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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Critical length scales for chemical heterogeneity at Cu/Nb 3D interfaces by atom probe tomography

Cu/Nb nanocomposites containing sharp, two-dimensional (2D) interfaces have outstanding strength but limited deformability. In contrast, Cu/Nb with three dimensional (3D) biphase interfaces exhibiting crystallographic, topological, and chemical variations in all spatial dimensions overcomes this limitation by simultaneously enhancing material strength and deformability. Here, while structural characterization of 3D interfaces has been performed to understand their mechanical behavior, three dimensional chemical characterization of such interfaces is lacking. In this work we quantify the local chemistry of 3D interfaces in Cu/Nb nanocomposites using atom probe tomography (APT). Our analysis demonstrates chemical heterogeneities along all spatial dimensions in 3D interfaces, establishes the length scale of such features, and quantifies the morphology of 3D interfaces. 3D interface heterogeneities form by surface diffusion during physical vapor deposition (PVD), suggesting that deposition parameters can be used to control interface structure and provide unique ways to explore processing-structure-property relationships in interface-dominated nanocomposites.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Preliminary design of composite wings for buckling, strength and displacement constraints

An unstiffened panel buckling constraint for balanced, symmetric laminated composites is included on the global design level in a mathematical programming structural optimization procedure for designing wing structures. Constraints are introduced by penalty functions, and Newton's method based on approximate second derivatives of the penalty terms is used as the search algorithm to obtain minimum-mass designs. Constraint approximations used during the optimization process contribute to the computational efficiency of the procedure. A criterion is developed that identifies the appropriate conservative form of the constraint approximations that are used with the optimization procedure. Minimum-mass design results are obtained for a multispar high-aspect-ratio wing subjected to material strength, minimum-gage, displacement, panel buckling and twist constraints. The material systems considered for the examples are all graphite-epoxy, graphite-epoxy with boron-epoxy spar caps, and all aluminum. The composite material designs are shown to have an advantage over the aluminum designs since they can often satisfy additional constraints with only small mass increases.

Starnes, J. H., Jr.↗
DOE OSTI2023

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Lifetime Predictions of a Titanium Silicate Glass with Machined Flaws

A dynamic fatigue study was performed on a Titanium Silicate glass to assess its susceptibility to delayed failure and to compare the results with those of a previous study. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions. The material strength and lifetime was seen to increase due to the removal of residual stress through grinding and polishing. Influence on time-to-failure is addressed for the case with and without residual stress present. Titanium silicate glass otherwise known as ultra-low expansion (ULE)* glass is a candidate for use in applications requiring low thermal expansion characteristics such as telescope mirrors. The Hubble Space Telescope s primary mirror was manufactured from ULE glass. ULE contains 7.5% titanium dioxide which in combination with silica results in a homogenous glass with a linear expansion coefficient near zero. delayed failure . This previous study was based on a 230/270 grit surface. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing the material with successively smaller grinding media. This results in an increase in strength of the optic during the grinding and polishing sequence. Thus, a second study was undertaken using samples with a surface finish typically achieved for mirror elements, to observe the effects of surface finishing on the time-to-failure predictions. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure, most likely due to stress corrosion, which can significantly shorten lifetime. Fortunately, a theory based on fracture mechanics has been developed enabling lifetime predictions to be made for brittle materials susceptible to delayed failure. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct a time-to-failure diagram for polished ULE glass.

Tucker, Dennis S.↗
NASA NTRS2008

Full-Field Strain Methods for Investigating Failure Mechanisms in Triaxial Braided Composites

Recent advancements in braiding technology have led to commercially viable manufacturing approaches for making large structures with complex shape out of triaxial braided composite materials. In some cases, the static load capability of structures made using these materials has been higher than expected based on material strength properties measured using standard coupon tests. A more detailed investigation of deformation and failure processes in large-unit-cell-size triaxial braid composites is needed to evaluate the applicability of standard test methods for these materials and to develop alternative testing approaches. This report presents some new techniques that have been developed to investigate local deformation and failure using digital image correlation techniques. The methods were used to measure both local and global strains during standard straight-sided coupon tensile tests on composite materials made with 12- and 24-k yarns and a 0 /+60 /-60 triaxial braid architecture. Local deformation and failure within fiber bundles was observed and correlations were made between these local failures and global composite deformation and strength.

