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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 NTRS2011

Design, Development and Test Challenges: Separation Mechanisms for the Orion Pad Abort-1 Flight Test

On May 6, 2010, NASA launched the first successful integrated flight test, Pad Abort-1, of the Orion Project from the White Sands Missile Range in Las Cruces, New Mexico. This test demonstrated the ability to perform an emergency pad abort of a full-scale 4.8 m diameter, 8200 kg crew capsule. During development of the critical separation mechanisms for this flight test, various challenges were overcome related to environments definition, installation complications, separation joint retraction speed, thruster ordnance development issues, load path validation and significant design loads increases. The Launch Abort System retention and release (LAS R&R) mechanism consisted of 6 discrete structural connections between the LAS and the crew module (CM) simulator, each of which had a preloaded tension tie, Superbolt torque-nut and frangible nut. During the flight test, the frangible nuts were pyrotechnically split, permitting the CM to separate from the LAS. The LAS separation event was the driving case in the shock environment for many co-located hardware items. During development testing, it was necessary to measure the source shock during the separation event so the predicted shock environment could be validated and used for certification testing of multiple hardware items. The Lockheed Martin test team measured the source separation shock due to the LAS R&R function, which dramatically decreased the predicted environment by 90% at 100 Hz. During development testing a hydraulic tensioner was used to preload the joint; however, the joint relaxation with the tensioner proved unsatisfactory so the design was modified to include a Superbolt torque-nut. The observed preload creep during lab testing was 4% after 30 days, with 2.5% occurring in the first 24 hours. The conversion of strain energy (preload) to kinetic energy (retraction) was measured to be 50-75%. Design features and careful monitoring of multiple strain gauges on each tension tie allowed a pure tensile load to be applied after stacking at the launch pad. Following installation, preload in each joint was monitored for 24 hours. Due to unforeseen complications and the influence of temperature on the portable data acquisition system, the team encountered difficulty in tracking the joint relaxation. In some cases, bond-line failure of the strain gauges occurred.

Dinsel, Alison↗
DOE OSTI2025

A simplified approach for creep damage and remaining life calculation for materials surveillance in advanced reactors

High temperature reactor materials will experience a combination of mechanical degradation caused by creep and fatigue and environmental degradation caused by neutron irradiation and, in some cases, exposure to corrosive coolants. A materials surveillance program is one option for ensuring the safe, reliable operation of key reactor components under these conditions. Such a program would monitor the degradation in key material properties over time, using this data to predict how changes in the material properties affect components performance. This could then be used to make plant operational decisions and support eventual plant license extensions. Past work de-scribes such a material surveillance program based on passively actuated mechanical test articles that impose creep-fatigue type loading on test materials driven only by changes in temperature, for example those experienced by components under standard operating cycles. This report focuses on two aspects of the proposed material surveillance program: how to design the test articles to mimic the mechanical response of the corresponding component and how to use ex-situ test data to deter-mine the amount of damaged experienced by the test article (and hence the corresponding compo-nent) in service. Specifically, this report derives and validated simplified methods for both tasks, replacing earlier, more complicated approaches based on simulating the test article response and finding the best specimen design or current damage via complex numerical optimization. The sim-plified methods for each task developed here can be implemented in spreadsheet software and are simple enough for practical use in future operating plants. This report derives the methods (one for sizing and two options for damage inference), verifies the simplified approaches versus more so-phisticated methods, and compares the results of applying the simplified methods to previous re-sults using the complex numerical optimization approach. The report also provides a worked sam-pled problem applying the simplified techniques to a realistic high temperature reactor component.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2007

Capabilities and History of NASA Marshall Space Flight Center's Hydrogen Test Facility

