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NASA NTRS1989

Structural materials for space applications

The long-term performance of structural materials in the space environment is a key research activity within NASA. The primary concerns for materials in low Earth orbit (LEO) are atomic oxygen erosion and space debris impact. Atomic oxygen studies have included both laboratory exposures in atomic oxygen facilities and flight exposures using the Shuttle. Characterization of atomic oxygen interaction with materials has included surface recession rates, residual mechanical properties, optical property measurements, and surface analyses to establish chemical changes. The Long Duration Exposure Facility (LDEF) is scheduled to be retrieved in 1989 and is expected to provide a wealth of data on atomic oxygen erosion in space. Hypervelocity impact studies have been conducted to establish damage mechanisms and changes in mechanical properties. Samples from LDEF will be analyzed to determine the severity of space debris impact on coatings, films, and composites. Spacecraft placed in geosynchronous Earth orbit (GEO) will be subjected to high doses of ionizing radiation which for long term exposures will exceed the damage threshold of many polymeric materials. Radiation interaction with polymers can result in chain scission and/or cross-linking. The formation of low molecular weight products in the epoxy plasticize the matrix at elevated temperatures and embrittle the matrix at low temperatures. This affects both the matrix-dominated mechanical properties and the dimensional stability of the composite. Embrittlement of the matrix at low temperatures results in enhanced matrix microcracking during thermal cycling. Matrix microcracking changes the coefficient of thermal expansion (CTE) of composite laminates and produces permanent length changes. Residual stress calculations were performed to estimate the conditions necessary for microcrack development in unirradiated and irradiated composites. The effects of UV and electron exposure on the optical properties of transparent polymer films were also examined to establish the optimum chemical structure for good radiation resistance. Thoughts on approaches to establishing accelerated testing procedures are discussed.

Tenney, Darrel R.↗

NASA NTRS1990

Effect of KOH concentration on LEO cycle life of IPV nickel-hydrogen flight battery cells

A breakthrough in the low-earth-orbit (LEO) cycle life of individual pressure vessel (IPV) nickel hydrogen battery cells is reported. The cycle life of boiler plate cells containing 26 percent potassium hydroxide (KOH) electrolyte was about 40,000 LEO cycles compared to 3500 cycles for cells containing 31 percent KOH. The effect of KOH concentration on cycle life was studied. The cycle regime was a stressful accelerated LEO, which consisted of a 27.5 min charge followed by a 17.5 min charge (2 x normal rate). The depth of discharge (DOD) was 80 percent. The cell temperature was maintained at 23 C. The next step is to validate these results using flight hardware and real time LEO test. NASA Lewis has a contract with the Naval Weapons Support Center (NWSC), Crane, Indiana to validate the boiler plate test results. Six 48 A-hr Hughes recirculation design IPV nickel-hydrogen flight battery cells are being evaluated. Three of the cells contain 26 percent KOH (test cells) and three contain 31 percent KOH (control cells). They are undergoing real time LEO cycle life testing. The cycle regime is a 90-min LEO orbit consisting of a 54-min charge followed by a 36-min discharge. The depth-of-discharge is 80 percent. The cell temperature is maintained at 10 C. The cells were cycled for over 8000 cycles in the continuing test. There were no failures for the cells containing 26 percent KOH. There were two failures, however, for the cells containing 31 percent KOH.

Smithrick, John J.↗

NASA NTRS2007

Measurement of Creep Properties of Ultra-High-Temperature Materials by a Novel Non-Contact Technique

