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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1974

On the propagation velocity of a detonation-shock combined wave

A quasi-one-dimensional analysis and a generalized Chapman-Jouguet condition are developed for a gaseous free detonation in an inert environment. Two characteristic features derived from the results are that there exists a lower limit on the heat of combustion, the charge diameter, and the molecular weight of the ambient gas and that there are two propagation velocities for a parameter combination above a certain critical value. Therefore the detonation failure of a free gas column is a hydrodynamic rather than a chemical phenomenon.

Tsuge, S.↗
NASA NTRS1979

Evaluation of CBS 600 carburized steel as a gear material

Gear endurance tests were conducted with one lot of consumable-electrode vacuum-melted (CVM) AISI 9310 gears and one lot of air-melt CBS 600 gears. The gears were 8 pitch with a pitch diameter of 8.89 centimeters (3.5 in.). Bench-type rolling-element fatigue tests were also conducted with one lot of CVM AISI 9310, three lots of CVM CBS 600, and one of air-melt CBS 600 material. The rolling-element bars were 0.952 centimeter (0.375 in.) in diameter. The CBS 600 material exhibited pitting fatigue lives in both rolling-element specimens and gears at least equivalent to that of CVM AISI 9310. Tooth fracture failure occurred with the CBS 600 gears after overrunning a fatigue spall, but it did not occur with the CVM AISI 9310 gears. Tooth fracture in the CBS 600 was attributed to excessive carbon content in the case, excessive case depth, and a higher than normal core hardness.

Townsend, D. P.↗
NASA NTRS1982

Development of tough, moisture resistant laminating resins

Tough, moisture resistant laminating resins for employment with graphite fibers were developed. The new laminating resins exhibited cost, handleability and processing characteristics equivalent to 394K (250 F) curing epoxies. The laminating resins were based on bisphenol A dicyanate and monofunctional cyanates with hydrophobic substituents. These resins sorb only small quantities of moisture at equilibrium (0.5% or less) with minimal glass transition temperature depression and represent an improvement over epoxies which sorb around 2% moisture at equilibrium. Toughening was accomplished by the precipitation of small diameter particles of butadiene nitrile rubber throughout the resin matrix. The rubber domains act as microcrack termini and energy dissipation sites, allowing increased stress accommodation prior to catastrophic failure. A unique blend of amine terminated butadiene nitrile elastomer (MW 2,000) and a high nitrile content butadiene nitrile rubber yielded the desired resin morphology.

Brand, R. A.↗
NASA NTRS1992

Compressive residual strength of graphite/epoxy laminates after impact

The issue of damage tolerance after impact, in terms of the compressive residual strength, was experimentally examined in graphite/epoxy laminates using Hercules AS4/3501-6 in a (+ or - 45/0)(sub 2S) configuration. Three different impactor masses were used at various velocities and the resultant damage measured via a number of nondestructive and destructive techniques. Specimens were then tested to failure under uniaxial compression. The results clearly show that a minimum compressive residual strength exists which is below the open hole strength for a hole of the same diameter as the impactor. Increases in velocity beyond the point of minimum strength cause a difference in the damage produced and cause a resultant increase in the compressive residual strength which asymptotes to the open hole strength value. Furthermore, the results show that this minimum compressive residual strength value is independent of the impactor mass used and is only dependent upon the damage present in the impacted specimen which is the same for the three impactor mass cases. A full 3-D representation of the damage is obtained through the various techniques. Only this 3-D representation can properly characterize the damage state that causes the resultant residual strength. Assessment of the state-of-the-art in predictive analysis capabilities shows a need to further develop techniques based on the 3-D damage state that exists. In addition, the need for damage 'metrics' is clearly indicated.

Guy, Teresa A.↗
NASA NTRS1994

Cratering and penetration experiments in teflon targets at velocities from 1 to 7 km/s

