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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.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Creep Testing of High-Temperature Cu-8 Cr-4 Nb Alloy Completed

A Cu-8 at.% Cr-4 at.% Nb (Cu-8 Cr-4 Nb) alloy is under development for high-temperature, high heatflux applications, such as actively cooled, hypersonic vehicle heat exchangers and rocket engine combustion chambers. Cu-8 Cr-4 Nb offers a superior combination of strength and conductivity. It has also shown exceptional low-cycle fatigue properties. Following preliminary testing to determine the best processing route, a more detailed testing program was initiated to determine the creep lives and creep rates of Cu-8 Cr-4 Nb alloy specimens produced by extrusion. Testing was conducted at the NASA Lewis Research Center with constant-load vacuum creep units. Considering expected operating temperatures and mission lives, we developed a test matrix to accurately determine the creep properties of Cu-8 Cr-4 Nb between 500 and 800 C. Six bars of Cu-8 Cr-4 Nb were extruded. From these bars, 54 creep samples were machined and tested. The figure on the left shows the steady-state, or second-stage, creep rates for the samples. Comparison data for NARloy-Z (Cu-3 wt % Ag-0.5 wt % Zr), the alloy currently used in combustion chamber liners, were not unavailable. Therefore the steady-state creep rates for Cu at similar temperatures are presented. As expected, in comparison to pure Cu, the creep rates for Cu-8 Cr-4 Nb are much lower. The lives of the samples are presented in the figure on the right. As shown, Cu-8 Cr-4 Nb at 800 C is comparable to NARloy-Z at 648 C. At equivalent temperatures, Cu-8 Cr-4 Nb enjoys a 20 to 50 percent advantage in stress for a given life and 1 to 3 orders of magnitude greater life at a given stress. The improved properties allow for design tradeoffs and improvements in new and existing heat exchangers such as the next generation of combustion chamber liners. Average creep rates for Cu-8 Cr-4 Nb and pure Cu are shown. Average creep lives for Cu-8 Cr- 4 Nb and NARloy-Z are also shown. Currently, two companies are interested in the commercial usage of the Cu-8 Cr-4 Nb alloy. The Rocketdyne Division of Rockwell International is conducting independent testing to analyze the properties for their projected needs in advanced rocket engine applications. Metallamics, a company based in Traverse City, Michigan, is entering into a Space Act Agreement to evaluate and test Cu-Cr-Nb alloys as materials for welding electrodes that are used in robotic welding operations. Creep rate is one of the alloy properties that determines the degree to which a welding electrode will mushroom or expand at the tip. A material with a low creep rate will resist mushrooming and give the electrode a longer life, minimizing downtime. This application holds the potential for large-scale usage of the alloy in the automotive and other industries. Success here would dramatically decrease the cost of the alloy and increase availability for aerospace applications.

Source record↗
DOE OSTI2025

Microstructure-Based Understanding of High-Temperature Deformation Behaviors in Laser Powder Bed Fusion (LPBF) 316H Stainless Steel

This report presents the results of high-temperature mechanical property testing and microstructural analysis of laser powder bed fusion (LPBF) 316H stainless steel (SS) conducted during Fiscal Year 2025 (FY25) under the U.S. Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program. The study builds upon prior work by expanding the mechanical property test matrix and advancing a microstructure-based mechanistic understanding of LPBF 316H SS performance, with a focus on the solution annealed (SA, 1100°C for 1 hour) materials. High-temperature tension, creep, fatigue, and creep-fatigue tests were performed. Thermal aging studies were conducted. Advanced characterization techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), and high-energy synchrotron X-ray diffraction, were employed to investigate the microstructural evolution during thermal aging and mechanical testing. It was discovered that the as-built (AB) LPBF 316H SS exhibited precipitation kinetics during thermal aging that are 10–100 times faster than its wrought counterpart due to the presence of high densities of preferred nucleation sites, while the precipitation kinetics in SA LPBF 316H was under investigation. The accelerated precipitation of embrittling phases such as sigma phase in LPBF 316H SS compared to its wrought counterpart led to significant impacts on creep ductility. The influence of laser printing parameters and build orientations on fatigue and creep-fatigue performance was observed. In assessing the creep-fatigue performance, it was discovered that the SA LPBF 316H samples failed in less than 200 cycles under 595°C, 0.5% (strain amplitude) with a 60-minute hold time. This work establishes a mechanistic framework for predicting the long-term behavior of LPBF 316H SS, supporting its rapid qualification under the ASME BPVC. The findings contribute to the broader goal of enabling the deployment of advanced materials in next-generation nuclear energy systems. An outlook for FY26 work, including continued aging studies, mechanical testing, and microstructural characterization, is provided.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Characterization testing of a 40 ampere hour bipolar nickel-hydrogen battery