A non-contact technique for measuring the creep properties of materials has been developed and validated as part of a collaboration among the University of Massachusetts, NASA Marshall Space Flight Center Electrostatic Levitation Facility (ESL), and the University of Tennessee. This novel method has several advantages over conventional creep testing. The sample is deformed by the centripetal acceleration from the rapid rotation, and the deformed shapes are analyzed to determine the strain. Since there is no contact with grips, there is no theoretical maximum temperature and no concern about chemical compatibility. Materials may be tested at the service temperature even for extreme environments such as rocket nozzles, or above the service temperature for accelerated testing of materials for applications such as jet engines or turbopumps for liquid-fueled engines. The creep measurements have been demonstrated to 2400 C with niobium, while the test facility, the NASA MSFC ESL, has processed materials up to 3400 C. Furthermore, the ESL creep method employs a distribution of stress to determine the stress exponent from a single test, versus the many tests required by conventional methods. Determination of the stress exponent from the ESL creep tests requires very precise measurement of the surface shape of the deformed sample for comparison to deformations predicted by finite element models for different stress exponents. An error analysis shows that the stress exponent can be determined to about 1% accuracy with the current methods and apparatus. The creep properties of single-crystal niobium at 1985 C showed excellent agreement with conventional tests performed according to ASTM Standard E-139. Tests on other metals, ceramics, and composites relevant to rocket propulsion and turbine engines are underway.

Hyers, Robert W.↗

NASA NTRS1979

Plasma volume during stress in man - Osmolality and red cell volume

The purpose was (1) to test the hypothesis that in man there is a range of plasma osmolality within which the red cell volume (RCV) and mean corpuscular volume (MCV) remain essentially constant and (2) to determine the upper limit of this range. During a variety of stresses - submaximal and maximal exercise, heat and altitude exposure, +Gz acceleration, and tilting - changes in plasma osmolality between -1 and +13 mosmol/kg resulted in essentially no change in the regression of percent change in plasma volume (PV) calculated from a change in hematocrit (Hct) on that calculated from a change in Hct + hemoglobin (Hb), i.e., the RCV and MCV were constant. Factors that do not influence RCV are the level of metabolism, heat exposure at rest, and short-term orthostasis (heat-to-foot acceleration). Factors that may influence RCV are exposure to high altitude and long-term orthostasis (head-up tilting). Factors that definitely influence RCV are prior dehydration and extended periods of stress. Thus, either the Hct or the Hct + Hb equations can be used to calculate percent changes in PV under short-term periods of stress when the change in plasma osmolality is less than 13 mosmol/kg.

Greenleaf, J. E.↗

NASA NTRS1990

Effect of KOH concentration on LEO cycle life of IPV nickel-hydrogen flight battery cells

A breakthrough in low earth orbit (LEO) cycle life of individual pressure vessel (IPV) nickel hydrogen battery cells was reported. The cycle life of boiler plate cells containing 26 percent potassium hydroxide (KOH) electrolyte was about 40,000 LEO cycles compared to 3500 cycles for cells containing 31 percent KOH. The effect of KOH concentration on cycle life was studied. The cycle regime was a stressful accelerated LEO, which consisted of a 27.5 min charge followed by a 17.5 min charge (2 x normal rate). The depth of discharge (DOD) was 80 percent. The cell temperature was maintained at 23 C. The next step is to validate these results using flight hardware and a real time LEO test. NASA Lewis has a contract with the Naval Weapons Support Center (NWSC), Crane, Indiana, to validate the boiler plate test results. Six 48 A-hr Hughes recirculation design IPV nickel-hydrogen flight battery cells are being evaluated. Three of the cells contain 26 percent KOH (test cells) and three contain 31 percent KOH (control cells). They are undergoing real time LEO cycle life testing. The cycle regime is a 90-min LEO orbit consisting of a 54-min charge followed by a 36-min discharge. The depth-of-discharge is 80 percent. The cell temperature is maintained at 10 C. The cells were cycled for over 8000 cycles in the continuing test. There were no failures for the cells containing 26 percent KOH. There was two failures, however, for the cells containing 31 percent KOH.

