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This slide presentation reviews the trends in materials' outgassing. The work utilized a database of reports to identify common outgassing chemical species from flight hardware, spacecraft, and ground support equipment (GSE). This work updates an earlier work that reported on chemical analysis from 1970-1978.
The commercial HyperSizer aerospace-composite-material-structure-sizing software has been enhanced by incorporating capabilities for representing coupled thermal, piezoelectric, and piezomagnetic effects on the levels of plies, laminates, and stiffened panels. This enhancement is based on a formulation similar to that of the pre-existing HyperSizer capability for representing thermal effects. As a result of this enhancement, the electric and/or magnetic response of a material or structure to a mechanical or thermal load, or its mechanical response to an applied electric or magnetic field can be predicted. In another major enhancement, a capability for representing micromechanical effects has been added by establishment of a linkage between HyperSizer and Glenn Research Center s Micromechanics Analysis Code With Generalized Method of Cells (MAC/GMC) computer program, which was described in several prior NASA Tech Briefs articles. The linkage enables Hyper- Sizer to localize to the fiber and matrix level rather than only to the ply level, making it possible to predict local failures and to predict properties of plies from those of the component fiber and matrix materials. Advanced graphical user interfaces and database structures have been developed to support the new HyperSizer micromechanics capabilities.
The additive manufacturing (AM) industry has experienced rapid growth in recent decades as industrial interest in the process has grown. Because of this, there are many groups interested in simulations of the AM process. However, the influence of thermophysical property variability on the melt pool geometry during processing of various AM alloys is unclear. The goal of my work at NASA Langley Research Center (LaRC) was to characterize this influence on Ti-6Al-4V during AM processing alongside developing a tool to enable equivalent studies on other AM materials. To facilitate this process, a database tool was developed to contain and organize thermophysical data previously reported by primary sources. The specific thermophysical properties of interest for this study were density, specific heat capacity, and conductivity. Thermal diffusivity was calculated using the other three properties. This data was then fit with a Gaussian distribution and then randomly sampled from using Monte Carlo random value sampling. Using the Rosenthal equation, this sample data was used to simulate the temperature field during additive manufacturing and extract the melt pool geometry. Specifically, the melt pool’s length, width, and depth. This process was repeated an arbitrary number of times, with the default being 1000. Once this information was obtained, histograms were made showing the distributions of the sizes of the melt pool’s length, width, and depth. Representative statistical metrics of the distributions were calculated (mean, standard deviation, and coefficient of variance). This work found that at the simulated processing values, the melt pool’s width and depth had a 5.7% variation while the length had a 3.2% variation. Additionally, a tool was constructed to graph a thermal color map representation of the melt pool for specific, arbitrary values of density, specific heat, and conductivity. This tool allowed for more efficient plotting of individual queries of the thermophysical properties. The results that were observed in the research were that values reported in literature vary and this variance can have a significant impact on the simulation. Predictions of the melt pool’s dimensions show that length has a standard deviation of approximately 6 μm, width has a standard deviation of approximately 5 μm, and depth can vary by approximately 3 μm. Considering the mean sizes of length, width, and depth are 185 μm, 88 μm, and 44 μm respectively, such a deviation is significant. This shows that depth, for example, could be more than 10% larger or smaller than expected. This demonstrates that variability in the reported thermophysical properties are not negligible and should be expected to have an influence on the results of the laser powder bed fusion additive manufacturing process. When simulating this process in the future, measures should be taken to account for this discrepancy and the uncertainty involved
Ni-Ti based shape memory alloys (SMAs) have found wide-spread use in aerospace, automotive, biomedical, and commercial applications owing to their favorable properties and ease of operation. Especially important for many NASA applications is the ability to tune the martensitic transformation temperature of Ni-Ti alloys by varying the alloy composition and processing conditions. Recently, researchers at NASA have compiled an extensive database of shape memory properties of materials, including over 8,000 multi-component Ni-Ti alloys containing 37 different alloying elements. Using this dataset, machine learning models are trained to predict transformation temperatures, hysteresis, and transformation strain with extremely low mean absolute errors. These models are used to learn relationships between shape memory behavior and input parameters in the composition and processing space. ML predictions are validated through new experiments. The combination of an extensive experimental dataset and accurate learning models, together, make our approach highly suitable for the rapid discovery and design of novel SMAs with targeted properties. We are not aware of any current approaches capable of predicting SMA transformation behavior over such a wide range of compositions and processing conditions.
