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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

On the performance of explicit and implicit algorithms for transient thermal analysis

The status of an effort to increase the efficiency of calculating transient temperature fields in complex aerospace vehicle structures is described. The advantages and disadvantages of explicit and implicit algorithms are discussed. A promising set of implicit algorithms, known as the GEAR package is described. Four test problems, used for evaluating and comparing various algorithms, have been selected and finite element models of the configurations are discribed. These problems include a space shuttle frame component, an insulated cylinder, a metallic panel for a thermal protection system and a model of the space shuttle orbiter wing. Calculations were carried out using the SPAR finite element program, the MITAS lumped parameter program and a special purpose finite element program incorporating the GEAR algorithms. Results generally indicate a preference for implicit over explicit algorithms for solution of transient structural heat transfer problems when the governing equations are stiff. Careful attention to modeling detail such as avoiding thin or short high-conducting elements can sometimes reduce the stiffness to the extent that explicit methods become advantageous.

Adelman, H. M.↗
NASA NTRS2026

Mechanical Design and Operation of a Novel Lunar Environment Structural Test Rig (LESTR)

The Lunar Environment Structural Test Rig (LESTR) was developed to address a critical gap in mechanical property data for metal alloy wire materials under lunar-relevant conditions down to 40 K. Conventional aerospace material databases provide thermophysical properties for bulk metals over a wide temperature range, but validated mechanical and physical property data below 77 K, particularly for small-diameter wires, remain limited and are generally the exception rather than the rule. These conditions are essential for Artemis mission hardware such as shape memory alloy (SMA) rover tires. LESTR’s design requirements were to combine a high-stiffness electrodynamic load frame with closed- cycle cryogenic cooling, high-vacuum capability (10–6 torr), and noncontact optical strain measurement to enable tensile, four-point bend, and fatigue testing of wires or other materials and geometries at temperatures from 40 to 125 K. These considerable requirements were merged with the need to lower the barrier of testing for the end user as measured in terms of cost-per-test cycle, safety improvement, and reduction in upkeep costs associated with state-of-the-art solutions associated with cryomechanical material characterization. The system incorporates modular gripping and alignment fixtures; precision thermal management using cryocoolers and embedded heaters; and integrated instrumentation for displacement, load, temperature, and vacuum control. Calibration procedures establish correlations between tooling and specimen temperature, ensuring accurate thermal conditions across the design envelope unbound by cryofluid conditions in heritage immersion-based test systems. Initial validation tests using Inconel (Special Metals Corp.) wire demonstrated accurate ultimate strength and post-yield behavior. The load frame operation was also verified under representative service conditions, including thermal cycling and prolonged fatigue loading. By generating mechanical property data at ultralow temperatures, LESTR fills a critical gap in existing materials databases and provides a scalable platform for iterative alloy development and durability assessment for planetary hardware. This capability supports NASA’s long-term objectives for surface exploration by enabling design confidence for components operating in extreme cryogenic environments.