Smithrick, John J.↗

NASA NTRS1977

The effect of increased gravitational stress on bone

A group of 34 adult male chickens were chronically accelerated over an 18-week period; for the last 4 weeks the surviving animals were subjected to a 3-g field. Males of a similar weight and age were used as static controls. The objective was to evaluate the effects of an altered gravitational state on the physical properties of the tibia bone tested for torsional fracture. Of the 34 initial animals, 15 survived for the entire period and were subjected to analysis. The results suggest that the altered morphology produced by increased gravitational fields does not materially affect bone strength, at least in torsion. Decreased bone diameters were accompanied by increased cortical thickness without change in the bone resistance to torsion. The findings of increased cortical thickness with decreased bone diameter suggest reversal of the usual cellular dynamics of adult bone. Data on bone ash and density failed to reveal any substantial changes in bone mineral or organic content. Histological examination of the cortical bone did not disclose any evidence of pathology.

Riggins, R. S.↗

NASA NTRS1987

Measurement, data analysis and prediction of pyrotechnic shock from pin-pullers and separation joints

To evaluate the potential for spacecraft damage caused by activation of pyrotechnic mechanisms, pyrotechnic shock tests were conducted on three configurations: pin-pullers on an orthogonal double Hopkinson bar arrangement, pin-pullers on a mock-up of the HALOE (Halogen Occultation Experiment) structure, and a section of separation joint on a single Hopkinson bar. Strains and accelerations were measured. The strains were converted to output stresses, forces and moments. Acceleration shock response spectra are presented for both acceleration- and force-time signals. The devices were attached to the Hopkinson bars with adaptors, which are typical of attachments used in practice. In order to predict the effect of the adaptors, finite element models of the adaptor-bar combinations were analyzed and results are presented with regard to grid size, time interval, and frequency range required to predict the response to pulses of 10 and 100 microsecond duration.

Evans, Maria J.↗

NASA NTRS1959

Engine Operating Conditions that Cause Thermal-Fatigue Cracks in Turbojet-Engine Buckets

Five engine tests were conducted to definitely establish the failure mechanism of leading-edge cracking and to determine which conditions of engine operation cause the failures. Five groups of S-616 and M-252 buckets from master lots were run consecutively in the same J47-25 engine. The tests included a steady-state run at full-power conditions, rapid cycling between idle and rated speed, and three different start-stop tests. The first start-stop test consisted of cycles of start and stop with 5 minutes of idle speed before each stop; the second included cycles of start and stop but with 15 minutes of rated speed before each stop; the third consisted of cycles of gradual starts and normal stops with 5 minutes at idle speed before each stop. The test results demonstrated that the primary cause of leading-edge cracking was thermal fatigue produced by repeated engine starts. The leading edge of the bucket experiences plastic flow in compression during starts and consequently is subjected to a tensile stress when the remainder of the bucket becomes heated and expands. Crack initiation was accelerated when rated-speed operation was added to each normal start-stop cycle. This acceleration of crack formation was attributed to localized creep damage and perhaps to embrittlement resulting from overaging. It was demonstrated that leading-edge cracking can be prevented simply by starting the engine gradually.

Johnston, James R.↗

NASA NTRS1998

Accelerated Strength Testing of Thermoplastic Composites

Constant ramp strength tests on unidirectional thermoplastic composite specimens oriented in the 90 deg. direction were conducted at constant temperatures ranging from 149 C to 232 C. Ramp rates spanning 5 orders of magnitude were tested so that failures occurred in the range from 0.5 sec. to 24 hrs. (0.5 to 100,000 MPa/sec). Below 204 C, time-temperature superposition held allowing strength at longer times to be estimated from strength tests at shorter times but higher temperatures. The data indicated that a 50% drop in strength might be expected for this material when the test time is increased by 9 orders of magnitude. The shift factors derived from compliance data applied well to the strength results. To explain the link between compliance and strength, a viscoelastic fracture model was investigated. The model, which used compliance as input, was found to fit the strength data only if the critical fracture energy was allowed to vary with temperature reduced stress rate. This variation in the critical parameter severely limits its use in developing a robust time-dependent strength model. The significance of this research is therefore seen as providing both the indication that a more versatile acceleration method for strength can be developed and the evidence that such a method is needed.

