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NASA NTRS2003

Modeling of 3-D Woven Ceramic Matrix Composites

Three different approaches are being pursued at the NASA Glenn Research Center to predict the nanostructural behavior of three-dimensional woven ceramic matrix composites. These are: a micromechanics-based approach using W-CEMCAN (Woven Ceramic Matrix Composite Analyzer), a laminate analogy method and a structural frame approach (based on the finite element method). All three techniques are applied to predict the thermomechanical properties of a three-dimensional woven angle interlock C/SiC composite. The properties are predicted for room temperature and 1100 C and the predicted properties are compared to measurements. General observations regarding the three approaches for three-dimensional composite modeling are discussed.

Murthy, Pappu L. N.↗

NASA NTRS2002

Bulk Micromachined 6H-SiC High-g Piezoresistive Accelerometer Fabricated and Tested

High-g accelerometers are needed in certain applications, such as in the study and analysis of high-g impact landings and projectiles. Also, these accelerometers must survive the high electromagnetic fields associated with the all-electric vehicle technology needed for aerospace applications. The choice of SiC is largely due to its excellent thermomechanical properties over conventional silicon-based accelerometers, whose material properties inhibit applicability in high electromagnetic radiation and high temperatures (>150 C) unless more complex and sometimes costly packaging schemes are adopted. This work was the outcome of a NASA Glenn Research Center summer internship program, in collaboration with Cornell University and the Munitions Directorate of the U.S. Air Force in Eglin, Florida. It aimed to provide the enabling technology infrastructure (modeling, fabrication, and validation) for the implementation of SiC accelerometers designed specifically for harsh environments.

Okojie, Robert S.↗

NASA NTRS2008

High Temperature Electronics for Intelligent Harsh Environment Sensors

The development of intelligent instrumentation systems is of high interest in both public and private sectors. In order to obtain this ideal in extreme environments (i.e., high temperature, extreme vibration, harsh chemical media, and high radiation), both sensors and electronics must be developed concurrently in order that the entire system will survive for extended periods of time. The semiconductor silicon carbide (SiC) has been studied for electronic and sensing applications in extreme environment that is beyond the capability of conventional semiconductors such as silicon. The advantages of SiC over conventional materials include its near inert chemistry, superior thermomechanical properties in harsh environments, and electronic properties that include high breakdown voltage and wide bandgap. An overview of SiC sensors and electronics work ongoing at NASA Glenn Research Center (NASA GRC) will be presented. The main focus will be two technologies currently being investigated: 1) harsh environment SiC pressure transducers and 2) high temperature SiC electronics. Work highlighted will include the design, fabrication, and application of SiC sensors and electronics, with recent advancements in state-of-the-art discussed as well. These combined technologies are studied for the goal of developing advanced capabilities for measurement and control of aeropropulsion systems, as well as enhancing tools for exploration systems.

Evans, Laura J.↗

NASA NTRS2007

Electroform/Plasma-Spray Laminates for X-Ray Optics

Electroform/plasma-spray laminates have shown promise as lightweight, strong, low-thermal-expansion components for xray optics. The basic idea is to exploit both (1) the well-established art of fabrication of optical components by replication and (2) plasma spraying as a means of reinforcing a thin replica optic with one or more backing layer(s) having tailorable thermomechanical properties. In x-ray optics as in other applications, replication reduces the time and cost of fabrication because grinding and polishing can be limited to a few thick masters, from which many lightweight replicas can thereafter be made. The first step in the fabrication of a component of the type in question is to make a replica optic by electroforming a thin layer of nickel on a master. Through proper control of the electroforming process conditions, it is possible to minimize residual stress and, hence, to minimize distortion in the replica. Next, a powder comprising ceramic particles coated with a metal compatible with the electroformed nickel is plasma-sprayed onto the backside of the nickel replica. Then through several repetitions and variations of the preceding steps or perhaps a small compressive stress, alternating layers of electroformed nickel and plasma-sprayed metal-coated ceramic powder are deposited. The thicknesses of the layers and the composition of the metal-coated ceramic powder are chosen to optimize the strength, areal mass density, and toughness of the finished component. An important benefit of using both electroforming and plasma spraying is the possibility of balancing stresses to a minimum level, which could be zero or perhaps a small net compressive stress designed to enhance the function of the component in its intended application.