Approximately 20 sq m of protective thermal blankets, largely composed of Teflon, were retrieved from the Long Duration Exposure Facility after the spacecraft spent approximately 5.7 years in space. Examination of these blankets revealed that they contained thousands of hypervelocity impact features ranging from micron-sized craters to penetration holes several millimeters in diameter. We conducted impact experiments to reproduce such features and to understand the relationships between projectile size and the resulting crater or penetration hole diameter over a wide range of impact velocities. Such relationships are needed to derive the size and mass frequency distribution and flux of natural and man-made particles in low-earth orbit. Powder propellant and light-gas guns were used to launch soda-lime glass spheres into pure Teflon targets at velocities ranging from 1 to 7 km/s. Target thickness varied over more than three orders of magnitude from finite halfspace targets to very thin films. Cratering and penetration of massive Teflon targets is dominated by brittle failure and the development of extensive spall zones at the target's front and, if penetrated, the target's rear side. Mass removal by spallation at the back side of Teflon targets may be so severe that the absolute penetration hole diameter can become larger than that of a standard crater. The crater diameter in infinite halfspace Teflon targets increases, at otherwise constant impact conditions, with encounter velocity by a factor of V (exp 0.44). In contrast, the penetration hole size in very thin foils is essentially unaffected by impact velocity. Penetrations at target thicknesses intermediate to these extremes will scale with variable exponents of V. Our experimental matrix is sufficiently systematic and complete, up to 7 km/s, to make reasonable recommendations for velocity-scaling of Teflon craters and penetrations. We specifically suggest that cratering behavior and associated equations apply to all impacts in which the shock-pulse duration of the projectile is shorter than that assigned a unique projectile size, provided an impact velocity is known or assumed. This calibration seems superior to the traditional ballistic-limit approach.

Horz, Friedrich↗
DOE OSTI2023

A parametric finite element study for determining burst strength of thin and thick-walled pressure vessels

To accurately predict the burst strength of both thin and thick-walled pressure vessels (PVs), a parametric study of PV burst strength was performed for a wide range of vessel geometries and materials using elastic-plastic finite element analysis (FEA). A valid FEA model was established through a detailed study of 2D versus 3D FEA models, the critical stress failure criterion versus the limit load criteria, and the thick-wall effect on the FEA simulations. Here, the results show that the stresses and strains at the mean diameter, rather than outside diameter, determines a more accurate burst strength for both thin and thick-walled PVs. On this basis, a parametrized FEA script using the ABAQUS Python application programming interface (API) was used to create a large database of PV burst strengths for a variety of vessel geometries and materials, demonstrating that Python scripting is a powerful technique for performing parametric studies or generating large databases. From the FEA results, using the regression method, a new burst pressure model was developed as a function of the vessel geometry (D/t ratio) and material properties (UTS and n). As validated by a large number of full-scale burst test data, the proposed burst model can very accurately predict the burst strength for both thin and thick-walled PVs.

42 ENGINEERING↗
NASA NTRSDate not supplied

Calorimeter Heat Flux Trends in NASA’s Subscale Rotating Detonation Rocket Engine

A calorimeter-style rotating detonation rocket engine (RDRE) outer chamber body was designed, additively manufactured in GRCop-42, and hot-fire tested in test cell 105 at NASA Marshall Space Flight Center (MSFC) in Huntsville, AL in August 2024. Steady-state, spatially resolved heat flux and chamber pressure were measured at 13 and 9 locations from the injector face, respectively, for a variety of test conditions and hardware configurations with gaseous methane and oxygen propellants. The 2-in. diameter highly instrumented design, enabled by metal additive manufacturing (AM), allowed for simultaneous measurement of heat flux and chamber pressure through 44 long duration hot-fire tests without failure. Of the 44 tests, only 3 of the tests featured chamber pressures below 100 psia and are discussed in this work. Heat flux trends for this subscale hardware are explored with respect to local propellant mass flux for several different injectors, chamber lengths, and chamber “subsonic” area ratios (contraction ratios). Results show that for increasing chamber pressure, a reduced amount of energy per kilogram of propellant is transferred to the wall. Switching injectors affects the near-face heat flux and chamber pressure profiles. Chamber length does not noticeably affect the heat flux profile but increases bulk heat load. A subsonic area ratio greater than 1 reduces heat losses to the wall compared to a straight annulus case. Equivalence ratio shift did not significantly affect heat flux. Computational fluid dynamics (CFD) and conjugate heat transfer (CHT) analyses were performed to delineate 3-D heat transfer and coolant mass flow maldistribution effects and create a calorimeter transfer function to transform heat flux data and mitigate the profile distortions. Additional CFD/CHT simulations were performed using experimental data as boundary conditions to assess local nucleate boiling propensity during testing and to assess projected hot wall temperatures for future fatigue assessment. Vapor fractions were observed locally for several cases. It is anticipated that this effort will provide a common framework for coolant system design/analysis in calorimeter systems for rocket-based and air-breathing combustors, ensuring greater repeatability in calorimetry measurements across the research community.