The Hydrogen Test Facility (HTF) has conducted mechanical testing for aerospace materials at NASA's Marshall Space Flight Center for many years. One of the first facilities of its kind to run high-pressure cryogenic permeability tests in liquid hydrogen, HTF is now characterized as a unique national resource capable of overcoming hazardous conditions to perform tests directly in various hydrogen environments. At HTF, custom test systems are operated in eight structurally reinforced test cells from 0 to 68,948 kPa (0 to 10,000 psi) at -253 to 982 C (--423 to 1800 F) in hydrogen, air, helium, and nitrogen, with other environments available upon request. Standard mechanical procedures include compression, fatigue crack growth rate, four-point bend, high/low cycle fatigue, fracture toughness, shear, strain-to-crack, and tensile testing. Cryogenic permeability and thermal conductivity and gaseous creep testing are offered, as well as simulated service under different combinations of operating environment(s), stress, pressure, and ambient-to-extreme temperatures. Advanced tests are routinely developed upon demand, and special component testing is also available. Current efforts include the renovation of two high-pressure gaseous test cells to generate data for a J-2X engine designed for Constellation's Ares I and V vehicles. In the past, HTF has supported other critical NASA programs, such as Apollo, Space Shuttle, and Next Generation Launch Technologies. During the 1990's, hundreds of tests were conducted in liquid hydrogen and liquid nitrogen during development of the Space Shuttle's super lightweight tank, which provided the thrust required to achieve low Earth orbit for the International Space Station. This facility was designed and built in 1963. Originally called the Low Temperature Test Facility, it became known as the Cryogenic Test Facility in the late 1980's and HTF in the early 1990's.

Malone, T. W.↗
NASA NTRS1974

The peel test in experimental adhesive fracture mechanics

Several testing methods have been proposed for obtaining critical energy release rate or adhesive fracture energy in bond systems. These tests include blister, cone, lap shear, and peel tests. Peel tests have been used for many years to compare relative strengths of different adhesives, different surface preparation techniques, etc. The present work demonstrates the potential use of the peel test for obtaining adhesive fracture energy values.

Anderson, G. P.↗
NASA NTRS2004

Mechanical Components Branch Test Facilities and Capabilities

The Mechanical Components Branch at NASA Glenn Research Center formulates, conducts, and manages research focused on propulsion systems for both present and advanced aeronautical and space vehicles. The branch is comprised of research teams that perform basic research in three areas: mechanical drives, aerospace seals, and space mechanisms. Each team has unique facilities for testing aerospace hardware and concepts. This report presents an overview of the Mechanical Components Branch test facilities.

Oswald, Fred B.↗
NASA NTRSDate not supplied

Nb-1Zr L-PBF In-situ Alloying and Elevated Temperature Mechanical Performance

Nb-1Zr is a readily-fabricable, dispersion-strengthened niobium alloy with improved elevated temperature properties compared to commercially pure niobium. This moderate strength niobium alloy is desirable in thermal management systems for fission power and propulsion applications; however, pre-alloyed spherical feedstock is generally unavailable. Laser powder bed fusion (L-PBF) in-situ alloying of a Nb-1Zr chemistry was performed using a pure niobium feedstock coated with 1 wt% of zirconium-based ceramic compound nano-powders. The additively manufactured material was mechanically tested at elevated temperatures in a controlled environment in the as-built condition. For comparison, traditionally manufactured wrought feedstock was also tested under identical conditions. Examination of the materials’ microstructure and elevated temperature mechanical response aimed to determine the Zr-compound nano-powder addition with the best performance, and the overall feasibility of the in-situ alloying approach.

Niobium-based alloys↗
NASA NTRS1973

Pioneer Venus mechanical roots pump test and evaluation

A mechanical pump for use with the Pioneer-Venus probe mass spectrometer inlet system was obtained, and a limited performance testing program, including ultimate/compression ratio tests and throughput tests at three different pump speeds, was performed. Considerable operating experience with the pump was obtained over approximately 200 hours of running. The test results show general agreement with pump specifications.