Ni-Ti based shape memory alloys (SMAs) have found wide-spread use in aerospace, automotive, biomedical, and commercial applications owing to their favorable properties and ease of operation. Especially important for many NASA applications is the ability to tune the martensitic transformation temperature of Ni-Ti alloys by varying the composition and processing conditions. Recently, researchers at NASA have compiled an extensive database of shape memory properties of materials, including over 8,000 multi-component Ni-Ti alloys containing 37 different alloying elements. Using this dataset, machine learning models are trained to predict transformation temperatures, hysteresis, and transformation strain with extremely small errors. These models are used to learn relationships between shape memory behavior and input parameters in the composition and processing space. ML predictions are validated through new experiments. The combination of an extensive dataset and accurate learning models, together, make our approach highly suitable for the rapid discovery of novel SMAs with targeted properties.
In most previous work at NASA Ames Research Center, ablation predictions for carbonaceous materials were obtained using a species thermodynamics database developed by Aerotherm Corporation. This database is derived mostly from the JANAF thermochemical tables. However, the CEA thermodynamics database, also used by NASA, is considered more up to date. In this work, the FIAT code was modified to use CEA-based curve fits for species thermodynamics, then analyses using both the JANAF and CEA thermodynamics were performed for carbon and carbon phenolic materials over a range of test conditions. The ablation predictions are comparable at lower heat fluxes where the dominant mechanism is carbon oxidation. However, the predictions begin to diverge in the sublimation regime, with the CEA model predicting lower recession. The disagreement is more significant for carbon phenolic than for carbon, and this difference is attributed to hydrocarbon species that may contribute to the ablation rate.
The objective of the first project involving the HYDRA laser system was to determine what effects, if any, could been seen in the system's measurements when testing was done with objects composed of different materials. Ideally we would like to have seen that the range of measurements were all within the accepted 0.4 millimeter accuracy of the system. Unfortunately our results were not as we had hoped, and there did appear to be some significant difference in the measurements made on objects composed of different materials. The second project is a continuing project at Old Dominion University. The ultimate goal is to develop a medical database that allows a doctor or hospital to keep medical records on line. The current data of the system consisted of one patient whose medical data had been hard coded to allow for a demonstration of the potentials of the system. The short term goal for this summer was to add additional patients to the system for testing, and to eliminate the hard coding of data by creating a database where data could be stored and queried to produce the results seen in the current state.
The Materials Contamination Team of the Environmental Effects Group, Materials, Processes, and Manufacturing Department, has been recognized for its contribution to space flight, including space transportation, space science and flight projects, such as the reusable solid rocket motor, Chandra X-Ray Observatory, and the International Space Station. The Materials Contamination Team s realm of responsibility encompasses all phases of hardware development including design, manufacturing, assembly, test, transportation, launch-site processing, on-orbit exposure, return, and refurbishment if required. Contamination is a concern in the Space Shuttle with sensitivity bondlines and reactive fluid (liquid oxygen) compatibility as well as for sensitive optics, particularly spacecraft such as Hubble Space Telescope and Chandra X-Ray Observatory. The Materials Contamination Team has a variety of facilities and instrumentation capable of contaminant detection identification, and monitoring. The team addresses material applications dealing with environments, including production facilities, clean rooms, and on-orbit exposure. The team of engineers and technicians also develop and evaluates new surface cleanliness inspection technologies. Databases are maintained by the team for proces! materials as well as outgassing and optical compatibility test results for specific environments.
Ground vibration tests are routinely conducted for supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicles, thermoelastic vibration testing techniques are neither well established nor routinely performed. New high-temperature material systems, fabrication technologies and high-temperature sensors expand the opportunities to develop advanced techniques for performing ground vibration tests at elevated temperatures. When high-temperature materials, which increase in stiffness when heated, are incorporated into a hot-structure that contains metallic components that decrease in stiffness when heated, the interaction between those materials can affect the hypersonic flutter analysis. A high-temperature modal survey will expand the research database for hypersonics and improve the understanding of this dual-material interaction. This report discusses the vibration testing of the carbon-silicon carbide Ruddervator Subcomponent Test Article, which is a truncated version of a full-scale hot-structure control surface. Two series of room-temperature modal test configurations were performed in order to define the modal characteristics of the test article during the elevated-temperature modal survey: one with the test article suspended from a bungee cord (free-free) and the second with it mounted on the strongback (fixed boundary). Testing was performed in the NASA Dryden Flight Research Center Flight Loads Laboratory Large Nitrogen Test Chamber.