Reeder, J. R.↗

NASA NTRS1987

Time-temperature-stress capabilities of composite materials for advanced supersonic technology application

Advanced composites will play a key role in the development of the technology for the design and fabrication of future supersonic vehicles. However, incorporating the material into vehicle usage is contingent on accelerating the demonstration of service capacity and design technology. Because of the added material complexity and lack of extensive data, laboratory replication of the flight service will provide the most rapid method to document the airworthiness of advanced composite systems. Consequently, a laboratory program was conducted to determine the time-temperature-stress capabilities of several high temperature composites. Tests included were thermal aging, environmental aging, fatigue, creep, fracture, tensile, and real-time flight simulation exposure. The program had two phases. The first included all the material property determinations and aging and simulation exposures up through 10,000 hours. The second continued these tests up to 50,000 cumulative hours. This report presents the results of the Phase 1 baseline and 10,000-hr aging and flight simulation studies, the Phase 2 50,000-hr aging studies, and the Phase 2 flight simulation tests, some of which extended to almost 40,000 hours.

Kerr, James R.↗

NASA NTRS2006

Aeolian Shear Stress Ratio Measurements within Mesquite-Dominated Landscapes of the Chihuahuan Desert, New Mexico, USA

A field study was conducted to ascertain the amount of protection that mesquite-dominated communities provide to the surface from wind erosion. The dynamics of the locally accelerated evolution of a mesquite/coppice dune landscape and the undetermined spatial dependence of potential erosion by wind from a shear stress partition model were investigated. Sediment transport and dust emission processes are governed by the amount of protection that can be provided by roughness elements. Although shear stress partition models exist that can describe this, their accuracy has only been tested against a limited dataset because instrumentation has previously been unable to provide the necessary measurements. This study combines the use of meteorological towers and surface shear stress measurements with Irwin sensors to measure the partition of shear stress in situ. The surface shear stress within preferentially aligned vegetation (within coppice dune development) exhibited highly skewed distributions, while a more homogenous surface stress was recorded at a site with less developed coppice dunes. Above the vegetation, the logarithmic velocity profile deduced roughness length (based on 10-min averages) exhibited a distinct correlation with compass direction for the site with vegetation preferentially aligned, while the site with more homogenously distributed vegetation showed very little variation in the roughness length. This distribution in roughness length within an area, defines a distribution of a resolved shear stress partitioning model based on these measurements, ultimately providing potential closure to a previously uncorrelated model parameter.

King, James↗

NASA NTRS2000

Bed Rest and Orthostatic-Hypotensive Intolerance

Orthostatic tolerance may be defined as the ability of humans to maintain cerebral perfusion and consciousness upon movement from a supine or sitting position to the upright posture; for example, subjects can stand suddenly or be tilted to the head-up body position. Similar but not identical physiological responses can be induced by positive G(sub Z) (head to foot) acceleration or exposure to lower body negative pressure (LBNP). The objective is to suddenly shift blood to the lower body to determine how effectively cardiovascular and neural-hormonal compensatory responses react to maintain blood pressure. In the most precise method for measuring tolerance, individuals would be stressed until they faint (syncope). However, the potential consequences and discomforts of such a test usually prohibit such a procedure so that few investigators actually induce syncope. In a more common approach, subjects are exposed to a given level of stress, for example, head-up tilt for 15 min, and any increases in heart rate or decreases in blood pressure are interpreted as indicators of progress toward syncope. Presumably, the greater the perturbation of heart rate and blood pressure, the closer to "tolerance," i.e., point of unconsciousness. Another more appropriate approach is to induce a progressively increasing hypotensive stress until pre-determined physiological responses or pre-syncopal symptoms appear. The physiological criteria may include a sudden drop in systolic blood pressure (greater than 25 mm/min), a sudden drop in heart rate (greater than 15 beats/min), or a systolic blood pressure less than 70 mmHg. The most common pre-syncopal symptoms include lightheadedness, stomach awareness or distress, feelings of warmth, tingly skin, and light to profuse sweating. Usually a combination of physiological responses and symptoms occurs such that, on different days, the tolerance time to the same orthostatic protocol is reproducible for a given individual. The assumption is that by taking subjects to near fainting, one can determine their tolerance. This latter pre-syncopal approach is better for estimating orthostatic or hypotensive tolerance than the former measurement of heart rate and blood pressure responses to a given stress. There is considerable variability in individual responses to orthostasis. For example, some subjects are "heart-rate responders" and have a pronounced cardiovascular response similar to that when performing moderately hard aerobic exercise, whereas others may experience pre-syncopal symptoms with very little increase in heart rate. Some individuals have a slow, gradual fall in blood pressure to orthostasis, and others have little change in blood pressure until a sudden precipitous fall in pressure occurs just prior to fainting. With both tilt and LBNP tests there is a low correlation between heart-rate or blood-pressure responses to a sub-tolerance stress as a measure of pre-syncopal limited orthostatic-hypotensive tolerance.