Joseph Hernandez-McCloskey↗
DOE OSTI2020

Notch insensitivity in fatigue failure of chopped carbon fiber chip-reinforced composites using experimental and computational analysis

This study focuses on the notch effect on the fatigue failure of chopped carbon fiber chip-reinforced sheet molding compound (SMC) composites by using both experimental and numerical methods. The S-N diagrams of notched specimens are first obtained experimentally, which exhibit large scatter and are shown to depend on the spatial distribution of local fiber orientations. After considering the effect of this spatial distribution by adopting a new fatigue damage parameter to normalize the results, we achieve a much better correlation in the normalized S-N diagram for all the notched specimens with different hole diameters. Next, compared with the fatigue results of smooth specimens without notches, we find that SMC composites under tension-tension fatigue loading exhibit notch-insensitivity, which renders this type of composites a better candidate in joints or similar applications. Meanwhile, the fatigue failure mechanisms of notched SMC composites are explored through a microstructure characterization procedure. On this basis, a computational micromechanics model considering the notch effect and an improved multi-scale progressive damage fatigue law, calibrated by coupon-level fatigue tests of smooth SMC composites under different loading conditions, are employed to predict the fatigue behavior of notched SMC composites. We show that detailed failure processes and fatigue life of notched SMC composites can be efficiently and adequately predicted by this computational framework.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Assessment of Cold Spraying Mild-Steel Powder onto Mild-Steel Substrate for Development of Waste Tank Repair System - 20515

Infrastructure for nuclear waste storage and processing (e.g., waste tanks, transfer pipelines, evaporators) at the U.S. Department of Energy (DOE) Hanford Site has been in service well beyond its original design life. Past corrosion control methods at Hanford for waste tanks have not been fully successful, as evidenced by leaks forming in tank AY-102, the first double-shell tank (DST) constructed, and significant degradation detected in the primary tanks of AP-102 and AY-101. Failure of infrastructure components can pose a significant risk to the environment, worker safety, and project schedules. Therefore, remotely deployable methods for repairing and extending the service life of the existing tank waste infrastructure are needed. Cold spray has been identified as a potential technique for performing in situ repairs and material buildup for life extension of waste storage and processing infrastructure. Cold-spray repair methods and technology are well-established and are used extensively by industry and the military for making repairs using dissimilar materials. Pacific Northwest National Laboratory is evaluating the process of making repairs using mild-steel powder applied to a mild-steel substrate to minimize the galvanic corrosion potential. This paper presents the initial results for a feasibility ('go/no-go') assessment as to whether low-density deposits with sound metallurgic bonds, to build-back steel plate material, can be achieved using existing commercial cold-spray equipment. An assessment of steel-on-steel deposit is necessary to determine if cold spray is a viable candidate for DST carbon steel plate restoration/repair and thus DST service life extension. Powder properties and preparation requirements have been investigated and operating conditions and parameters for depositing a cold-spray buildup of mild steel on a mild-steel substrate have been determined. Soundness of metallurgic bonding as a function of the operating parameters exercised and results from applying cold spray to lay a deposit over simulated small-diameter flaws in 1/2-inch mild-steel plate are presented. Application of in situ cold-spray repair to the DOE complex has the potential to reduce cost and schedule impacts associated with component failures and the need to procure and construct replacement infrastructure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Defective rapid cell shape and transendothelial migration by calpain-1 null neutrophils

Highlights: • The role of calpain-1 in neutrophil shape change was investigated. • Neutrophils were obtained from knock-out mice and assessed ex vivo. • These cells failed to migrate through endothelial monolayers. • Spontaneous cell spreading was grossly abberant. • Calpain-1 null cells failed to spread in response to IP{sub 3} -induced Ca{sup 2+} signals. It has been proposed that Ca{sup 2+} activation of calpain-1 is an important trigger for rapid cell spreading by neutrophils. In this paper, we have investigated this by assessing the ex vivo functioning of neutrophils from calpain-1 null mice, Calpain-1 null neutrophils failed to migrate through TNF-activated endothelial monolayers. The failure to transmigrate through endothelial monolayers was therefore unlikely to be due to a failure of chemotaxis as chemotaxis by adherent calpain-1 null neutrophils towards fMLP was unpaired. In contrast, the capacity of calpian-1 neutrophils to spontaneously spread was limited to smaller diameters than for wild type cells. Photolytic uncaging of IP{sub 3} with Individual wild type neutrophils resulted in a large Ca{sup 2+} signal and rapid cell spreading. In contrast, calpain-1 neutrophils failed to spread in response to the IP{sub 3}-induced Ca{sup 2+} signal. This work has therefore demonstrated that the presence of calpain-1 was required for effective rapid cell spreading by neutrophils.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Mjölnir: a miniature triaxial rock deformation apparatus for 4D synchrotron X-ray microtomography