Ulmer, Melville P.↗

NASA NTRS2007

Cryogenic Shrouds for Testing Thermal-Insulation Panels

Cryogenic shrouds have been designed and built for use in thermomechanical testing of samples of thermalinsulation panels on cryogenic vessels. In the original application for which these shrouds were specifically designed, the samples are representative of the large-area thermal-insulation panels on the space-shuttle external tanks that hold liquid hydrogen and liquid oxygen, and the purpose of the testing is to demonstrate the ability of bonded layers in the panels to resist delamination under a combination of applied uniaxial mechanical loads and realistic operational temperatures. Presumably, the shrouds and the tests performed by use of them could be modified to enable similar evaluation of thermomechanical properties of thermal-insulation panels for cryogenic vessels other than the external tanks of the space shuttles. The shrouds are required to enable maintenance of required temperatures on the inner and outer surfaces of the thermal-insulation-panel samples, to enable visual observation of the outer surfaces of the samples, and not to introduce any measurable loads into the panels. For each panel sample, there are two shrouds: one to be mounted on the inner surface (the surface that would be in contact with a tank containing a cryogenic liquid during normal use) and one to be mounted on the outer surface (the surface that would be exposed to ambient air or other warmer environment during normal use). The shrouds for testing specimens of thermal-insulation- panels for the liquid-hydrogen tank are made largely of titanium; the shrouds for testing specimens of thermal- insulation-panels for the liquid-oxygen tank are made largely of an aluminum- lithium alloy. The specific temperature requirements are the following: The inner shroud must make it possible to maintain a temperature of 321 degrees F (196 degrees C) [the approximate temperature of liquid nitrogen] or 453 F (about 269 C) [the approximate temperature of liquid helium] on the inner face of the sample. The outer shroud must make it possible to maintain a temperature between 30 degrees and 0 degrees F (between about 34 degrees and about 18 degrees C) on the outer surface of the sample by blowing a cryogenic gas or missile grade air along that surface. To enable viewing of the outer surface of the sample during testing, the outer shroud includes a window comprising two layers of poly(methyl methacrylate) with a gap between them to reduce fogging. To ensure that the shrouds do not introduce any measurable loads into a panel specimen, the shrouds are cushioned on the specimen by seals made of a fluoropolymer-membrane/fabric composite material and are held in place on the specimen by means of symmetrically placed clamps with poly(tetrafluoroethylene) pads. Instrumentation ports for thermocouples and strain gauges used in the tests are incorporated into the shrouds.

