Vacuum application of thermal barrier plasma coatings

Coatings are presently applied to Space Shuttle Main Engine (SSME) turbine blades for protection against the harsh environment realized in the engine during lift off-to-orbit. High performance nickel, chromium, aluminum, and yttrium (NiCrAlY) alloy coatings, which are applied by atmospheric plasma spraying, crack and spall off because of the severe thermal shock experienced during start-up and shut-down of the engine. Ceramic coatings of yttria stabilized zirconia (ZrO2-Y2O3) were applied initially as a thermal barrier over coating to the NiCrAlY but were removed because of even greater spalling. Utilizing a vacuum plasma spraying process, bond coatings of NiCrAlY were applied in a low pressure atmosphere of argon/helium, producing significantly improved coating-to-blade bonding. The improved coatings showed no spalling after 40 MSFC burner rig thermal shock cycles, cycling between 1700 and -423 F. The current atmospheric plasma NiCrAlY coatings spalled during 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2-Y2O3 to the turbine blades of first stage high-pressure fuel turbopumps utilizing the vacuum plasma process. The improved thermal barrier coating has successfully passed 40 burner rig thermal shock cycles without spalling. Hot firing in an SSME turbine engine is scheduled for the blades. Tooling was installed in preparation for vacuum plasma spray coating other SSME hardware, e.g., the titanium main fuel valve housing (MFVH) and the fuel turbopump nozzle/stator

A Ground-based Search for Lunar Resources Using High-resolution Imaging in the Infrared

When humans return to the Moon, lunar resources will play an important role in the successful deployment and maintenance of the lunar base. Previous studies have illustrated the abundance of resource materials available on the surface of the Moon, as well as their ready accessibility. Particularly worth considering are the lunar regional (2,000-30,000 sq km) pyroclastic deposits scattered about the lunar nearside. These 30-50-m-thick deposits are composed of fine-grained unconsolidated titanium- and iron-rich mafic glasses and may be used as bulk feedstock for the beneficiation of oxygen, iron, titanium, sulfur, and other solar wind gases, or simply used as is for construction and shielding purposes. A groundbased observing survey of the resource-rich regions on the lunar nearside using a new imaging technique designed to obtain much higher resolution images, and more precise compositional analyses than previously obtainable is proposed

Metallurgy and properties of plasma spray formed materials

Understanding the fundamental metallurgy of vacuum plasma spray formed materials is the key to enhancing and developing full material properties. Investigations have shown that the microstructure of plasma sprayed materials must evolve from a powder splat morphology to a recrystallized grain structure to assure high strength and ductility. A fully, or near fully, dense material that exhibits a powder splat morphology will perform as a brittle material compared to a recrystallized grain structure for the same amount of porosity. Metallurgy and material properties of nickel, iron, and copper base alloys will be presented and correlated to microstructure

Progress in Fabrication of Rocket Combustion Chambers by VPS

Several documents in a collection describe aspects of the development of advanced materials and fabrication processes intended to enable the manufacture of advanced rocket combustion chambers and nozzles at relatively low cost. One concept discussed in most of the documents is the fabrication of combustion-chamber liners by vacuum plasma spraying (VPS) of an alloy of 88Cu/8Cr/4Nb (numbers indicate atomic percentages) -- a concept that was reported in "Improved Alloy for Fabrication of Combustion Chambers by VPS" (MFS-26546). Another concept is the deposition of graded-composition wall and liner structures by VPS in order to make liners integral parts of wall structures and to make oxidation- and thermal-protection layers integral parts of liners: The VPS process is started at 100 percent of a first alloy, then the proportion of a second alloy is increased gradually from zero as deposition continues, ending at 100 percent of the second alloy. Yet another concept discussed in one of the documents is the VPS of oxidation-protection coats in the forms of nickel-and-chromium-containing refractory alloys on VPS-deposited 88Cu/8Cr/4Nb liners

Better VPS Fabrication of Crucibles and Furnace Cartridges

An experimental investigation has shown that by (1) vacuum plasma spraying (VPS) of suitable refractory metal alloys on graphite mandrels, and then (2) heat-treating the VPS alloy deposits under suitable conditions, it is possible to fabricate improved crucibles and furnace cartridges that could be used at maximum temperatures between 1,400 and 1,600 C and that could withstand chemical attack by the materials to be heated in the crucibles and cartridges. Taken by itself, the basic concept of fabricating furnace cartridges by VPS of refractory materials onto graphite mandrels is not new; taken by itself, the basic concept of heat treatment of VPS deposits for use as other than furnace cartridges is also not new; however, prior to this investigation, experimental crucibles and furnace cartridges fabricated by VPS had not been heat treated and had been found to be relatively weak and brittle. Accordingly, the investigation was directed toward determining whether certain combinations of (1) refractory alloy compositions, (2) VPS parameters, and (3) heat-treatment parameters could result in VPS-fabricated components with increased ductility

Method of fabricating a rocket engine combustion chamber

A process for making a combustion chamber for a rocket engine wherein a copper alloy in particle form is injected into a stream of heated carrier gas in plasma form which is then projected onto the inner surface of a hollow metal jacket having the configuration of a rocket engine combustion chamber is described. The particles are in the plasma stream for a sufficient length of time to heat the particles to a temperature such that the particles will flatten and adhere to previously deposited particles but will not spatter or vaporize. After a layer is formed, cooling channels are cut in the layer, then the channels are filled with a temporary filler and another layer of particles is deposited

Thermoregulation in free-ranging Nycteris thebaica (Nycteridae) during winter : no evidence of torpor