An X-ray transparent experimental triaxial rock deformation apparatus, here named 'Mjölnir', enables investigations of brittle-style rock deformation and failure, as well as coupled thermal, chemical and mechanical processes relevant to a range of Earth subsurface environments. Designed to operate with cylindrical samples up to 3.2 mm outside-diameter and up to 10 mm length, Mjölnir can attain up to 50 MPa confining pressure and in excess of 600 MPa axial load. The addition of heaters extends the experimental range to temperatures up to 140°C. Deployment of Mjolnir on synchrotron beamlines indicates that full 3D datasets may be acquired in a few seconds to a few minutes, meaning full 4D investigations of deformation processes can be undertaken. Mjölnir is constructed from readily available materials and components and complete technical drawings are included in the supporting information.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Direct Subsurface Measurements through Precise Micro Drilling

Wellbore integrity is a significant problem in the U.S. and worldwide, which has serious adverse environmental and energy security consequences. Wells are constructed with a cement barrier designed to last about 50 years. Indirect measurements and models are commonly used to identify wellbore damage and leakage, often producing subjective and even erroneous results. The research presented herein focuses on new technologies to improve monitoring and detection of wellbore failures (leaks) by developing a multi-step machine learning approach to localize two types of thermal defects within a wellbore model, a prototype mechatronic system for automatically drilling small diameter holes of arbitrary depth to monitor the integrity of oil and gas wells in situ, and benchtop testing and analyses to support the development of an autonomous real-time diagnostic tool to enable sensor emplacement for monitoring wellbore integrity. Each technology was supported by experimental results. This research has provided tools to aid in the detection of wellbore leaks and significantly enhanced our understanding of the interaction between small-hole drilling and wellbore materials.

42 ENGINEERING↗
NASA NTRS1987

Solid rocket motor aft field joint flow field analysis

An efficient Navier-Stokes analysis was successfully applied to simulate the complex flow field in the vicinity of a slot in a solid rocket motor with segment joints. The capability of the computer code to resolve the flow near solid surfaces without using a wall function assumption was demonstrated. In view of the complex nature of the flow field in the vicinity of the slot, this approach is considered essential. The results obtained from these calculations provide valuable design information, which would otherwise be extremely difficult to obtain. The results of the axisymmetric calculations indicate the presence of a region of reversed axial flow at the aft-edge of the slot and show the over-pressure in the slot to be only about 10 psi. The results of the asymmetric calculations indicate that a pressure asymmetry more than two diameters downstream of the slot has no noticeable effect on the flow field in the slot. They also indicate that the circumferential pressure differential caused in the slot due to failure of a 15 deg section of the castable inhibitor will be approximately 1 psi.

Sabnis, Jayant S.↗
DOE OSTI2023

ANS MiNES 2023 Poster

The dynamic mechanical properties of four varieties of high purity graphite as well as the depth of penetration (DoP) of a small-scale shaped charge into these grades was experimentally determined. The grades chosen were PCEA, NBG-18, and NBG-25. These grades provide a wide range of physical properties: in density from 1.80 – 1.85 g/cc, in maximum particle size from 10s to 1000s of µm, and in porosity from 18% to 20%. The quasistatic and dynamic compressive strengths of each grade were determined and correlated to their physical properties. The split Hopkinson pressure bar experiments showed both the dynamic strength and dominant shear failure mechanisms. A small scale shaped charge was used to compare the resistance of graphite to hypervelocity jet impacts: the Teledyne RP-4. The RP-4 has a 1.01” outer diameter and 3.44 g of RDX with an RP-80 booster (86 mg PETN + 123 mg RDX). A select number of samples were analyzed using X-Ray Computed Tomography (XCT), allowing for the full characterization of the undisturbed wound channel. A selection of other samples were physically sectioned and wound channels mapped from the sections. In addition to DoP, the wound geometry was characterized in terms of total volume and diameter at different depths. The wound channel characteristics for each grade were correlated to the compressive strengths and physical properties. In several of the test samples, the wound channel diameter was smaller than the diameter of the shaped charge slug just behind where the slug had penetrated the sample. These results indicated that the wound geometry was dependent on the compressive hysteresis behavior of graphite.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Real-time visualization of impact damage in monolithic silicon carbide and fibrous silicon carbide ceramic composite