Norris, Jeffrey↗

NASA NTRS2006

NASA Tech Briefs, September 2006

Topics covered include: Improving Thermomechanical Properties of SiC/SiC Composites; Aerogel/Particle Composites for Thermoelectric Devices; Patches for Repairing Ceramics and Ceramic- Matrix Composites; Lower-Conductivity Ceramic Materials for Thermal-Barrier Coatings; An Alternative for Emergency Preemption of Traffic Lights; Vehicle Transponder for Preemption of Traffic Lights; Automated Announcements of Approaching Emergency Vehicles; Intersection Monitor for Traffic-Light-Preemption System; Full-Duplex Digital Communication on a Single Laser Beam; Stabilizing Microwave Frequency of a Photonic Oscillator; Microwave Oscillators Based on Nonlinear WGM Resonators; Pointing Reference Scheme for Free-Space Optical Communications Systems; High-Level Performance Modeling of SAR Systems; Spectral Analysis Tool 6.2 for Windows; Multi-Platform Avionics Simulator; Silicon-Based Optical Modulator with Ferroelectric Layer; Multiplexing Transducers Based on Tunnel-Diode Oscillators; Scheduling with Automated Resolution of Conflicts; Symbolic Constraint Maintenance Grid; Discerning Trends in Performance Across Multiple Events; Magnetic Field Solver; Computing for Aiming a Spaceborne Bistatic- Radar Transmitter; 4-Vinyl-1,3-Dioxolane-2-One as an Additive for Li-Ion Cells; Probabilistic Prediction of Lifetimes of Ceramic Parts; STRANAL-PMC Version 2.0; Micromechanics and Piezo Enhancements of HyperSizer; Single-Phase Rare-Earth Oxide/Aluminum Oxide Glasses; Tilt/Tip/Piston Manipulator with Base-Mounted Actuators; Measurement of Model Noise in a Hard-Wall Wind Tunnel; Loci-STREAM Version 0.9; The Synergistic Engineering Environment; Reconfigurable Software for Controlling Formation Flying; More About the Tetrahedral Unstructured Software System; Computing Flows Using Chimera and Unstructured Grids; Avoiding Obstructions in Aiming a High-Gain Antenna; Analyzing Aeroelastic Stability of a Tilt-Rotor Aircraft; Tracking Positions and Attitudes of Mars Rovers; Stochastic Evolutionary Algorithms for Planning Robot Paths; Compressible Flow Toolbox; Rapid Aeroelastic Analysis of Blade Flutter in Turbomachines; General Flow-Solver Code for Turbomachinery Applications; Code for Multiblock CFD and Heat-Transfer Computations; Rotating-Pump Design Code; Covering a Crucible with Metal Containing Channels; Repairing Fractured Bones by Use of Bioabsorbable Composites; Kalman Filter for Calibrating a Telescope Focal Plane; Electronic Absolute Cartesian Autocollimator; Fiber-Optic Gratings for Lidar Measurements of Water Vapor; Simulating Responses of Gravitational-Wave Instrumentation; SOFTC: A Software Correlator for VLBI; Progress in Computational Simulation of Earthquakes; Database of Properties of Meteors; Computing Spacecraft Solar-Cell Damage by Charged Particles; Thermal Model of a Current-Carrying Wire in a Vacuum; Program for Analyzing Flows in a Complex Network; Program Predicts Performance of Optical Parametric Oscillators; Processing TES Level-1B Data; Automated Camera Calibration; Tracking the Martian CO2 Polar Ice Caps in Infrared Images; Processing TES Level-2 Data; SmaggIce Version 1.8; Solving the Swath Segment Selection Problem; The Spatial Standard Observer; Less-Complex Method of Classifying MPSK; Improvement in Recursive Hierarchical Segmentation of Data; Using Heaps in Recursive Hierarchical Segmentation of Data; Tool for Statistical Analysis and Display of Landing Sites; Automated Assignment of Proposals to Reviewers; Array-Pattern-Match Compiler for Opportunistic Data Analysis; Pre-Processor for Compression of Multispectral Image Data; Compressing Image Data While Limiting the Effects of Data Losses; Flight Operations Analysis Tool; Improvement in Visual Target Tracking for a Mobile Robot; Software for Simulating Air Traffic; Automated Vectorization of Decision-Based Algorithms; Grayscale Optical Correlator Workbench; "One-Stop Shopping" for Ocean Remote-Sensing and Model Data; State Analysis Database Tool; Generating CAHV and CAHVOmages with Shadows in ROAMS; Improving UDP/IP Transmission Without Increasing Congestion; FORTRAN Versions of Reformulated HFGMC Codes; Program for Editing Spacecraft Command Sequences; Flight-Tested Prototype of BEAM Software; Mission Scenario Development Workbench; Marsviewer; Tool for Analysis and Reduction of Scientific Data; ASPEN Version 3.0; Secure Display of Space-Exploration Images; Digital Front End for Wide-Band VLBI Science Receiver; Multifunctional Tanks for Spacecraft; Lightweight, Segmented, Mostly Silicon Telescope Mirror; Assistant for Analyzing Tropical-Rain-Mapping Radar Data; and Anion-Intercalating Cathodes for High-Energy- Density Cells.