Littell, Justin D.↗
NASA NTRS1972

Oxidation protected carbon-carbon

Pyrolized carbon-carbon has one unique advantage over other materials that makes its application to the space shuttle thermal protection system very attractive. This unique characteristic is the increase in material strength and modulus with increase in temperature up to about 2500 K (4040 F). Offsetting this unique advantage are disadvantages which include brittleness, high cost, and the tendency of the material to react with oxygen, particularly at high temperatures. The development of an oxidation inhibitor for the material and the definition of fabrication processes for selected full-scale components are considered.

Pavlosky, J. E.↗
NASA NTRS1993

Probabilistic material degradation under high temperature, fatigue, and creep

A methodology has been developed and embodied in two computer codes for quantitatively characterizing the material strength degradation of aerospace propulsion system structural components that are subjected to various random effects over the course of their service lives. The codes, PROMISS and PROMISC, constitute a material-resistance model that is used in the NESSUS aerospace structural-reliability program. NESSUS addresses the service life-reducing effects of high temperature, mechanical fatigue, and creep.

Boyce, L.↗
NASA NTRS2013

Creep and Environmental Durability of EBC/CMCs Under Imposed Thermal Gradient Conditions

Interest in SiC fiber-reinforced SiC ceramic matrix composite (CMC) environmental barrier coating (EBC) systems for use in high temperature structural applications has prompted the need for characterization of material strength and creep performance under complex aerospace turbine engine environments. Stress-rupture tests have been performed on SiC/SiC composites systems, with varying fiber types and coating schemes to demonstrate material behavior under isothermal conditions. Further testing was conducted under exposure to thermal stress gradients to determine the effect on creep resistance and material durability. In order to understand the associated damage mechanisms, emphasis is placed on experimental techniques as well as implementation of non-destructive evaluation; including electrical resistivity monitoring. The influence of environmental and loading conditions on life-limiting material properties is shown.

Appleby, Matthew↗
NASA NTRS1991

Cryogenic piping material selection for the Component Test Facility (CTF)

The anticipated high cost of the 8500 psi cryogenic and 15,000 psi gas piping systems used in the CTF at NASA's John C. Stennis Space Center led to the consideration of high-strength materials for these piping systems. Based on years of satisfactory service using austenitic stainless steels in cryogenic applications, particularly for hydrogen service, consideration was limited to the austenitic stainless steels. Attention was focused on alternatives to the 304/304L grades of stainless steel traditionally used in these applications. This paper discusses the various considerations that resulted in the decision to continue using 304/304L for the cryogenic piping and the selection of the nitrogen-strengthened 21Cr-6Ni-9Mn alloy (UNS S21903) for the high-pressure gas systems at the CTF.

St. Cyr, William W.↗
NASA NTRS1991

Areas of Seal R/D at GE

About four years ago, work was completed on a 36 inch diameter gas to gas carbon ring seal used to buffer low pressure turbine air at the rim of the forward outer flowpath on the GE36 unducted fan (UDF) engine. At about the same time, we were developing a long life counter-rotating intershaft air-oil seal of approximately 7.6 inch diameter for operation at 800 fps, 800 F, and 50 psid. Although we were successful in meeting most program goals with a split ring seal of the axial bushing type, the seal with the greatest payoff in life and air leakage rates, bearing many features in common with the GE36 seal, could not be successfully tested because of the structural weakness of the primary seal ring carbon material. This was a split ring seal using a hybrid combination of orifice compensated hydrostatic and shrouded hydrodynamic gas bearings. We are presently working to develop this design in conjunction with high strength materials being developed by Pure Carbon Co. In the area of engine secondary gas flow path-sealing for performance improvement, we are currently working with carbon and all metal face seals. A 15 inch diameter all metal 'aspirating' face seal, using self-acting hydrostatic bearings, was successfully tested to 700 fps, 100 psid, and 1000 F, demonstrating long life at flow reduction of 86 percent compared to a 'best' labyrinth. This seal will be developed through 1400 F, 900 fps, and 350 psid. The seal 'aspirates' closed at about idle speed pressure during engine start and reopens at engine shutdown. A hydraulic thrust balance seal, currently using orifice compensated hydrostatics, is under development. Other aspects of these projects are briefly covered.