Extensive characterization testing has been done on a second 40-ampere hour (A h), 10-cell, bipolar nickel-hydrogen (Ni-H2) battery, to study the effects of operating parameters such as charge and discharge rates, temperature, and pressure on capacity, A h and watt hour (W h) efficiencies, and end-of-charge and midpoint discharge voltages. Testing to date has produced many interesting results, with the battery performing well throughout the test matrix except during the high-rate (5 C and 10 C) discharges, where poorer than expected results were observed. The exact cause of this poor performance is, as yet, unknown. Small scale 2 in. x 2 in. battery tests are to be used in studying this problem. Low earth orbit cycle life testing at a 40-percent depth of discharge and 10 C is scheduled to follow the characterization testing.

Brewer, Jeffrey C.↗
NASA NTRS2003

Life Cycle Testing of Viscoelastic Material for Hubble Space Telescope Solar Array 3 Damper

During the March 2002 Servicing Mission by Space Shuttle (STS 109), the Hubble Space Telescope (HST) was refurbished with two new solar arrays that now provide all of its power. These arrays were built with viscoelastic/titanium dampers, integral to the supporting masts, which reduce the interaction of the wing bending modes with the Telescope. Damping of over 3% of critical was achieved. To assess the damper s ability to maintain nominal performance over the 10-year on-orbit design goal, material specimens were subjected to an accelerated life test. The test matrix consisted of scheduled events to expose the specimens to pre-determined combinations of temperatures, frequencies, displacement levels, and numbers of cycles. These exposure events were designed to replicate the life environment of the damper from fabrication through testing to launch and life on-orbit. To determine whether material degradation occurred during the exposure sequence, material performance was evaluated before and after the accelerated aging with complex stiffness measurements. Based on comparison of pre- and post-life-cycle measurements, the material is expected to maintain nominal performance through end of life on-orbit. Recent telemetry from the Telescope indicates that the dampers are performing nominally.

Maly, Joseph R.↗
NASA NTRSDate not supplied

Mars Sample Return, Sample Retrieval Lander, Reaction Control System Jet Interaction Supersonic Wind Tunnel Test Overview with CFD Predictions