Source record↗

NASA NTRS2005

Temperature-Controlled Clamping and Releasing Mechanism

A report describes the development of a mechanism that automatically clamps upon warming and releases upon cooling between temperature limits of approx. =180 K and approx. =293 K. The mechanism satisfied a need specific to a program that involved repeated excursions of a spectrometer between a room-temperature atmospheric environment and a cryogenic vacuum testing environment. The mechanism was also to be utilized in the intended application of the spectrometer, in which the spectrometer would be clamped for protection during launch of a spacecraft and released in the cold of outer space to allow it to assume its nominal configuration for scientific observations. The mechanism is passive in the sense that its operation does not depend on a control system and does not require any power other than that incidental to heating and cooling. The clamping and releasing action is effected by bolt-preloaded stacks of shape-memory-alloy (SMA) cylinders. In designing this mechanism, as in designing other, similar SMA mechanisms, it was necessary to account for the complex interplay among thermal expansion, elastic and inelastic deformation under load, and SMA thermomechanical properties.

Rosing, David↗

NASA NTRS2004

Improved BN Coatings on SiC Fibers in SiC Matrices

Modifications of BN-based coatings that are used as interfacial layers between the fibers and matrices of SiCfiber/SiC-matrix composite materials have been investigated to improve the thermomechanical properties of these materials. Such interfacial coating layers, which are also known as interphases (not to be confused with interphase in the biological sense), contribute to strength and fracture toughness of a fiber/matrix composite material by providing for limited amounts of fiber/matrix debonding and sliding to absorb some of the energy that would otherwise contribute to the propagation of cracks. Heretofore, the debonding and sliding have been of a type called inside debonding because they have taken place predominantly on the inside surfaces of the BN layers that is, at the interfaces between the SiC fibers and the interphases. The modifications cause the debonding and sliding to include more of a type, called outside debonding, that takes place at the outside surfaces of the BN layers that is, at the interfaces between the interphases and the matrix (see figure). One of the expected advantages of outside debonding is that unlike in inside debonding, the interphases would remain on the crack-bridging fibers. The interphases thus remaining should afford additional protection against oxidation at high temperature and should delay undesired fiber/fiber fusion and embrittlement of the composite material. A secondary benefit of outside debonding is that the interphase/matrix interfaces could be made more compliant than are the fiber/interphase interfaces, which necessarily incorporate the roughness of the SiC fibers. By properly engineering BN interphase layers to favor outside debonding, it should be possible, not only to delay embrittlement at intermediate temperatures, but also to reduce the effective interfacial shear strength and increase the failure strain and toughness of the composite material. Two techniques have been proposed and partially experimentally verified as candidate means to promote outside debonding in state-of-the-art SiC/SiC composites.

Morscher, Gregory N.↗

NASA NTRSDate not supplied

Influence of Microstructural Features on Austenite-Martensite Interfaces in NiTi Shape Memory Alloys

Shape memory alloys (SMAs) exhibit several unique thermomechanical properties due to a reversible martensitic phase transformation. A key aspect of this transformation is the austenite-martensite interface. Here we present a molecular dynamics (MD) simulation methodology to study the atomic-scale features of austenite-martensite interface migration under near-equilibrium conditions. In single crystals, the interfaces migrate rapidly with only a small thermodynamic driving force. In polycrystals, however, interface migration is significantly impeded due to the change in orientation relationship at grain boundaries and the stored elastic energy resulting from microstructural constraints. This behavior can be linked to several mechanisms associated with transformation width and hysteresis in SMAs, properties of great importance for applications involving actuation. Additionally, we will present preliminary MD simulation results on the influence of precipitates on the formation and migration of austenite-martensite interfaces.