Pope, A. Nelson↗
NASA NTRS1994

Mechanical property characterization and impact resistance of selected graphite/PEEK composite materials

To use graphite polyetheretherketone (PEEK) material on highly curved surfaces requires that the material be drapable and easily conformable to the surface. This paper presents the mechanical property characterization and impact resistance results for laminates made from two types of graphite/PEEK materials that will conform to a curved surface. These laminates were made from two different material forms. These forms are: (1) a fabric where each yarn is a co-mingled Celion G30-500 3K graphite fiber and PEEK thermoplastic fiber; and (2) an interleaved material of Celion G30-500 3K graphite fabric interleaved with PEEK thermoplastic film. The experimental results from the fabric laminates are compared with results for laminates made from AS4/PEEK unidirectional tape. The results indicate that the tension and compression moduli for quasi-isotropic and orthotropic laminates made from fabric materials are at least 79 percent of the modulus of equivalent laminates made from tape material. The strength of fabric material laminates is at least 80 percent of laminates made from tape material. The evaluation of fabric material for shear stiffness indicates that a tape material laminate could be replaced by a fabric material laminate and still maintain 89 percent of the shear stiffness of the tape material laminate. The notched quasi-isotropic compression panel failure strength is 42 to 46 percent of the unnotched quasi-isotropic laminate strength. Damage area after impact with 20 ft-lbs of impact energy is larger for the co-mingled panels than for the interleaved panels. The inerleaved panels have less damage than panels made from tape material. Residual compression strength of quasi-isotropic panels after impact of 20 ft-lbs of energy varies between 33 percent of the undamaged quasi-isotropic material strength for the tape material and 38 percent of the undamaged quasi-isotropic material strength for the co-mingled fabric material.

Baker, Donald J.↗
NASA NTRS2014

Multilayer Pressure Vessel Materials Testing and Analysis

To provide NASA a comprehensive suite of materials strength, fracture toughness and crack growth rate test results for use in remaining life calculations for aging multilayer pressure vessels, Southwest Research Institute (R) (SwRI) was contracted in two phases to obtain relevant material property data from a representative vessel. This report describes Phase 1 of this effort which includes a preliminary material property assessment as well as a fractographic, fracture mechanics and fatigue crack growth analyses of an induced flaw in the outer shell of a representative multilayer vessel that was subjected to cyclic pressure test. SwRI performed this Phase 1 effort under contract to the Digital Wave Corporation in support of their contract to Jacobs ATOM for the NASA Ames Research Center.

Cardinal, Joseph W.↗
DOE OSTI2022

Design of high-pressure iron Rayleigh–Taylor strength experiments for the National Ignition Facility

Iron is an important metal, scientifically and technologically. It is a common metal on Earth, forming the main constituent of the planet's inner core, where it is believed to be in solid state at high pressure and high temperature. It is also the main component of many important structural materials used in quasistatic and dynamic conditions. Laser-driven Rayleigh–Taylor instability provides a means of probing material strength at high pressure and high temperature. The unavoidable phase transition in iron at relatively low pressure induces microstructural changes that ultimately affect its strength in this extreme regime. This inevitable progression can make it difficult to design experiments and understand their results. Here, we address this challenge with the introduction of a new approach: a direct-drive design for Rayleigh–Taylor strength experiments capable of reaching up to 400 GPa over a broad range of temperatures. We use 1D and 2D hydrodynamic simulations to optimize target components and laser pulse shape to induce the phase transition and compress the iron to high pressure and high temperature. At the simulated pressure–temperature state of 350 GPa and 4000 K, we predict a ripple growth factor of 3–10 depending on the strength with minimal sensitivity to the equation of state model used. The growth factor is the primary observable, and the measured value will be compared to simulations to enable the extraction of the strength under these conditions. These experiments conducted at high-energy laser facilities will provide a unique way to study an important metal.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Innovations in the vapor deposition of metal coatings for target payloads in laser-based physics experiments under extreme conditions

The synthesis of metal foils with unique surface features such as waves and steps is of interest for use as payloads in targets for laser-driven physics experiments under dynamic loading conditions. Changes to the surface features are used to quantify the effects of the material strength during the deformation at high-strain rate high pressure. Additionally, a traditional path to produce these target features is by precision machining processes using diamond tools. Limitations are encountered since many of the materials of interest and the size of the surface features are not often compatible with conventional machining-process methods. An alternative method to produce targets with unique surface features is through vapor synthesis. Two general approaches are taken—one is by replicating the features from the surface of a substrate mandrel, whereas the second is by using hard masks with timed exposure to the deposition vapor. In these approaches, postdeposition removal of a release layer yields a free-standing target with the desired surface features. Here, specific cases are presented for the physical vapor deposition of copper, aluminum, iron, vanadium, and tantalum to form targets with multiple layers, steps, and sinusoidal surface waves.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Effect of directed aging on nonlinear elasticity and memory formation in a material