Post-Scan Interactive Data Display (PSIDD) III is a user-oriented Windows-based system that facilitates the display and comparison of ultrasonic contact data. The system is optimized to compare ultrasonic measurements made at different locations within a material or at different stages of material degradation. PSIDD III provides complete analysis of the primary wave forms in the time and frequency domains along with the calculation of several frequency dependent properties including Phase Velocity and Attenuation Coefficient and several frequency independent properties, like the Cross Correlation Velocity. The system allows image generation on all of the frequency dependent properties at any available frequency (limited by the bandwidth used in the scans) and on any of the frequency independent properties. From ultrasonic contact scans, areas of interest on an image can be studied with regard to underlying raw waveforms and derived ultrasonic properties by simply selecting the point on the image. The system offers various modes of in-depth comparison between scan points. Up to five scan points can be selected for comparative analysis at once. The system was developed with Borland Delphi software (Visual Pascal) and is based on a SQL database. It is ideal for classification of material properties, or location of microstructure variations in materials.
In this study, design requirements for a dynamically viable, four-square type gear test machine are investigated. Variations of four-square type gear test machines have been in use for durability and dynamics testing of both parallel- and cross-axis gear set. The basic layout of these machines is illustrated. The test rig is formed by two gear pairs, of the same reduction ratio, a test gear pair and a reaction gear pair, connected to each other through shafts of certain torsional flexibility to form an efficient, closed-loop system. A desired level of constant torque is input to the circuit through mechanical (a split coupling with a torque arm) or hydraulic (a hydraulic actuator) means. The system is then driven at any desired speed by a small DC motor. The main task in hand is the isolation of the test gear pair from the reaction gear pair under dynamic conditions. Any disturbances originated at the reaction gear mesh might potentially travel to the test gearbox, altering the dynamic loading conditions of the test gear mesh, and hence, influencing the outcome of the durability or dynamics test. Therefore, a proper design of connecting structures becomes a major priority. Also, equally important is the issue of how close the operating speed of the machine is to the resonant frequencies of the gear meshes. This study focuses on a detailed analysis of the current NASA Glenn Research Center gear pitting test machine for evaluation of its resonance and vibration isolation characteristics. A number of these machines as the one illustrated has been used over last 30 years to establish an extensive database regarding the influence of the gear materials, processes surface treatments and lubricants on gear durability. This study is intended to guide an optimum design of next generation test machines for the most desirable dynamic characteristics.
Mechanical behavior of free standing, plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings, including strength, fracture toughness, fatigue, constitutive relation, elastic modulus, and directionality, has been determined under various loading-specimen configurations. This report presents and describes a summary of mechanical properties of the plasma-sprayed coating material to provide them as a design database.
The NASA Thesaurus contains the authorized NASA subject terms used to index and retrieve materials in the NASA Aeronautics and Space Database (NA&SD) and NASA Technical Reports Server (NTRS). The scope of this controlled vocabulary includes not only aerospace engineering, but all supporting areas of engineering and physics, the natural space sciences (astronomy, astrophysics, planetary science), Earth sciences, and the biological sciences. The NASA Thesaurus Data File contains all valid terms and hierarchical relationships, USE references, and related terms in machine-readable form. The Data File is available in the following formats: RDF/SKOS, RDF/OWL, ZThes-1.0, and CSV/TXT.
The need to preserve works and NASA documented articles is done via the collection of various Space Environments and Effects (SEE) related articles. (SEE) contains and lists the various projects that are ongoing, or have been conducted with the help of NASA. The goal of the (SEE) program is to make publicly available the environment technologies that are required to design, manufacture and operate reliable, cost-effective spacecraft for the government and commercial sectors. Of the many projects contained within the (SEE) program the Lunar-E Library and Spacecraft Materials Selector (SMS) have been selected for a more user friendly means to make the tools easily available to the public. This information which is still available required a person or entity to request access from a point of contact at NASA and wait for the requested bundled software DVD via postal service. Redesigning the material presentation and availability has been mapped to a single step process with faster turnaround time via Materials and Processes Technical Information System (MAPTIS) database. This process requires users to register and be verified in order to gain access to the information contained within. Aiding in the progression of making the software tools/documents available required a combination of specialized in-house data gathering software tools and software archeology.