NASA's Mars Sample Return campaign will be launching several missions over the next decade that will work together to return rock samples from Mars back to Earth. The Sample Retrieval Lander (SRL) will deliver the Mars Ascent Vehicle and fetch rover to the surface of Mars in 2006. Rock samples collected by the Mars 2020 Perseverance rover, landing in early 2021, will be loaded on the the ascent vehicle to be launched into Mars orbit for retrieval by yet another spacecraft. The Sample Retrieval Lander will be a blunt entry capsule similar to past Mars entry vehicles like Mars Science Laboratory and Viking. The vehicle will fly a guided entry, using a small lift vector produced by a non-zero trim angle of attack to eliminate downrange and crossrange position errors at the point of parachute deploy. This energy and heading management is achieved with a reaction control system (RCS) that directs the bank angle of the vehicle and also minimizes unwanted capsule dynamics. The reaction control system and control design is based on the Mars Science Laboratory and Mars 2020 RCS systems. However, due to packaging constraints, the backshell of this new entry vehicle has a different geometry than those earlier designs. To certify the RCS system for flight the project must characterize the jet plume interactions with the capsule backshell that could impair or significantly augment the RCS control authority. This characterization will be done through a combination of computational fluid dynamics (CFD) analysis and wind tunnel test. Two candidate arrangements of the RCS jets have been identified for the SRL vehicle and are currently under evaluation before final selection. The aero/RCS plume interactions of these candidate configurations have been measured in a supersonic wind tunnel test in NASA Langley's Unitary Plan Wind Tunnel. The test was conducted in the fall of 2020 and data is currently being reduced. An overview of the candidate RCS configurations are presented here with an overview of the wind tunnel model design, jet scaling and scaled nozzle design, and the test matrix. Preliminary CFD runs are presented with an assessment of the predicted plumes and their interaction with the wake flow of the vehicle. The predicted effects of the model sting is provided as well. This high fidelity wind tunnel test is being conducted much earlier in the SRL project than would normally be done. The test was funded as part of a CFD evaluation task funded by NASA's Aerosciences Evaluation and Test Capabilities Project. The objective of the evaluation task was to compare the ability of CFD to predict complex flows with data that can be measured in the Langley Unitary Plan Wind Tunnel. RCS Jet interactions were selected as a type of complex flow that is important to NASA missions. In addition to providing useful data to the SRL project, there was added emphasis on quantifying the accuracy of the CFD predictions and wind tunnel test data. An overview of the uncertainty quantification methodologies for computational and experimental portions of this test is presented.

blunt body↗
NASA NTRS1994

An overview of a model rotor icing test in the NASA Lewis Icing Research Tunnel

During two entries in late 1989, a heavily instrumented sub-scale model of a helicopter main rotor was tested in the NASA LeRC Icing Research Tunnel (IRT). The results of this series of tunnel tests were published previously. After studying the results from the 1989 test and comparing them to predictions, it became clear that certain test conditions still needed investigation. Therefore, a re-entry of the Sikorsky Aircraft Powered Force Model (PFM) in the IRT was instituted in order to expand upon the current rotor craft sub-scale model experimental database. The major areas of interest included expansion of the test matrix to include a larger number of points in the FAA AC 29-2 icing envelope, inclusion of a number of high power rotor performance points, close examination of warm temperature operations, operation of the model in constant lift mode, and testing for conditions for icing test points in the full scale helicopter database. The expanded database will allow further and more detailed examination and comparison with analytical models. Participants in the test were NASA LeRC, the U.S. Army Vehicle Propulsion Directorate based at LeRC, and Sikorsky Aircraft. The model rotor was exposed to a range of icing conditions (temperature, liquid water content, median droplet diameter) and was operated over ranges of shaft angle, rotor tip speed, advance ratio, and rotor lift. The data taken included blade strain gage and balance data, as well as still photography, video, ice profile tracings, and ice molds. A discussion of the details of the test is given herein. Also, a brief examination of a subset of the data taken is also given.