Gabriel Plummer↗

NASA NTRSDate not supplied

Influence of Microstructural Features on Austenite-Martensite Interfaces in NiTi Shape Memory Alloys

Gabriel Plummer↗

NASA NTRSDate not supplied

Special Grain Boundaries in NiTi Shape Memory Alloys as Sites for Preferential Martensite Nucleation

Shape memory alloys (SMAs) exhibit unique thermomechanical properties due to a reversible martensitic transformation which can be controlled via chemical composition and microstructural features. Among the latter, grain boundaries (GBs) are key in determining how the transformation nucleates and propagates. We performed molecular dynamics simulations to examine the roles of a few special GBs in the austenite phase of NiTi. The GBs can act as preferential host sites for martensite nuclei which can substantially lower the nucleation barrier for transformation and thereby result in reduced thermal hysteresis, an important SMA property for cyclic actuation applications. Free energy calculations show that a characteristic of these GBs is a negative entropy which drops sharply close to the transformation temperature, an anomalous behavior for GBs with fixed composition which is a direct result of the martensitic transformation. We discuss implications of these results with respect to SMA processing techniques for achieving improved properties.

Gabriel Plummer↗

DOE OSTI2023

Evaluation of Irradiation Creep Effects in HT9 Cladding for FAST Experiments

The push for advanced reactor fuels for improved reactor safety and efficiency had led to a renewed interest in metallic fuel for nuclear reactor applications. Experimental investigation is necessary to ensure a robust understanding of the thermomechanical properties of new metallic fuel designs. Unfortunately, with the current experimental facilities, thoroughly investigating the responses of metallic fuel burnup would take a prohibitively long time. To alleviate this, the Fission Accelerated Steady State Test (FAST) was developed to accelerate the irradiation testing while simultaneously decreasing the sensitivity to fabrication tolerances by reducing the fuel diameter and scaling the experiment. This method successfully scales the radiation effects on the fuel, but the HT9 cladding is not exposed to prototypic radiation conditions. This raises questions on whether the FAST experiment results are truly indicative of the HT9 cladding performance due to radiation induced creep effects not being appropriately accounted for. Using BISON fuel performance code, the simulated FAST cladding strain is compared to simulated EBR-II cladding strain. This is done through a sensitivity study of input parameters and scaling of neutron fluence on the cladding. This allows a parametric comparison of physical phenomena on the effective difference between cladding strains between FAST and equivalent burnup EBR-II fuel pins. The results show that the irradiation induced deformation (creep or swelling) is insignificant compared to the thermal-mechanical deformation. Therefore, the difference between the FAST experiment cladding and the EBR-II experiment cladding is negligible and comparison of fuel system performance between the two experiments is appropriate.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Use of latent metathesis polymerization systems for photopolymerization-based additive manufacturing

Photolatent olefin metathesis catalysts can be used in combination with metathesis-active monomers or resins for photopolymerization-based additive manufacturing via ring-opening metathesis polymerization (ROMP). A variety of alternative catalysts and photosensitizers are commercially available that allows for tuning of thermomechanical properties, potlifes, activation rates, and irradiation wavelengths. As an example, two optimized catalyst/photosensitizer systems were demonstrated in the rapid stereolithographic printing of complex, multidimensional poly-dicyclopentadiene structures with microscale features under ambient conditions.

Leguizamon, Samuel↗

DOE OSTI2023

MEASURING THERMALLY-INDUCED DISTORTION OF LARGE-SCALE COMPOSITE PRINTED STRUCTURES USING DIGITAL IMAGE CORRELATION

Additive manufacturing (AM) gives designers the ability to create complex part geometries without several of the limitations of traditional manufacturing. Large-Scale AM (LSAM) allows the creation of large composite structures and is a popular area of composite tooling research. Fiber-reinforced polymers are common feedstock for LSAM tooling but introduce anisotropic thermomechanical properties that can lead to the warpage of tools at autoclave conditions. Digital image correlation (DIC) has been used to measure the coefficient of thermal expansion (CTE) of LSAM parts using a novel DIC Oven design. This method was utilized to measure the CTE of LSAM structures printed using different fiber-reinforced materials and multiple geometries. Specifically, glass fiber ABS (GF-ABS) and carbon fiber ABS (CF-ABS) samples were compared as well as cube and plate geometries for each material. The temperature profile over time was also evaluated to determine how rapidly the strain of the sample increased as temperature of the DIC Oven was increased. A thermal model was developed to predict temperature profiles for various samples and identify when the samples had reached thermal equilibrium.