LESTR↗
NASA NTRS2026

Polymer Composite Material Testing for a Cryotank Application

Composite cryotanks will play a key role in enabling the next generation of efficient aircraft. Carbon fiber reinforced polymer (CFRP) composites have the benefits of reduced weight and potentially higher structural strength compared to traditional metallic fuel tanks. A material screening study was conducted to inform material selection for liquid hydrogen (LH2) fuel storage. Three composite materials were considered because of their aerospace grade toughness, strength, and existing data to compare against. These materials were a thermoplastic low-melt polyaryletherketone (LM-PAEK)/carbon fiber (CF), thermoset/CF, and hybrid thermoset/thermoplastic polyurethane (TPU) veil/CF composite. Mechanical screening tests included tension, compression, in-plane shear (IPS), and tensile-tensile fatigue (TTF). Each material was tested at both a baseline (no liquid nitrogen/LN2 cycling) and 100 LN2-cycled conditions to determine the knockdown factor, if any, of each material when exposed to environmental loading effects in a cryotank. Results show minimal effects of the LN2-cycling compared against baseline values. The three materials behaved similarly in tension; however, the thermoplastic/CF had the highest IPS toughness. The hybrid thermoset/TPU/CF composite had the lowest IPS strength, compressive strength, and toughness. LN2-cycling had minimal effects on tensile-tensile fatigue performance of the thermoplastic/CF material. Mechanical data was captured to guide material down selection for future commercially viable hydrogen aircraft design. In its current state, there does not exist a consolidated, publicly available database for CFRP composite material performance data at cryogenic temperatures. The next step in this work is to test the thermoplastic and thermoset CFRP composites, as well as the neat resins, at LH2 relevant temperature (20 K) to capture this crucial material property data. These results are essential to inform cryotank design and modeling efforts. The process to start this next round of testing has begun. Planned mechanical tests include toughness (single-edge notched beam), tension (unidirectional and quasi-isotropic), thermal expansion, and thermal conductivity. Some tests will also be conducted at an intermediate temperature of 111 K relevant to liquid natural gas (LNG), another attractive fuel choice. The ultimate goal is to manufacture a sub-scale cryotank part that can pass relevant burst, fatigue, permeation, and thermal cycling tests. This work is a part of NASA’s Commercially viable Hydrogen Aircraft for Robust Growth in Efficiency (CHARGE) Project under the larger NASA Subsonic Vehicle Technologies and Tools (SVTT) Project.

composites↗
NASA NTRS2012

Reducing Undue Conservatism in "Higher Frequency" Structural Design Loads in Aerospace Components

This study is intended to investigate the frequency dependency of significant strain due to vibratory loads in aerospace vehicle components. The notion that "higher frequency" dynamic loads applied as static loads is inherently conservative is perceived as widely accepted. This effort is focused on demonstrating that principle and attempting to evolve methods to capitalize on it to mitigate undue conservatism. It has been suggested that observations of higher frequency modes that resulted in very low corresponding strain did so due to those modes not being significant. Two avionics boxes, one with its first significant mode at 341 Hz and the other at 857 Hz, were attached to a flat panel installed on a curved orthogrid panel which was driven acoustically in tests performed at NASA/MSFC. Strain and acceleration were measured at select locations on each of the boxes. When possible, strain gage rosettes and accelerometers were installed on either side of a given structural member so that measured strain and acceleration data would directly correspond to one another. Ultimately, a frequency above which vibratory loads can be disregarded for purposes of static structural analyses and sizing of typical robust aerospace components is sought.

Knight, J. Brent↗
NASA NTRS1994

Split mandrel versus split sleeve coldworking: Dual methods for extending the fatigue life of metal structures

It is common practice to use split sleeve coldworking of fastener holes as a means of extending the fatigue life of metal structures. In search of lower manufacturing costs, the aerospace industry is examining the split mandrel (sleeveless) coldworking process as an alternative method of coldworking fastener holes in metal structures. The split mandrel process (SpM) significantly extends the fatigue life of metal structures through the introduction of a residual compressive stress in a manner that is very similar to the split sleeve system (SpSl). Since the split mandrel process is significantly less expensive than the split sleeve process and more adaptable to robotic automation, it will have a notable influence upon other new manufacture of metal structures which require coldworking a significant number of holes, provided the aerospace community recognizes that the resulting residual stress distributions and fatigue life improvement are the same for both processes. Considerable testing has validated the correctness of that conclusion. The findings presented in this paper represent the results of an extensive research and development program, comprising data collected from over 400 specimens fabricated from 2024-T3 and 7075-T651 aluminum alloys in varied configurations, which quantify the benefits (fatigue enhancement and cost savings) of automating a sleeveless coldworking system.