Thomas, N. C.↗
NASA NTRSDate not supplied

Environmental Testing Of High Temperature Materials and Coatings

Materials for today′s extreme environments have unique challenges and design requirements that require multi-faceted evaluations. Thermal and mechanical testing and analysis is important in design, but environmental effects are often the limiting factor of materials in service. Degradation modes such as oxidation, recession, erosion, foreign object damage, and chemical corrosion can negatively impact the materials thermo-mechanical behavior. While materials may ultimately fail under thermo−mechanical stresses, environmental effects are many times the root cause. Evaluation of materials systems under relevant conditions are critical.....start by identifying mechanisms and develop corresponding test methods. Comprehensive modeling begins with thermo-mechanical behavior, then considers environmental degradation modes that provide a “knock down” of that behavior.

Thermal testing Mechanical testing↗
NASA NTRSDate not supplied

In-situ Inspection of Reflowable-Interface Composite Joints During Cure in an Autoclave

In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bonded performance. Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process. The reflow and intermixing of the matrix resin during assembly can eliminate the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion at a nearly two-dimensional boundary. AERoBOND process development has evaluated a multitude of parameters including the materials used, the stoichiometric offset of the epoxy resins, time and temperature of cure, and thickness of each ply. Without in-situ process monitoring, the condition of a test article is unknown until mechanical testing is completed. This presentation describes the use of an in-situ ultrasonic inspection system to monitor the joining of two composite parts assembled using the AERoBOND technique. This work quantifies the elimination of the interface by measuring the wave reflection, or lack thereof, at the joint throughout the cure cycle. In addition, the results indicate when reflow and cure of the epoxy resin at the joint occurred. By using the recently developed in-situ inspection with a mobile ultrasonic transducer, localized results can be obtained across a large portion of the joint with high resolution.

Tyler B Hudson↗
NASA NTRSDate not supplied

In-situ Inspection of Reflowable-Interface Composite Joints During Cure in an Autoclave

In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bonded performance. Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process. The reflow and intermixing of the matrix resin during assembly can eliminate the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion at a nearly two-dimensional boundary. AERoBOND process development has evaluated a multitude of parameters including the materials used, the stoichiometric offset of the epoxy resins, time and temperature of cure, and thickness of each ply. Without in-situ process monitoring, the condition of a test article is unknown until mechanical testing is completed. This presentation describes the use of an in-situ ultrasonic inspection system to monitor the joining of two composite parts assembled using the AERoBOND technique. This work quantifies the elimination of the interface by measuring the wave reflection, or lack thereof, at the joint throughout the cure cycle. In addition, the results indicate when reflow and cure of the epoxy resin at the joint occurred. By using the recently developed in-situ inspection with a mobile ultrasonic transducer, localized results can be obtained across a large portion of the joint with high resolution.

Tyler B Hudson↗
NASA NTRSDate not supplied

In-situ Inspection of Reflowable-Interface Composite Joints During Cure in an Autoclave

In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded primary-structures to alleviate the inability to certify bonded performance. To address this issue, the NASA Convergent Aeronautics Solutions (CAS): Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process. The reflow and intermixing of the matrix resin during assembly can eliminate the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion at a nearly two-dimensional boundary. AERoBOND process development has evaluated a multitude of parameters including the materials used, the stoichiometric offset of the epoxy resins, time and temperature of cure, and thickness of each ply. Without in-situ process monitoring, the condition of a test article is unknown until mechanical testing is completed. This paper describes the use of an in-situ ultrasonic inspection system to monitor the joining of two composite parts assembled using the AERoBOND technique. This work quantifies the interface by measuring the wave reflection, or lack thereof, at the joint throughout the cure cycle. In addition, the results indicate when reflow and cure of the epoxy resin at the joint occurred. By using the recently developed in-situ inspection method with a mobile ultrasonic transducer, localized results can be obtained across a large portion of the joint with high resolution.