Corum, Tyler↗

DOE OSTI2024

Buffer-IPyC separation process in TRISO fuel particles simulated with Bison code

During High Temperature Gas-cooled Reactor (HTGR) operation, tristructural isotropic (TRISO) coated-particle fuel undergoes irradiation-induced changes in morphology and thermomechanical properties. Experimental results from the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program show, among other things, the mechanism of gap formation between the buffer and inner pyrolytic carbon (IPyC) layers, which could be explored further via computational simulations using the Bison code. Two simulation models were developed, the debonding restricted model, where no gap formation between buffer and IPyC layers is permitted, and the debonding enabled model, where the gap between those layers is created. The inputs of the simulated models are based on the irradiation conditions from the AGR-1 experiment. The research included simulations on spherical and aspherical fuel types. Under the specific temperatures and fluences of the AGR-1 irradiation experiment, and the Bison simulations, it was concluded that the most common scenario is a gap formation along the buffer-IPyC interface, while the least possible scenario is the situation where there is no gap formation at the buffer-IPyC junction. The computational results confirmed that the sphericity of the fuel influences the thickness of the gap that occurs at the buffer-IPyC junction, in a way that with increasing aspect ratio the gap thickness increases. The results obtained for spherical and aspherical fuel are nearly identical. Finally, performed simulations match conclusions observed from the AGR-1 experiment, which as such shows that the Bison code is a good computational method for simulating the TRISO fuel. Future simulations will include the validation of performed research and comparison of the results between Bison and PARFUME codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

3D printed features on nuclear fuel cladding for optimized heat transfer

A nuclear fuel cladding with improved thermomechanical properties is provided. The nuclear fuel cladding includes a double-walled construction having inner and outer hexagonal sidewalls. The inner sidewall and the outer sidewall are spaced apart from each other to form a cooling channel therebetween, and the inner sidewall surrounds a nuclear fuel and is spaced apart from the nuclear fuel by a small gap. Helical fins extend into the cooling channel to interconnect the inner sidewall and the outer sidewall. Resilient fingers extend toward the nuclear fuel through the small gap to comply with variations in the size of the nuclear fuel due to fabrication tolerances as well as thermal expansion and swelling of the nuclear fuel, for example UO 2 , when undergoing fission. The nuclear fuel cladding is formed according to an additive manufacturing process, for example laser powder bed fusion printing.

Petrie, Christian M.↗

DOE OSTI2025

Examining Constituent Redistribution in U-19Pu-10Zr Fuel as it Evolves with Local Burnup

While constituent redistribution is a known irradiation behavior in U-Pu-Zr fuel, new data have shown it is more complex than our current understanding and predictive capabilities. The size and composition of redistributed rings evolve as a function of pin composition, burnup, geometry, and irradiation temperature. In this work, we extract microstructural information from optical microscopy conducted on U-19Pu-10Zr pins (irradiated between 1.9 at. % and 11.6 at. % peak burnup). Both manual image analysis techniques and machine learning-assisted segmentation are used to quantify the thicknesses of the cladding, fuel-cladding interaction layers, and rings of fuel constituent redistribution in addition to pore distribution. These microstructural features and individual redistributed regions affect local thermomechanical properties, and identifying the relationship between burnup and constituent redistribution will improve accurate prediction of advanced reactor fuel performance.

Constituent Redistribution↗

NASA NTRS1975

Structure-property relationships in thermomechanically treated beryllia dispersed nickel alloys

BeO dispersed nickel alloys, produced by powder metallurgy techniques, were studied extensively in stress rupture at 815, 982, and 1093 C (1088, 1255, and 1366 K) and by transmission electron microscopy. The alloys were subjected to a variety of thermomechanical treatments (TMT) to determine the benefits of TMT on properties. It is shown that the use of intermediate annealing treatments after 10 pct reduction steps is highly beneficial on both low and high temperature properties. It is indicated that the high temperature strength is not primarily dependent on the grain aspect ratio or texture but depends strongly on the dislocation density and distribution of dislocations in a stable substructure which is pinned by the fine oxide dispersion.

Grewal, M. S.↗