Schneider, Suzanne M.↗

NASA NTRS2003

Numerical Modeling, Thermomechanical Testing, and NDE Procedures for Prediction of Microcracking Induced Permeability of Cryogenic Composites

Reusable Space Vehicles will include light cryogenic composite fuel tanks that must not leak excessively even after multiple launches. Damage in cryogenic composite fuel tanks induced during manufacturing and advanced by thermomechanical cycling can accelerate leakage of the propellant. Whether the leakage exceeds tolerable levels depends on many factors, including pressure gradients, microcrack density, other damage such as delamination, connectivity of the cracks, residual stresses from manufacture, service-induced stresses from thermal and mechanical loads, and composite lay-up. Although it is critical to experimentally characterize permeability during various thermal and mechanical load histories, optimal design depends on having analytical models that can predict the effect of various parameters on performance. Our broad goal is to develop such models that are experimentally validated by destructive and non-destructive evaluation means.

Noh, Jae↗

NASA NTRS1994

An Acoustic Charge Transport Imager for High Definition Television Applications: Reliability Modeling and Parametric Yield Prediction of GaAs Multiple Quantum Well Avalanche Photodiodes

Reliability modeling and parametric yield prediction of GaAs/AlGaAs multiple quantum well (MQW) avalanche photodiodes (APDs), which are of interest as an ultra-low noise image capture mechanism for high definition systems, have been investigated. First, the effect of various doping methods on the reliability of GaAs/AlGaAs multiple quantum well (MQW) avalanche photodiode (APD) structures fabricated by molecular beam epitaxy is investigated. Reliability is examined by accelerated life tests by monitoring dark current and breakdown voltage. Median device lifetime and the activation energy of the degradation mechanism are computed for undoped, doped-barrier, and doped-well APD structures. Lifetimes for each device structure are examined via a statistically designed experiment. Analysis of variance shows that dark-current is affected primarily by device diameter, temperature and stressing time, and breakdown voltage depends on the diameter, stressing time and APD type. It is concluded that the undoped APD has the highest reliability, followed by the doped well and doped barrier devices, respectively. To determine the source of the degradation mechanism for each device structure, failure analysis using the electron-beam induced current method is performed. This analysis reveals some degree of device degradation caused by ionic impurities in the passivation layer, and energy-dispersive spectrometry subsequently verified the presence of ionic sodium as the primary contaminant. However, since all device structures are similarly passivated, sodium contamination alone does not account for the observed variation between the differently doped APDs. This effect is explained by the dopant migration during stressing, which is verified by free carrier concentration measurements using the capacitance-voltage technique.