Tyler B Hudson↗
NASA NTRS2017

Overview of the Acoustic Testing of the European Service Module Structural Test Article (E-STA)

The European Space Agency (ESA) and their prime contractor Airbus Defense Space (ADS) are developing the European Service Module (ESM) for integration and utilization with other modules of NASAs Orion Multi-Purpose Crew Vehicle. As part of this development, ESA, ADS, NASA and the Lockheed Martin Company performed a series of reverberant acoustic tests in April-May 2016 on the ESM Structural Test Article (E-STA), the mechanical mock-up of the ESM designated for mechanical tests. Testing the E-STA under acoustic qualification loads verifies whether it can successfully withstand the medium and high frequency mechanical environment occurring during the vehicles lift-off and atmospheric phases of flight. The testing occurred at the Reverberant Acoustic Test Facility (RATF) at the NASA Glenn Research Centers Plum Brook Station site in Sandusky, OH, USA. This highly successful acoustic test campaign excited the E-STA to acoustic test levels as high as 149.4 dB Overall Sound Pressure Level. This acoustic testing met all the ESA and ADSs test objectives, including establishing/verifying the random vibration qualification test levels for numerous hardware components of the ESM, and qualifying the ESMs Solar Array Wing electrical power system. This paper will address the test objectives, the test articles configuration, the test instrumentation and excitation levels, the RATF site and capabilities, the series of acoustic tests performed, and the technical issues faced and overcome to result in a successful acoustic test campaign for the ESM. A discussion of several test results is also included.

Qualification↗
NASA NTRS2017

Overview of the Acoustic Testing of the European Service Module Structural Test Article (E-STA)

The European Space Agency (ESA) and their prime contractor Airbus Defense Space (ADS) are developing the European Service Module (ESM) for integration and utilization with other modules of NASAs Orion Multi-Purpose Crew Vehicle. As part of this development, ESA, ADS, NASA and the Lockheed Martin Company performed a series of reverberant acoustic tests in April-May 2016 on the ESM Structural Test Article (E-STA), the mechanical mock-up of the ESM designated for mechanical tests. Testing the E-STA under acoustic qualification loads verifies whether it can successfully withstand the medium and high frequency mechanical environment occurring during the vehicles lift-off and atmospheric phases of flight. The testing occurred at the Reverberant Acoustic Test Facility (RATF) at the NASA Glenn Research Centers Plum Brook Station site in Sandusky, OH, USA. This highly successful acoustic test campaign excited the E-STA to acoustic test levels as high as 149.4 dB Overall Sound Pressure Level. This acoustic testing met all the ESA and ADSs test objectives, including establishingverifying the random vibration qualification test levels for numerous hardware components of the ESM, and qualifying the ESMs Solar Array Wing electrical power system. This paper will address the test objectives, the test articles configuration, the test instrumentation and excitation levels, the RATF site and capabilities, the series of acoustic tests performed, and the technical issues faced and overcome to result in a successful acoustic test campaign for the ESM. A discussion of several test results is also included.

Testing↗
NASA NTRS2017

Overview of the Acoustic Testing of the European Service Module Structural Test Article (E-STA)

The European Space Agency (ESA) and their prime contractor Airbus Defense Space (ADS) are developing the European Service Module (ESM) for integration and utilization with other modules of NASAs Orion Multi-Purpose Crew Vehicle. As part of this development, ESA, ADS, NASA and the Lockheed Martin Company performed a series of reverberant acoustic tests in April-May 2016 on the ESM Structural Test Article (E-STA), the mechanical mock-up of the ESM designated for mechanical tests. Testing the E-STA under acoustic qualification loads verifies whether it can successfully withstand the medium and high frequency mechanical environment occurring during the vehicles lift-off and atmospheric phases of flight. The testing occurred at the Reverberant Acoustic Test Facility (RATF) at the NASA Glenn Research Centers Plum Brook Station site in Sandusky, OH, USA. This highly successful acoustic test campaign excited the E-STA to acoustic test levels as high as 149.4 dB Overall Sound Pressure Level. This acoustic testing met all the ESA and ADSs test objectives, including establishingverifying the random vibration qualification test levels for numerous hardware components of the ESM, and qualifying the ESMs Solar Array Wing electrical power system. This paper will address the test objectives, the test articles configuration, the test instrumentation and excitation levels, the RATF site and capabilities, the series of acoustic tests performed, and the technical issues faced and overcome to result in a successful acoustic test campaign for the ESM. A discussion of several test results is also included.

