Mylar is rolled through a bath of water, which allows catalyst-coated flakes to detach from the Mylar. The flakes are then collected and dried. The method described here for making such flakes is analogous to that which is used to make birefringent ink that is coated on U.S. currency. After deposition, the growth is carried out in a hot-filament chemical vapor deposition apparatus. A tungsten hot filament placed in the flow of H2 at a temperature greater than 1,600 C creates atomic hydrogen, which serves to reduce the Fe catalyst into a metallic state. The catalyst can now precipitate SWNTs in the presence of growth gases. The gases used for the experiments reported are C2H2, H2O, and H2, at rates of 2, 2, and 400 standard cubic centimeters per minute (sccm), respectively. In order to retain the flakes, a cage is constructed by spot welding stainless steel or copper mesh to form an enclosed area, in which the flakes are placed prior to growth. This allows growth gases and atomic hydrogen to reach the flakes, but does not allow the flakes, which rapidly nucleate SWNTs, to escape from the cage.

Schmidt, Howard K.↗
NASA NTRS2006

Orbital Debris Shape and Orientation Effects on Impact Damage to Shuttle Tiles

Taking the damage results from a previous paper as a guide, and using a tile model created for the STS-107 accident investigation, we used the SPHC hydrodynamic code to evaluate the probable worst-case impact effects of flat, rectangular, "flake-shaped," orbital debris particles on Space Shuttle thermal tiles. We compared the damage from flakes with that produced by spheres. The flakes and spheres were sized according to a "characteristic length" (Lc) derived from radar cross-section measurements, and embodied in the NASA Standard Breakup Model (SBM). Impacts were simulated at near-normal obliquity, at 12 km/sec. We modeled the worst-case flake orientation: a corner-on impact, an orientation we term a "Face A-B" impact. Results of our simulations indicate that flake impactors are less damaging than spheres of the same Lc. Since spherical impactors have been assumed in analyses of shuttle orbital debris impact risk, we find that these risks may have been overestimated. This work represents a preliminary second step, i.e., a follow-on to [1], in developing a sensitivity analysis for the expected range of effects on damage considering spherical vs. non-spherical impactors, as recommended by the Institute for Defense Analyses (IDA) report to the Columbia Accident Investigation Board.

Evans, Steven W.↗
NASA NTRS1973

Influence of various surface pretreatments on adherence of sputtered molybdenum disulfide to silver, gold, copper, and bronze

Solid film lubricants of radio frequency sputtered molybdenum disulfide (MoS2) were applied to silver, gold, copper, and bronze surfaces that had various pretreatments (mechanical polishing, sputter etching, oxidation, and sulfurization). Optical and electron transmission micrographs and electron diffraction patterns were used to interpret the film formation characteristics and to evaluate the sputtering conditions in regard to the film and substrate compatibility. Sputtered MoS2 films flaked and peeled on silver, copper, and bronze surfaces except when the surfaces had been specially oxidized. The flaking and peeling was a result of sulfide compound formation and the corresponding grain growth of the sulfide film. Sputtered MoS2 films showed no peeling and flaking on gold surfaces regardless of surface pretreatment.

Spalvins, T.↗
NASA NTRS1974

Structure and properties of a splat cooled 2024 aluminum alloy

In the investigation the alloy was melted, heated to 750 C, and atomized into fine droplets. The droplets were rapidly quenched against a heavy copper disk rotating at 1725 rpm. The resultant splat cooled flakes were screened. Three flake sizes were finally separated. Flakes of each size were separately processed. The characteristics of the splat cooling process and the properties of the obtained products are discussed. Splat cooling against a metallic substrate permits cooling rates up to about 1,000,000 deg C/sec. Increases in yield strength and tensile strength of 14 to 19% are observed for the splat products. Other improvements are connected with increases in fatigue life and stress rupture performance.

Lebo, M.↗
NASA NTRS1983

Sputtering phenomena in ion thrusters

Sputtering effects in discharge chambers of ion thrusters are lifetime limiting in basically two ways: (1) ion bombardment of critical thruster components at energies sufficient to cause sputtering removes significant quantities of material; enough to degrade operation through adverse dimensional changes or possibly lead to complete component failure, and (2) metals sputtered from these intensely bombarded components are deposited in other locations as thin films and subsequently flake or peel off; the flakes then lodge elsewhere in the discharge chamber with the possibility of providing conductive paths for short circuiting of thruster components such as the ion optics. This experimental work has concentrated in two areas. The first has been to operate thrusters for multi-hour periods and to observe and measure the films found inside the thruster. The second was to simulate the environment inside the discharge chamber of the thruster by means of a dual ion beam system. Here, films were sputter deposited in the presence of a second low energy bombarding beam to simulate film deposition on thruster interior surfaces that undergo simultaneous sputtering and deposition. Mo presents serious problems for use in a thruster as far as film deposition is concerned. Mo films were found to be in high stress, making them more likely to peel and flake.

Robinson, R. S.↗
NASA NTRS1985

Graphite Formation in Cast Iron

In the first phase of the project it was proven that by changing the ratio between the thermal gradient and the growth rate for commercial cast iron samples solidifying in a Bridgman type furnace, it is possible to produce all types of graphite structures, from flake to spheroidal, and all types of matrices, from ferritic to white at a certain given level of cerium. KC-135 flight experiments have shown that in a low-gravity environment, no flotation occurs even in spheroidal graphite cast irons with carbon equivalent as high as 5%, while extensive graphite flotation occurred in both flake and spheroidal graphite cast irons, in high carbon samples solidified in a high gravity environment. This opens the way for production of iron-carbon composite materials, with high carbon content (e.g., 10%) in a low gravity environment. By using KC-135 flights, the influence of some basic elements on the solidification of cast iron will be studied. The mechanism of flake to spheroidal graphite transition will be studied, by using quenching experiments at both low and one gravity for different G/R ratios.

Stefanescu, D. M.↗