Impact resistance from foreign debris is a critical requirement for brittle ceramic and ceramic composite materials intended for use in the hot-section of gas turbine engines. A design to mitigate against such impact failures necessitates a detailed understanding of the driving failure mechanisms. The present study introduces a unique time-resolved experimental method which advances the latter effort. Specifically, a pulsed synchrotron X-ray source, in phase contrast imaging (PCI) configuration, is used as a medium, to visually characterize the evolution of damage inside the target materials during impact. As a proof of concept, two types of ceramic materials were tested: monolithic silicon carbide and fibrous silicon carbide composite. Impact was performed using a light-gas gun and 1.5 mm diameter spheres of partially stabilized zirconia (PSZ) and silicon nitride (Si 3 N 4 ). The retrieved dynamic X-ray image sequences provided clear outlines of the damage features. In the case of the monolithic ceramic, the impact by a PSZ projectile initially produced a cone crack and complete failure resulted by extension of a median crack. By contrast, the fibrous composite deformed readily prior to cone crack formation. Nearly identical damage features were observed in the monolith for the Si 3 N 4 projectile, with the exception of the added vertical tensile crack. For this same projectile, the fibrous ceramic showed very limited surface deformation and enhanced cone cracking and kinking of laminates along the crack path. The latter response is attributed to the change in projectile properties. Some of the target materials were recovered, and post-mortem analysis via scanning electron microscopy (SEM) showed correlation with observed X-ray damage profiles. Furthermore, simple Hertzian contact was used to estimate damage for the elastic portion of impact. This approach was found to yield a reasonable match with experimental results for the surface displacement near the contact interface.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Z-2 Threaded Insert Design and Testing

NASA's Z-2 prototype space suit contains several components fabricated from an advanced hybrid composite laminate consisting of IM10 carbon fiber and fiber glass. One requirement was to have removable, replaceable helicoil inserts to which other suit components would be fastened. An approach utilizing bonded in inserts with helicoils inside of them was implemented. During initial assembly, cracking sounds were heard followed by the lifting of one of the blind inserts out of its hole when the screws were torqued. A failure investigation was initiated to understand the mechanism of the failure. Ultimately, it was determined that the pre-tension caused by torqueing the fasteners is a much larger force than induced from the pressure loads of the suit which was not considered in the insert design. Bolt tension is determined by dividing the torque on the screw by a k value multiplied by the thread diameter of the bolt. The k value is a factor that accounts for friction in the system. A common value used for k for a non-lubricated screw is 0.2. The k value can go down by as much as 0.1 if the screw is lubricated which means for the same torque, a much larger tension could be placed on the bolt and insert. This paper summarizes the failure investigation that was performed to identify the root cause of the suit failure and details how the insert design was modified to resist a higher pull out tension.

Ross, Amy↗
DOE OSTI2017

Microstructural Effects on Creep-Fatigue Life of Alloy 709

Cyclic testing has been carried out to characterize the fatigue and creep-fatigue behavior of Alloy 709, an advanced austenitic structural alloy. Specimens were machined from several plates of 709, subjected to different processing conditions and resulting in varying microstructures in the specimens, dependent on both the plate used for the machining and the location the specimen originated from within the plate. The cyclic testing has been conducted primarily at a single fatigue and creep-fatigue condition, which was at 650 °C and 1.0% total strain (+/-0.5% strain). For creep-fatigue, a 30 min. hold time at peak tensile strain was introduced. The combined results of the cyclic testing and post-test metallographic characterization suggest that the investigated microstructures, ultimately controlled by the processing conditions, have limited influence on the Alloy 709 fatigue cycle life. In contrast, some effect on the creep-fatigue cycle life due to the microstructure was observed, specifically that the presence of large grains may negatively impact the creep-fatigue resistance. The number of cycles to failure at the selected creep-fatigue condition varied by up to a factor of 5 for the specimens tested. Specimens with an optimum microstructure, a uniform distribution of grains with diameters less than approximately 200 ?m, resulted in a creep-fatigue resistance similar to that of 316-type stainless steel. The majority of the Alloy 709 cyclic test data has been previously reported in milestone reports - and the microstructural and processing details for the specific heats have been reported by Yamamoto et al. - This summary report includes creep-fatigue test results on three additional heats (011502F, 011502H, and 011539 (note, same plate as ORNL 011593)) for which the processing and microstructural details are available in previous reports.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