Qualification↗
NASA NTRS2021

Latent Cure Epoxy Resins for Reliable Joints in Secondary-Bonded Composite Structures

In high-performance polymer matrix composite assemblies, adhesive bonding is generally superior to mechanical fastening in structural performance and manufacturing efficiency. However, adhesive bonds are susceptible to minute levels of contamination accumulated during assembly that can lead to unpredictable, weak bonds. Current methods of measuring bond strength are all destructive mechanical tests. To overcome these challenges, redundant load paths (e.g., mechanical fasteners) are often implemented in secondary-bonded, primary-structures, which can greatly reduce structural performance. This study investigated reformulated aerospace epoxy matrix resins with stoichiometric offset to inhibit cure of the matrix resin prior to assembly. Inhibited resins can reflow and mix across the joint interface, which eliminates the material discontinuity and forms a homogenous joint with reliable fracture properties. The goal of this study was to develop and demonstrate secondary composite assemblies that are mechanically and microscopically indistinguishable from a co-cured composite joint. This article describes the development of latent epoxy resins, the fabrication of test articles, and the mechanical properties measured from experimental joints compared with conventional, co-cured laminates. Methods of in-line quality control using and infrared spectroscopy and post-assembly forensics are also described. The final mode-II fracture toughness measured from precracked AERoBOND specimens was similar to that measured from co-cured laminates indicating that later cure epoxy materials could be a suitable replacement for secondary bonding.

Polymer-matrix composites (PMCs)↗
NASA NTRSDate not supplied

3D Printed Ceramic Reinforced Polymer Composites Microstructure and Mechanical Properties

In Fused Filament Fabrication (FFF) 3D printing a part is made by extruding material layer by layer. Benefits of FFF are the ability to print complex shapes quickly and at a lower cost compared to other manufacturing methods. In this work, filaments composed of either silicon carbide (SiC) or zirconium silicate ceramic particulates in a polylactic-acid (PLA) matrix were used to print specimens for microstructural analysis and mechanical testing. Pure PLA samples were also printed and tested as a baseline for comparison. A Design of Experiments approach was used to test the interactions between three different parameters and their effect on ultimate strength, Young’s modulus, and yield strength. For compression test specimens, these parameters were infill percentage, number of shells, and print orientation angle. For tensile test specimens, the parameters were layer height, number of shells, and infill orientation angle. Pre- and post-compression test samples were evaluated by scanning electron microscopy for microstructural analysis. Infill percentage had the greatest effect on mechanical properties while number of shells and print orientation angle had minor effects. When changing the layer lines from perpendicular to parallel, relative to the loading direction, SiC-PLA had higher mechanical properties while pure PLA properties had decreased, and zirconium silicate-PLA had mix results.

Fused filament fabrication↗
NASA NTRS2015

Mechanical Properties and Real-Time Damage Evaluations of Environmental Barrier Coated SiC/SiC CMCs Subjected to Tensile Loading Under Thermal Gradients

SiC/SiC ceramic matrix composites (CMCs) require new state-of-the art environmental barrier coatings (EBCs) to withstand increased temperature requirements and high velocity combustion corrosive combustion gasses. The present work compares the response of coated and uncoated SiC/SiC CMC substrates subjected to simulated engine environments followed by high temperature mechanical testing to asses retained properties and damage mechanisms. Our focus is to explore the capabilities of electrical resistance (ER) measurements as an NDE technique for testing of retained properties under combined high heat-flux and mechanical loading conditions. Furthermore, Acoustic Emission (AE) measurements and Digital Image Correlation (DIC) were performed to determine material damage onset and accumulation.

Ceramic matrix composites↗