Britton, Randall K.↗
NASA NTRS2004

Lithium-Ion Verification Test Program

In order to assess the capabilities of current aerospace lithium-ion cells to perform long-term NASA missions, low-earth-orbits (LEO) testing to evaluate long-term cycle life was initiated. A flexible program was developed at NASA Glenn Research Center to enable assessment of technology developments as they occur as well as provide information about different cell vendors and cell designs. Following extensive characterization testing, cells are tested using LEO charge and discharge profiles under ten different combinations of test conditions that were statistically chosen to determine the effects of depth-of-discharge, temperature, and end-of-charge voltage on LEO cycle life. Four cells from each vendor are tested at each specific combination of conditions. Conditions included in the test matrix are depth-of-discharges of 20%, 30, 35%, and 40%; temperatures of 20, 30, and 40 C; and end-of-charge voltages of 3.85 V, 3.95 V, and 4.05 V. Cells are randomly assigned to packs and packs are randomly assigned to test conditions. The capacity of the cells to 3.0 V at the conditions of the test is being periodically measured. The results of this testing will be used to model cell performance and degradation as a function of test operating conditions. Cells are being evaluated in 4-cell series strings with charge voltage limits being applied to individual cells by charge control units designed and built at NASA Glenn Research Center. Testing is being performed at the Naval Surface Warfare Center/Crane Division in Crane, IN. Testing was initiated in September 2004 with 40 Ah cells from Saft and 30 Ah cells from Lithion. The test program is being expanded with the addition of cells from MSA and the addition of small cell modules is being considered. Preliminary results showing voltage, temperature, usable capacity per unit mass, and voltage dispersion as their changes over time for the cells at 20 C is presented.

McKissock, Barbara↗
NASA NTRSDate not supplied

SLD Instrumentation in Icing Wind Tunnels – Investigation Overview

A collaborative effort to better understand cloud characterization probes in Supercooled Large Drop (SLD) conditions, as well the ability to simulate these conditions in several icing wind tunnels, was undertaken by NASA, NRCC, CIRA, ECCC, FAA and Met Analytics, Inc. Both drop sizing and liquid water content, LWC, were measured with various probes using current to emerging technologies. To ensure the best possible data quality from the newest probes, the probe manufacturers, SEA, Inc. and Artium, Inc. were invited to support testing and data analysis efforts. A common set of probes was identified to test in each of the three participating facilities: NRCC’s Altitude Icing Wind Tunnel, NASA’s Icing Research Tunnel and CIRA’s Icing Wind Tunnel. From the common set of probes, a subset were identified to use for comparison across the three facilities. These were the CDP-2 and 2D-S for drop sizing, and the Multi-wire for LWC. The LWC value was also checked by measuring the ice accretion thickness under hard rime conditions on a NACA-0012 airfoil. A common test matrix with sweeps in both LWC and median volume diameter, MVD, was developed. Each facility achieved these conditions as determined by their own calibration. The MVD ranged from 20 to at least 200 um, and LWC ranged from 0.5 to 3 g/m3. The comparison probes tested at common conditions in each facility were intended to allow for a direct comparison, and check of potential facility bias.

Icing Wind Tunnel↗
DOE OSTI2024

Data From Experiments on Bubbling Fluidization of Zeolite in a Rectangular Bubbling Fluidized Bed

Fluidization experiments were conducted in a lab-scale rectangular bubbling fluidized bed with the objective of generating a high-quality dataset for model validation and artificial intelligence/machine learning (AI/ML) training. Zeolite was chosen as the bed material, and the fluidizing medium was air as supplied by a compressor. Three different flow rates at the inlet were chosen such that the particles were fluidized but not elutriated from the system. The test matrix involved randomization and replicates to provide uncertainty estimates as well as four different batches of zeolite as the bed material. The quantities of interest obtained from this study were statistics of differential pressures, interface heights, and particle velocities. Considering all the components of the elaborate test plan, the results obtained were consistent and reproducible. Characterization tests were performed to estimate particle properties including size, density, coefficient of friction, coefficient of restitution, and minimum fluidization velocity. In addition, the angle of repose from granular discharge experiments has been reported to account for rolling friction, though its effect on the overall process is expected to be negligible.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1993

A designed experiment in stitched/RTM composites

The damage tolerance of composite laminates can be significantly improved by the addition of through-the-thickness fibrous reinforcement such as stitching. However, there are numerous stitching parameters which can be independently varied, and their separate and combined effects on mechanical properties need to be determined. A statistically designed experiment (a 2(sup 5-1) fractional factorial, also known as a Taguchi L16 test matrix) used to evaluate five important parameters is described. The effects and interactions of stitch thread material, stitch thread strength, stitch row spacing and stitch pitch are examined for both thick (48 ply) and thin (16 ply) carbon/epoxy (AS4/E905L) composites. Tension, compression and compression after impact tests are described. Preliminary results of completed tension testing are discussed. Larger threads decreased tensile strength. Panel thickness was found not to be an important stitching parameter for tensile properties. Tensile modulus was unaffected by stitching.