Rodman, Geoffrey A.↗
NASA NTRS1996

Study Thermographic Flaw Detection

The development of thermographic inspection methods for use on aerospace structures is under investigation. Several different material systems, structural geometries and defect types have been included in this study so as to establish a baseline from which future Infrared Thermography(IRT) testing can be made. This study examines various thermal loading techniques in an attempt to enhance the likelihood of capturing and identifying critically sized flaws under 'non laboratory' actual working conditions. Qualification techniques and calibration standards are also being investigated to standardize the thermographic method. In conjunction with the thermographic inspections, advanced image processing techniques including digital filtering and neural networks have been investigated to increase the ability of detecting and sizing flaws. Here, the digitized thermographic images are mathematically manipulated through various filtering techniques and/or artificial neural mapping schemes to enhance its overall quality, permitting accurate flaw identification even when the signal-to-noise ratio is low.

Walker, James L.↗
NASA NTRS2014

Magnetic Gearboxes for Aerospace Applications

Magnetic gearboxes are contactless mechanisms for torque-speed conversion. They present no wear, no friction and no fatigue. They need no lubricant and can be customized for other mechanical properties as stiffness or damping. Additionally, they can protect structures and mechanisms against overloads, limitting the transmitted torque. In this work, spur, planetary and "magdrive" or "harmonic drive" configurations are compared considering their use in aerospace applications. The most recent test data are summarized to provide some useful help for the design engineer.

Perez-Diaz, Jose Luis↗
NASA NTRSDate not supplied

High-Throughput Strategies that Encompass Experiments and Machine Learning to Predict the Mechanical Properties of Additive Manufactured Aerospace Alloys

Small Punch Test (SPT) uses a thin disk of material to predict mechanical properties. While SPT has existed for decades, it has been used largely as a qualitative evaluator of mechanical properties. Recent advances in computational modeling have enabled the extraction of uniaxial stress-strain response from the measured SPT load-displacement data. Due to small sample volumes and unidirectional testing, SPT is conducive to high-throughput automation and ideally suited to extract properties from high-cost materials. Aerospace alloys have been of recent interest to the Additive Manufacturing (AM) community due to AM’s unique ability to fabricate complex designs not possible, or extremely arduous, with conventional manufacturing. In this research, SPT, coupled with Materials Informatics and computational modeling, is used to develop relevant Process-Structure-Property relationships to decrease the cost and time of process optimization for AM aerospace alloys, namely Inconel 718, Inconel 625, and Niobium C103.

High-throughput Testing↗
DOE OSTI2024

DOC-DICAM: Domain Aware One Class Defect Identification in Composite Aerostructure Material

Fiber-reinforced composites are a common material used in the design of aircraft structures due to their good tensile strength and resistance to compression. During the manufacturing process, these structures are thoroughly inspected for flaws and defects to ensure structural integrity during commercial use. Non-destructive testing (NDT) is a collection of inspection methods that allow inspectors to evaluate material without altering it. Due to the high safety standards in aerospace manufacturing, the NDT process is done manually and can be a significant bottleneck in the development workflow. In this paper, we develop an AI-based assistance tool to drastically reduce inspection time. Typical AI workflows require large amounts of annotated data, but defects rarely occur resulting in strong class imbalance. To overcome this, we formulate the problem of defect identification as an anomaly detection task in which our primary focus is learning non-defect characteristics. To do this, we develop a multi-task self-supervised learning framework that embeds problem specific domain knowledge into the deep learning model. We verify our method using fuselage data generated in a production environment. As a result, we show that our method can effectively identify defects and requires minimal training and inference time.

anomaly detection↗
NASA NTRS1982

Studies of implicit and explicit solution techniques in transient thermal analysis of structures

Studies aimed at an increase in the efficiency of calculating transient temperature fields in complex aerospace vehicle structures are reported. The advantages and disadvantages of explicit and implicit algorithms are discussed and a promising set of implicit algorithms with variable time steps, known as GEARIB, is described. Test problems, used for evaluating and comparing various algorithms, are discussed and finite element models of the configurations are described. These problems include a coarse model of the Space Shuttle wing, an insulated frame tst article, a metallic panel for a thermal protection system, and detailed models of sections of the Space Shuttle wing. Results generally indicate a preference for implicit over explicit algorithms for transient structural heat transfer problems when the governing equations are stiff (typical of many practical problems such as insulated metal structures). The effects on algorithm performance of different models of an insulated cylinder are demonstrated. The stiffness of the problem is highly sensitive to modeling details and careful modeling can reduce the stiffness of the equations to the extent that explicit methods may become the best choice. Preliminary applications of a mixed implicit-explicit algorithm and operator splitting techniques for speeding up the solution of the algebraic equations are also described.

