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Improved method of fabricating cooled graphite-lined thrust chamber has been developed. Layer of nickel is electrodeposited onto outer surface of machined and contoured graphite liner. Coolant passages are machined into nickel layer, filled with wax, outer shell electroformed over this, and wax removed. Tests in flox/methane rocket engine were completely successful.
Combustion of metals in carbon dioxide is a promising source of energy for propulsion on Mars. This approach is based on the ability of some metals (e.g. Mg, Al) to burn in CO2 atmosphere and suggests use of the Martian carbon dioxide as an oxidizer in jet or rocket engines. Analysis shows that CO2/metal propulsion will reduce significantly the mass of propellant transported from Earth for long-range mobility on Mars and sample return missions. Recent calculations for the near-term missions indicate that a 200-kg ballistic hopper with CO2/metal rocket engines and a CO2 acquisition unit can perform 10-15 flights on Mars with the total range of 10-15 km, i.e. fulfill the exploration program typically assigned for a rover. Magnesium is currently recognized as a candidate fuel for such engines owing to easy ignition and fast burning in CO2. Aluminum may be more advantageous if a method for reducing its ignition temperature is found. Coating it by nickel is one such method. It is known that a thin nickel layer of nickel on the surface of aluminum particles can prevent their agglomeration and simultaneously facilitate their ignition, thus increasing the efficiency of aluminized propellants.
Combustion of metals in carbon dioxide is a promising source of energy for propulsion on Mars. This approach is based on the ability of some metals (e.g. Mg, Al) to burn in CO2 atmosphere and suggests use of the Martian carbon dioxide as an oxidizer in jet or rocket engines. Analysis shows that CO2/metal propulsion will reduce significantly the mass of propellant transported from Earth for long-range mobility on Mars and sample return missions. Recent calculations for the near-term missions indicate that a 200-kg ballistic hopper with CO2/metal rocket engines and a CO2 acquisition unit can perform 10-15 flights on Mars with the total range of 10-15 km, i.e. fulfill the exploration program typically assigned for a rover. Magnesium is currently recognized as a candidate fuel for such engines owing to easy ignition and fast burning in CO2. Aluminum may be more advantageous if a method for reducing its ignition temperature is found. Coating it by nickel is one such method. It is known that a thin nickel layer of nickel on the surface of aluminum particles can prevent their agglomeration and simultaneously facilitate their ignition, thus increasing the efficiency of aluminized propellants. Combustion of single Ni-coated Al particles in different gas environments (O2, CO2, air) was studied using electrodynamic levitation and laser ignition. It was shown that the combustion mechanisms depend on the ambient atmosphere. Combustion in CO2 is characterized by the smaller size and lower brightness of flame than in O2, and by phenomena such as micro-flashes and fragment ejection. The size and brightness of flame gradually decrease as the particle burns.
Electrical discharge machining /EDM/ damaged layer can be effectively removed from Rene 41, Inconel 625, Inconel 718, and Monel K-500 by abrasive-grit blasting or electropolishing /at room temperature/ at a current density of 5A/inches squared in a water solution of phosphoric and sulfuric acids.
A panel is described for selectively absorbing solar energy comprising an aluminum substrate. A zinc layer was covered by a layer of nickel and an outer layer of solar energy absorbing nickel oxide or a copper substrate with a nickel layer. A layer of solar energy absorbing nickel oxide distal from the copper substrate was included. A method for making these panels is disclosed.
We have designed a multiple-layer coating which selectively reflects 834 A radiation and suppresses 1025 A and 1216 A radiation. The structure of the coating material consists of a very thin (50-150 A) metal (nickel) layer, on top of a semitransparent dielectric material (magnesium fluoride), over an aluminum substrate. Three such coatings were produced at NASA Goddard Space Flight Center using an existing coating facility which is not optimized for thin coatings. In spite of such fabrication difficulties, we have obtained encouraging results.
Procedure devised to improve repair of hole through nickel-alloy layer and nickel layer that are parts of larger structure, and separated by thin gap. Involves established techniques of electroforming, grinding, filling, and masking. Conductive coat serves as weak fracture layer between repaired layers.
Porosity test goes for free ride with cryogenic adhesion test. Frosted areas marked so pores found after frost disappears. Plating stylus used for local repair of nickel layer.
A method of forming an environmental resistant thermal barrier coating on a copper alloy is disclosed. The steps include cleansing a surface of a copper alloy, depositing a bond coat on the cleansed surface of the copper alloy, depositing a NiAl top coat on the bond coat and consolidating the bond coat and the NiAl top coat to form the thermal barrier coating. The bond coat may be a nickel layer or a layer composed of at least one of copper and chromium-copper alloy and either the bond coat or the NiAl top coat or both may be deposited using a low pressure or vacuum plasma spray.