Dickinson, Larry C.↗
NASA NTRS2013

Piloted Simulation Assessment of the Impact of Flexible Structures on Handling Qualities of Generic Supersonic Aircraft

The NASA Langley Research Center Cockpit Motion Facility (CMF) was used to conduct a piloted simulation assessment of the impact of flexible structures on flying qualities. The CMF was used because of its relatively high bandwidth, six degree-of-freedom motion capability. Previous studies assessed and attempted to mitigate the effects of multiple dynamic aeroservoelastic modes (DASE). Those results indicated problems existed, but the specific cause and effect was difficult to ascertain. The goal of this study was to identify specific DASE frequencies, damping ratios, and gains that cause degradation in handling qualities. A generic aircraft simulation was developed and designed to have Cooper-Harper Level 1 handling qualities when flown without DASE models. A test matrix of thirty-six DASE modes was implemented. The modes had frequencies ranging from 1 to 3.5 Hz and were applied to each axis independently. Each mode consisted of a single axis, frequency, damping, and gain, and was evaluated individually by six subject pilots with test pilot backgrounds. Analysis completed to date suggests that a number of the DASE models evaluated degrade the handling qualities of this class of aircraft to an uncontrollable condition.

Stringer, Mary T.↗
NASA NTRS2017

Test and Analysis of Solid Rocket Motor Nozzle Ablative Materials

Asbestos free solid motor internal insulation samples were tested at the MSFC Hyperthermal Facility. Objectives of the test were to gather data for analog characterization of ablative and in-depth thermal performance of rubber materials subject to high enthalpy/pressure flow conditions. Tests were conducted over a range of convective heat fluxes for both inert and chemically reactive sub-sonic free stream gas flow. Instrumentation included use of total calorimeters, thermocouples, and a surface pyrometer for surface temperature measurement. Post-test sample forensics involved measurement of eroded depth, charred depth, total sample weight loss, and documentation of the general condition of the eroded profile. A complete Charring Material Ablator (CMA) style aero-thermal analysis was conducted for the test matrix and results compared to the measured data. In general, comparisons were possible for a number of the cases and the results show a limited predictive ability to model accurately both the ablative response and the in-depth temperature profiles. Lessons learned and modeling recommendations are made regarding future testing and modeling improvements that will increase understanding of the basic chemistry/physics associated with the complicated material ablation process of rubber materials.

Clayton, J. Louie↗
NASA NTRS2017

Arc Jet Test and Analysis of Asbestos Free Solid Rocket Motor Nozzle Dome Ablative Materials

Asbestos free solid motor internal insulation samples were recently tested at the MSFC Hyperthermal Arc Jet Facility. Objectives of the test were to gather data for solid rocket motor analog characterization of ablative and in-depth thermal performance of rubber materials subject to high enthalpy/pressure flow conditions. Tests were conducted over a range of convective heat fluxes for both inert and chemically reactive sub-sonic free stream gas flow. Active instrumentation included use of total calorimeters, in-depth thermocouples, and a surface pyrometer for in-situ surface temperature measurement. Post-test sample forensics involved determination of eroded depth, charred depth, total sample weight loss, and documentation of the general condition of the eroded profile. A complete Charring Material Ablator (CMA) style aero thermal analysis was conducted for the test matrix and results compared to the measured data. In general, comparisons were possible for a number of the cases and the results show a limited predictive ability to model accurately both the ablative response and the in-depth temperature profiles. Lessons learned and modeling recommendations are made regarding future testing and modeling improvements that will increase understanding of the basic chemistry/physics associated with the complicated material ablation process of rubber materials.