Hunt, W. D.↗

NASA NTRS1997

The Effect of ODC-Free Cleaning Techniques on Bearing Lifetimes in the Parched Elastohydrodynamic Regime

A parched elastohydrodynamic rig was used to determine relative bearing lifetimes as a function of cleaning procedures in a series of accelerated tests. Two ODC-free cleaning procedures (super critical CO2 and ultraviolet-ozone) were compared to a CFC-113 control. Bearings (52100 steel) were run in the counter rotating mode (equivalent to 4600 rpm) with a full complement (i.e. no retainer) and a single charge of lubricant (Krytox 143 AC). Test conditions included: an air atmosphere, 445N load, approx. 1.0 GPa mean Hertz stress. There was approximately a 50% reduction in life with bearings cleaned with UV/ozone and a 70% reduction in life with SFE CO2 when compared to the Freon control. Possible reasons for these decreases in lifetimes are presented.

Jones, William R., Jr.↗

NASA NTRS2009

Advances in Non-contact Measurement of Creep Properties

Our team has developed a novel approach to measuring creep at extremely high temperatures using electrostatic levitation (ESL). This method has been demonstrated on niobium up to 2300 C, while ESL has melted tungsten (3400 C). High-precision machined spheres of the sample are levitated in the NASA MSFC ESL, a national user facility, and heated with a laser. The laser is aligned off-center so that the absorbed photons transfer their momentum to the sample, causing it to rotate at up to 250,000+ RPM. The rapid rotation loads the sample through centripetal acceleration, causing it to deform. The deformation of the sample is captured on high-speed video, which is analyzed by machine-vision software from the University of Massachusetts. The deformations are compared to finite element models to determine the constitutive constants in the creep relation. Furthermore, the noncontact method exploits stress gradients within the sample to determine the stress exponent in a single test. This method was validated in collaboration with the University of Tennessee for niobium at 1985 C, with agreement within the uncertainty of the conventional measurements. A similar method is being employed on Ultra-High-Temperature ZrB2- SiC composites, which may see application in rocket nozzles and sharp leading edges for hypersonic vehicles.

Hyers, Robert W.↗

NASA NTRS1972

Interactions between creep, fatigue and strain aging in two refractory alloys

The application of low-amplitude, high-frequency fatigue vibrations during creep testing of two strain-aging refractory alloys (molybdenum-base TZC and tantalum-base T-111) significantly reduced the creep strength of these materials. This strength reduction caused dramatic increases in both the first stage creep strain and the second stage creep rate. The magnitude of the creep rate acceleration varied directly with both frequency and A ratio (ratio of alternating to mean stress), and also varied with temperature, being greatest in the range where the strain-aging phenomenon was most prominent. It was concluded that the creep rate acceleration resulted from a negative strain rate sensitivity which is associated with the strain aging phenomenon in these materials. (A negative rate sensitivity causes flow stress to decrease with increasing strain rate, instead of increasing as in normal materials). By combining two analytical expressions which are normally used to describe creep and strain aging behavior, an expression was developed which correctly described the influence of temperature, frequency, and A ratio on the TZC creep rate acceleration.

Sheffler, K. D.↗

NASA NTRS1985

What Is Being Done to Control Motion Sickness?

AFT (Autogenic Feedback Training) involves practicing a series of mental exercises to speed up or slow down the control of autonomic activity. This produces a reduced tendency for autonomic activity levels to diverge from baseline (at rest) under stressful motion-sickness-inducing conditions. Subjects conditions. Subjects engaged in applying AFT exercises are required to closely monitor their own bodily sensations during motion-sickness-eliciting tests. These tests include the Coriolis Sickness Susceptibility Index (CSSI), which consists of sitting a subject into a rotating chair that moves at various speeds while a visual background turns at differing speeds and directions, and the Vertical Acceleration Rotation Device (VARD) test, which involves the placing of a subject in a drum that moves in an upward and downward motion until he or she is sick, while simultaneously monitoring the subject's vital signs. These tests provide investigators with evidence of slight changes in autonomic activities such as increases in heart rate, skin temperature, and sweat. All of these symptoms occur in subjects that experience bodily weakness or discomfort with the onset of motion sickness.

Hall, Y. D.↗