Adelman, H. M.↗
NASA NTRS1987

Experiments in advanced control concepts for space robotics - An overview of the Stanford Aerospace Robotics Laboratory

The Stanford University Aerospace Robotics Laboratory is actively developing and experimentally testing advanced robot control strategies for space robotic applications. Early experiments focused on control of very lightweight one-link manipulators and other flexible structures. The results are being extended to position and force control of mini-manipulators attached to flexible manipulators and multilink manipulators with flexible drive trains. Experimental results show that end-point sensing and careful dynamic modeling or adaptive control are key to the success of these control strategies. Free-flying space robot simulators that operate on an air cushion table have been built to test control strategies in which the dynamics of the base of the robot and the payload are important.

Hollars, M. G.↗
NASA NTRS1992

Structural Tailoring/Analysis for Hypersonic Components - A computational simulation

The development of STAHYC (Structural Tailoring/Analysis for Hypersonic Components), a numerical tool for the optimum design of an engine inlet wall panel for hypersonic aerospace vehicles, is described. STAHYC integrates FORTRAN modules of different disciplines, including fluid dynamics, heat transfer, structural analysis, and optimization. The discussion covers the system design concept, system components, system automation, system testing, established links, and data transfer between different computational modules. The various algorithms used in STAHYC are also discussed.

Narayanan, G. V.↗
NASA NTRS1998

Development of Multi-Disciplinary Finite Element Method Analysis Courses at California State University, Los Angeles

The NASA Dryden Flight Research Center (DFRC) Partnership Awards Grant to California State University, Los Angeles (CSULA) has two primary goals that help to achieve NASA objectives. The overall objectives of the NASA Partnership Awards are to create opportunities for joint University NASA/Government sponsored research and related activities. One of the goals of the grant is to have university faculty researchers participate and contribute to the development of NASA technology that supports NASA goals for research and development (R&D) in Aeronautics and Astronautics. The other goal is technology transfer in the other direction, where NASA developed technology is made available to the general public and more specifically, targeted to industries that can profit from utilization of government developed technology. This years NASA Dryden Partnership Awards grant to CSULA entitled, "Computer Simulation of Multi-Disciplinary Engineering Systems", has two major tasks that satisfy overall NASA objectives. The first task conducts basic and applied research that contributes to technology development at the Dryden Flight Research Center. The second part of the grant provides for dissemination of NASA developed technology, by using the teaching environment created in the CSULA classroom. The second task and how this is accomplished is the topic of this paper. The NASA STARS (Structural Analysis Routines) computer simulation program is used at the Dryden center to support flight testing of high-performance experimental aircraft and to conduct research and development of new and advanced Aerospace technology.

McKinney, John↗
NASA NTRS2009

Exploring Modeling Options and Conversion of Average Response to Appropriate Vibration Envelopes for a Typical Cylindrical Vehicle Panel with Rib-stiffened Design

Although applications for Statistical Energy Analysis (SEA) techniques are more widely used in the aerospace industry today, opportunities to anchor the response predictions using measured data from a flight-like launch vehicle structure are still quite valuable. Response and excitation data from a ground acoustic test at the Marshall Space Flight Center permitted the authors to compare and evaluate several modeling techniques available in the SEA module of the commercial code VA One. This paper provides an example of vibration response estimates developed using different modeling approaches to both approximate and bound the response of a flight-like vehicle panel. Since both vibration response and acoustic levels near the panel were available from the ground test, the evaluation provided an opportunity to learn how well the different modeling options can match band-averaged spectra developed from the test data. Additional work was performed to understand the spatial averaging of the measurements across the panel from measured data. Finally an evaluation/comparison of two conversion approaches from the statistical average response results that are output from an SEA analysis to a more useful envelope of response spectra appropriate to specify design and test vibration levels for a new vehicle.