Clayton, J. Louie↗
NASA NTRS2022

The Development of a Real-Time Optical Angle-of-Attack Measurement Capability at the NASA Ames Unitary Plan Wind Tunnel

The following details the implementation of a real-time optical angle-of-attack capability under development at the NASA Ames Unitary Plan Wind Tunnel (UPWT). Recent advancements in the integration of high bandwidth imaging systems at the Ames UPWT has laid the groundwork for the deployment of a calibrated, imaging based measurement capability. Some of the measurement goals of this data system include: an estimation of the orientation of a wind tunnel model to six degrees of freedom, measurements made at framerates high enough to time resolve model dynamics, triangulate corresponding points of interest from multiple camera views in three-dimensional space, acquire imagery with no impact to the productivity of the test matrix, provide results in real-time, and finally compute an estimation of the errors associated with the measurement. The following will outline the imaging hardware and data systems architecture, describe the data flow and image processing routines currently implemented, and explore example data and results from previous wind tunnel test entries.

Ground Testing↗
NASA NTRS2008

Preliminary Analysis of Acoustic Measurements from the NASA-Gulfstream Airframe Noise Flight Test

The NASA-Gulfstream joint Airframe Noise Flight Test program was conducted at the NASA Wallops Flight Facility during October, 2006. The primary objective of the AFN flight test was to acquire baseline airframe noise data on a regional jet class of transport in order to determine noise source strengths and distributions for model validation. To accomplish this task, two measuring systems were used: a ground-based microphone array and individual microphones. Acoustic data for a Gulfstream G550 aircraft were acquired over the course of ten days. Over twenty-four test conditions were flown. The test matrix was designed to provide an acoustic characterization of both the full aircraft and individual airframe components and included cruise to landing configurations. Noise sources were isolated by selectively deploying individual components (flaps, main landing gear, nose gear, spoilers, etc.) and altering the airspeed, glide path, and engine settings. The AFN flight test program confirmed that the airframe is a major contributor to the noise from regional jets during landing operations. Sound pressure levels from the individual microphones on the ground revealed the flap system to be the dominant airframe noise source for the G550 aircraft. The corresponding array beamform maps showed that most of the radiated sound from the flaps originates from the side edges. Using velocity to the sixth power and Strouhal scaling of the sound pressure spectra obtained at different speeds failed to collapse the data into a single spectrum. The best data collapse was obtained when the frequencies were left unscaled.

Khorrami, Mehdi R.↗
NASA NTRS2000

Improved Quality in Aerospace Testing Through the Modern Design of Experiments

This paper illustrates how, in the presence of systematic error, the quality of an experimental result can be influenced by the order in which the independent variables are set. It is suggested that in typical experimental circumstances in which systematic errors are significant, the common practice of organizing the set point order of independent variables to maximize data acquisition rate results in a test matrix that fails to produce the highest quality research result. With some care to match the volume of data required to satisfy inference error risk tolerances, it is possible to accept a lower rate of data acquisition and still produce results of higher technical quality (lower experimental error) with less cost and in less time than conventional test procedures, simply by optimizing the sequence in which independent variable levels are set.

DeLoach, R.↗
DOE OSTI2025

Enhanced Hanford High-Aluminum Waste Glass Property Data Development

This study investigated the effects of aluminum concentration on simulated high level waste glass properties to eventually establish an aluminum limit (as single-component or multiple-component constraints) for glass formulations for high-aluminum Hanford wastes. A test matrix of 25 high-aluminum glasses (20 = Al 2 O 3 = 28.57 wt%) was generated, and the chemical compositions were measured. The following properties were measured: crystal formation after centerline canister cooling, crystallinity as a function of temperature, density, viscosity, electrical conductivity, toxic leaching characteristics using the Toxicity Characteristic Leaching Procedure, product consistency using the Product Consistency Test, and SO 3 solubility. These results are reported here.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