Corrosion of complex electronic systems is a growing and expensive concern. New materials and technology are constantly being introduced to increase performance of devices. There are many factors that can induce a corrosive environment during the various stages of manufacturing, processing, transport, and storage of these devices. The scope of this paper was to identify potential causes for the corrosion failure of optocoupler batches being used in launch applications. Optical microscope with surface profile measurements, scanning electron microscopy (SEM), energy-dispersive X-ray spectrometry (EDS), and X-ray photoelectron spectroscopy (XPS) were used to identify and analyze the source of these failure. These studies revealed that the loss of adhesion between the electrolytic plated gold and nickel layers is the critical area that traps impurity ions into the chip allowing for blisters to form along the pins of the optocoupler.
A method for making panels which selectively absorb solar energy is disclosed. The panels are comprised of an aluminum substrate, a layer of zinc thereon, a layer of nickel over the zinc layer and an outer layer of solar energy absorbing nickel oxide or a copper substrate with a layer of nickel thereon and a layer of solar energy absorbing nickel oxide distal from the copper substrate.
The concept of using layered separators to achieve the required electrolyte retention and bubble pressure fo nickel-hydrogen cells was evaluated in a boilerplate cell test. Zircar cloth, polyethylene paper and polypropylene felt were combined with a layer of radiation-grafted polyethylene film to achieve the required properties. Three cells of each layered separator were built and tested by characterization cycling and by low earth orbit cycling for 5000 cycles at 80 percent DOD. Three cells containing asbestos separators were used as the reference.
A composite material suitable for providing insulation for the nozzle structure of the Space Shuttle and other similar surfaces is disclosed. The composite layer is comprised of an outer skin layer of nickel chromium and an interleaved inner region comprising a top layer of nickel chromium foil which acts as a primary convective shield. There are at least two layers of alumina batting adjacent to the layers of silicon carbide fabric. An additional layer of nickel chromium foil is used as a secondary convective shield. The composite is particularly advantageous for use as nozzle insulation because of its ability to withstand high reentry temperatures, its flexibility, oxidation resistance, low conductivity, and light weight.
Two experimental contact systems were examined and compared to a baseline contact system consisting of evaporated layers of titanium, palladium, and silver and an electroplated layer of copper. The first experimental contact system consisted of evaporated layers of titanium, nickel, and copper and an electroplated layer of copper. This system performed as well as the baseline system in all respects, including its response to temperature stress tests, to a humidity test, and to an accelerated aging test. In addition, the cost of this system is estimated to be only 43 percent of the cost of the baseline system at a production level of 25 MW/year. The second experimental contact system consisted of evaporated layers of nickel and copper and an electroplated layer of copper. Cells with this system show serious degradation in a temperature stress test at 350 C for 30 minutes. Auger electron spectroscopy was used to show that the evaporated nickel layer is not an adequate barrier to copper diffusion even at temperatures as low as 250 C. This fact brings into question the long-term reliability of this contact system.
Reference electrodes made of nickel cores with surface layers of nickel chloride proposed for use in molten sodium tetracholoroaluminate electrolytes in experimental sodium/nickel chloride electrochemical cells. These and other sodium/metal chloride cells investigated for use in several applications, including powering electric vehicles and leveling loads in power-distribution systems. Offers potential advantages of greater durability, greater stability and reproducibility of electrochemical potentials, less sensitivity of electrochemical potentials to variations in compositions of electrolytes, and greater compatibility with cathodes, made of nickel chloride.
The manufacture and properties of a grating intended for extrasolar X-ray studies are described. The manufacturing process uses a split laser beam exposing an interference pattern on the photoresist-coated glass plated with a nickel parting layer. The grating, supporting structure, and mounting frame are electrodeposited on the nickel parting layer, and the final product is lifted from the glass substrate by selective etching of the nickel. A model was derived which relates the number of counts received in a given order m as a function of photon wavenumber. A 4-deg beam line was used to measure the efficiencies of gold transmission gratings for diffraction of X-rays in the range of 45 to 275 eV. The experimental results are in good agreement with model calculations.
A process for the spray-application of a strongly adhesive, thick antifriction layer on titanium and titanium alloys is proposed. The titanium/titanium alloy component to be coated is first subjected to cleaning in a pickling bath with reducing additives and sand-blasting, then coated with an intermediate layer of nickel, after which the final layer is applied. The formation of TiNi at the interface ensures strong bonding of the antifriction layer.
A 50 Ampere-hour nickel-hydrogen cell with a single-layer Zircar separator stack design was fully charged and then discharged at a 2C current rate to an end voltage of 1 volt. This extreme test resulted in high temperatures which were recorded at three locations on the cell, i.e., the cell wall, the boss (barrel of the compression seal), and a terminal. The results provide new information about the high-temperature and high-discharge-rate capabilities of nickel-hydrogen cells. This information also adds to the growing data base for single-layer zirconium-oxide-cloth (Zircar) separator cell designs.