Harrison, Phil↗
NASA NTRS2016

Aeroelastic Response of the Adaptive Compliant Trailing Edge Transtition Section

The Adaptive Compliant Trailing Edge demonstrator was a joint task under the Environmentally Responsible Aviation Project in partnership with the Air Force Research Laboratory and FlexSys, Inc. (Ann Arbor, Michigan), chartered by the National Aeronautics and Space Administration to develop advanced technologies that enable environmentally friendly aircraft, such as continuous mold-line technologies. The Adaptive Compliant Trailing Edge demonstrator encompassed replacing the Fowler flaps on the SubsoniC Aircraft Testbed, a Gulfstream III (Gulfstream Aerospace, Savannah, Georgia) aircraft, with control surfaces developed by FlexSys, Inc., a pair of uniquely-designed, unconventional flaps to be used as lifting surfaces during flight-testing to substantiate their structural effectiveness. The unconventional flaps consisted of a main flap section and two transition sections, inboard and outboard, which demonstrated the continuous mold-line technology. Unique characteristics of the transition sections provided a challenge to the airworthiness assessment for this part of the structure. A series of build-up tests and analyses were conducted to ensure the data required to support the airworthiness assessment were acquired and applied accurately. The transition sections were analyzed both as individual components and as part of the flight-test article assembly. Instrumentation was installed in the transition sections based on the analysis to best capture the in-flight aeroelastic response. Flight-testing was conducted and flight data were acquired to validate the analyses. This paper documents the details of the aeroelastic assessment and in-flight response of the transition sections of the unconventional Adaptive Compliant Trailing Edge flaps.

ground vibration test↗
NASA NTRS2009

Laser Surface Preparation and Bonding of Aerospace Structural Composites

A Nd:YAG laser was used to etch patterns conducive to adhesive bonding onto CFRP surfaces. These were compared to typical pre-bonding surface treatments including grit blasting, manual abrasion, and peel ply. Laser treated composites were then subjected to optical microscopy, contact angle measurements, and post-bonding mechanical testing.

Belcher, Marcus A.↗
NASA NTRS1982

Advances in metals processing

Research on metals processing being conducted to develop improved forming and joining methods with the potential of reducing the weight and cost of future aerospace structures is discussed. The approach followed is to assess the state of the art for fabricating a given structural system, define candidate methods for improving processing, evaluate the merits of each, fabricate and test subelement components, and then scale up the process to demonstrate validity. The development and the state of the art of weldbrazing, superplastic forming (SPF), superplastic forming and codiffusion bonding and superplastic forming and weldbrazing for titanium and the SPF of aluminum is discussed.

Thomas T. Bales↗
NASA NTRS2017

Assessment of Intralaminar Progressive Damage and Failure Analysis Using an Efficient Evaluation Framework

Reducing the timeline for development and certification for composite structures has been a long standing objective of the aerospace industry. This timeline can be further exacerbated when attempting to integrate new fiber-reinforced composite materials due to the large number of testing required at every level of design. computational progressive damage and failure analysis (PDFA) attempts to mitigate this effect; however, new PDFA methods have been slow to be adopted in industry since material model evaluation techniques have not been fully defined. This study presents an efficient evaluation framework which uses a piecewise verification and validation (V&V) approach for PDFA methods. Specifically, the framework is applied to evaluate PDFA research codes within the context of intralaminar damage. Methods are incrementally taken through various V&V exercises specifically tailored to study PDFA intralaminar damage modeling capability. Finally, methods are evaluated against a defined set of success criteria to highlight successes and limitations.

Hyder, Imran↗