Over the last few decades, advances in high-performance computing, new material characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. In 2016 NASA sponsored a 2040 Vision study (which appeared in 2018) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. The study envisions a cyber-physical-social ecosystem comprised of experimentally verified and validated (V & V) computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of “fit-for-purpose” materials, components, and systems. Consequently, the development of a robust information management system that incorporates (across the full life cycle) both experimental (real data) and virtual data resulting from the application of various simulation tools (at single or multiple length scales), therefore enabling the virtual design and optimization of materials throughout their processing – internal structure – property – performance envelope, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality, and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. This is particularly true when attempting to merge ICME practices with recent additive manufacturing technology which will enable production of the resulting 2040 Vision material and structural designs. At NASA Glenn Research Center we are exploring the future of material science through the use of novel characterization methodologies, high performance computing, and recently an emphasis on integrated computational materials engineering (ICME). Herein, recent efforts to incorporate an Application Table within NASA Glenn Research Center’s ICME Granta MI database is presented. The goal is to provide a place where material and structural application information/requirements can be linked so as to marry the “design the-material” and the “design-with-material” paradigms and thereby enable application-driven design and optimization of materials and structures by providing a central location that links material processing at various length scales to the application’s performance requirements. This paper discusses the specifics of this Application Table as well as best practices and key principles for the development of a robust materials information management system to enable the 2040 Vision integrated materials and structures ecosystem. Furthermore, it presents the intended role of the Application Table in the future of ICME design of “fit-for-purpose” materials, showing the need for a well-established framework that can successfully bridge the gap between the design “the material” and design “with-the-material” paradigms.
Over the last few decades, advances in high-performance computing, new material characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. In 2016 NASA sponsored a 2040 Vision study (which appeared in 2018) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. The study envisions a cyber-physical-social ecosystem comprised of experimentally verified and validated (V & V) computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of “fit-for-purpose” materials, components, and systems. Consequently, the development of a robust information management system that incorporates (across the full life cycle) both experimental (real data) and virtual data resulting from the application of various simulation tools (at single or multiple length scales), therefore enabling the virtual design and optimization of materials throughout their processing – internal structure – property – performance envelope, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality, and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. This is particularly true when attempting to merge ICME practices with recent additive manufacturing technology which will enable production of the resulting 2040 Vision material and structural designs. At NASA Glenn Research Center we are exploring the future of material science through the use of novel characterization methodologies, high performance computing, and recently an emphasis on integrated computational materials engineering (ICME). Herein, recent efforts to incorporate an Application Table within NASA Glenn Research Center’s ICME Granta MI database is presented. The goal is to provide a place where material and structural application information/requirements can be linked so as to marry the “design the-material” and the “design-with-material” paradigms and thereby enable application-driven design and optimization of materials and structures by providing a central location that links material processing at various length scales to the application’s performance requirements. This paper discusses the specifics of this Application Table as well as best practices and key principles for the development of a robust materials information management system to enable the 2040 Vision integrated materials and structures ecosystem. Furthermore, it presents the intended role of the Application Table in the future of ICME design of “fit-for-purpose” materials, showing the need for a well-established framework that can successfully bridge the gap between the design “the material” and design “with-the-material” paradigms.
In the decades since the 1950s, when NASA first developed mechanical impact testing of materials, researchers have continued efforts to gain a better understanding of the chemical, mechanical, and thermodynamic nature of the phenomenon. The impact mechanism is a real combustion ignition mechanism that needs understanding in the design of an oxygen system. The use of test data from this test method has been questioned due to lack of a clear method of application of the data and variability found between tests, material batches, and facilities. This effort explores a large database that has accumulated over a number of years and explores its overall nature. Moreover, testing was performed to determine the statistical nature of the test procedure to help establish sample size guidelines for material characterization. The current method of determining a pass/fail criterion based on either light emission or sound report or material charring is questioned.
Wire integrity has become an area of concern to the aerospace community including DoD, NASA, FAA, and Industry. Over time and changing environmental conditions, wire insulation can become brittle and crack. The cracks expose the wire conductor and can be a source of equipment failure, short circuits, smoke, and fire. The technique of using the ultrasonic phase spectrum to extract material properties of the insulation is being examined. Ultrasonic guided waves will propagate in both the wire conductor and insulation. Assuming the condition of the conductor remains constant then the stiffness of the insulator can be determined by measuring the ultrasonic guided wave velocity. In the phase spectrum method the guided wave velocity is obtained by transforming the time base waveform to the frequency domain and taking the phase difference between two waveforms. The result can then be correlated with a database, derived by numerical model calculations, to extract material properties of the wire insulator. Initial laboratory tests were performed on a simple model consisting of a solid cylinder and then a solid cylinder with a polymer coating. For each sample the flexural mode waveform was identified. That waveform was then transformed to the frequency domain and a phase spectrum was calculated from a pair of waveforms. Experimental results on the simple model compared well to numerical calculations. Further tests were conducted on aircraft or mil-spec wire samples, to see if changes in wire insulation stiffness can be extracted using the phase spectrum technique.