Bats are among the most heterothermic mammals, with nearly all species investigated under free-ranging conditions to date exhibiting some degree of daily torpor and/or hibernation. We investigated thermoregulation during late winter by seven Nycteris thebaica in a warm, semi-arid habitat in northern South Africa, using temperature-sensitive transmitters to measure skin temperature (Tskin). Unexpectedly, we found no evidence for any expression of daily torpor or hibernation based on a total of 86 days of data from 7 bats (one male and six females), despite air temperatures as low as ∼10 ◦C. Instead, daytime Tskin was distributed unimodally with most values in the 33–35 ◦C range, and a minimum Tskin of 28.4 ◦C at a roost temperature of 24.6 ◦C. There are several possible reasons why N. thebaica may avoid torpor, including predation in roosts, and the long nightly foraging periods of this species compared to many others.http://www.elsevier.com/locate /mambiohb201

Thermoregulation in desert birds : scaling and phylogenetic variation in heat tolerance and evaporative cooling

Evaporative heat dissipation is a key aspect of avian thermoregulation in hot environments.We quantified variation in avian thermoregulatory performance at high air temperatures (Ta) using published data on body temperature (Tb), evaporative water loss (EWL) and resting metabolic rate (RMR) measured under standardized conditions of very low humidity in 56 arid-zone species. Maximum Tb during acute heat exposure varied from 42.5±1.3°C in caprimulgids to 44.5±0.5°C in passerines. Among passerines, both maximum Tb and the difference between maximum and normothermic Tb decreased significantly with body mass (Mb). Scaling exponents for minimum thermoneutral EWL and maximum EWL were 0.825 and 0.801, respectively, even though evaporative scope (ratio of maximum to minimum EWL) varied widely among species. Upper critical limits of thermoneutrality (Tuc) varied by >20°C and maximumRMR during acute heat exposure scaled toMb 0.75 in both the overall data set and among passerines. The slope of RMR at Ta>Tuc increased significantly with Mb but was substantially higher among passerines, which rely on panting, comparedwith columbids, in which cutaneous evaporation predominates. Our analysis supports recent arguments that interspecific within-taxon variation in heat tolerance is functionally linked to evaporative scope and maximum ratios of evaporative heat loss (EHL) to metabolic heat production (MHP). We provide predictive equations for most variables related to avian heat tolerance. Metabolic costs of heat dissipation pathways, rather than capacity to increase EWL above baseline levels, appear to represent the major constraint on the upper limits of avian heat tolerance.The National Research Foundation and the National Science Foundation.http://jeb.biologists.orgam2022Zoology and Entomolog

The influence of transition metal solutes on dislocation core structure and values of Peierls stress and barrier in tungsten

Several transition metals were examined to evaluate their potential for improving the ductility of tungsten. The dislocation core structure and Peierls stress and barrier of $1/2$ screw dislocations in binary tungsten-transition metal alloys (W$_{1-x}$TM$_{x}$) were investigated using first principles electronic structure calculations. The periodic quadrupole approach was applied to model the structure of $1/2$ dislocation. Alloying with transition metals was modeled using the virtual crystal approximation and the applicability of this approach was assessed by calculating the equilibrium lattice parameter and elastic constants of the tungsten alloys. Reasonable agreement was obtained with experimental data and with results obtained from the conventional supercell approach. Increasing the concentration of a transition metal from the VIIIA group, i.e. the elements in columns headed by Fe, Co and Ni, leads to reduction of the $C^\prime$ elastic constant and increase of elastic anisotropy A=$C_{44}/C^\prime$. Alloying W with a group VIIIA transition metal changes the structure of the dislocation core from symmetric to asymmetric, similar to results obtained for W$_{1-x}$Re$_{x}$ alloys in the earlier work of Romaner {\it et al} (Phys. Rev. Lett. 104, 195503 (2010))\comments{\cite{WRECORE}}. In addition to a change in the core symmetry, the values of the Peierls stress and barrier are reduced. The latter effect could lead to increased ductility in a tungsten-based alloy\comments{\cite{WRECORE}}. Our results demonstrate that alloying with any of the transition metals from the VIIIA group should have similar effect as alloying with Re.Comment: 12 pages, 8 figures, 3 table

Mapping evaporative water loss in desert passerines reveals an expanding threat of lethal dehydration

Extreme high environmental temperatures produce a variety of consequences for wildlife, including mass die-offs. Heat waves are increasing in frequency, intensity, and extent, and are projected to increase further under climate change. However, the spatial and temporal dynamics of die-off risk are poorly understood. Here, we examine the effects of heat waves on evaporative water loss (EWL) and survival in five desert passerine birds across the southwestern United States using a combination of physiological data, mechanistically informed models, and hourly geospatial temperature data. We ask how rates of EWL vary with temperature across species; how frequently, over what areas, and how rapidly lethal dehydration occurs; how EWL and die-off risk vary with body mass; and how die-off risk is affected by climate warming. We find that smaller-bodied passerines are subject to higher rates of mass-specific EWL than larger-bodied counterparts and thus encounter potentially lethal conditions much more frequently, over shorter daily intervals, and over larger geographic areas. Warming by 4 °C greatly expands the extent, frequency, and intensity of dehydration risk, and introduces new threats for larger passerine birds, particularly those with limited geographic ranges. Our models reveal that increasing air temperatures and heat wave occurrence will potentially have important impacts on the water balance, daily activity, and geographic distribution of arid-zone birds. Impacts may be exacerbated by chronic effects and interactions with other environmental changes. This work underscores the importance of acute risks of high temperatures, particularly for small-bodied species, and suggests conservation of thermal refugia and water sources