Disordered solids often change their elastic response as they slowly age. Using experiments and simulations, we study how aging disordered planar networks under an applied stress affects their nonlinear elastic response. We are able to modify dramatically the elastic properties of our systems in the nonlinear regime. Using simulations, we study two models for the microscopic evolution of properties of such a material; the first considers changes in the material strength, while the second considers distortions in the microscopic geometry. Both models capture different aspects of the experiments including the encoding of memories of the aging history of the system and the dramatic effects on the material’s nonlinear elastic properties. Our results demonstrate how aging can be used to create complex elastic behavior in the nonlinear regime.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Radial turbine cooling

Radial turbines have been used extensively in many applications including small ground based electrical power generators, automotive engine turbochargers and aircraft auxiliary power units. In all of these applications the turbine inlet temperature is limited to a value commensurate with the material strength limitations and life requirements of uncooled metal rotors. To take advantage of all the benefits that higher temperatures offer, such as increased turbine specific power output or higher cycle thermal efficiency, requires improved high temperature materials and/or blade cooling. Extensive research is on-going to advance the material properties of high temperature superalloys as well as composite materials including ceramics. The use of ceramics with their high temperature potential and low cost is particularly appealing for radial turbines. However until these programs reach fruition the only way to make significant step increases beyond the present material temperature barriers is to cool the radial blading.

Roelke, Richard J.↗
DOE OSTI2020

Effects of secondary void-initiating particles on the steady-state crack growth resistance of high-strength steel

In this investigation, we focus on the dependence of stable crack growth resistance, as measured by the short-rod fracture toughness test, on secondary void-initiating particles such as AlN and Ti-based grain-refining precipitates in a variety of high-strength steels with tempered martensitic microstructures. The model developed by Ritchie and Thompson is modified to illustrate the significant amounts of toughening that can result from the refinement of secondary particles. Analysis of the data suggests that material strength is a predominant factor in increasing the short-rod fracture toughness relative to linear-elastic measures of initiation fracture toughness, but the extent of toughening is limited by the size and number density of secondary particles in the microstructure. The variation in estimates of secondary microvoid initiation and growth strains with precipitate size reinforce the notion that primary fracture at non-metallic inclusions and secondary fracture at smaller particles occur as sequential processes with a degree of concurrence that is dependent on the state of precipitation in both particle dispersions. Toughening in this connection is maximized by increases in microvoid growth strain that result from decreases in the size and areal number density of secondary void-initiating particles. Finally, the occurrence of transient instabilities during crack extension in short-rod specimens is explained with a phenomenological model that relates crack growth stability to natural variations in the dispersion of secondary void-initiating particles in the microstructure.

42 ENGINEERING↗
DOE OSTI2025

Influence of sizing concentration on strength, stiffness, and porosity in textile grade carbon fiber (TCF)-Epoxy composites: Revealing inverse trends

The effect of fiber sizing (i.e., surface treatment) concentration (0 %, 1.36 %, 1.52 %, 1.94 %, and 2.13 %) on the mechanical properties (tensile, flexural, interlaminar shear strength (ILSS), and low velocity impact) of textile grade carbon fiber (TCF)-epoxy composite is examined. An inverse relationship between the strength and stiffness of the composite is observed with increased sizing concentration. The root mean square (RMS) roughness of the fiber surface increased from 17.8 nm (unsized) to 22.7 nm with 2.13 % sizing concentration. It was found that the tensile strength increased by 131 % from 221.4 ± 18.5 MPa (unsized) to 510.8 ± 28.05 MPa (for 1.36 % sizing) and further by 155 %–563.7 ± 14.95 MPa at 2.13 % sizing. On the contrary, the stiffness is initially increased by 126 % from 33.52 ± 7.80 GPa (unsized) to 75.9 ± 3.21 GPa (for 1.36 % sizing) but reduced with further increase in the sizing concentration. A single fiber pull-out test is simulated using the finite element method to validate the reverse trend in strength and stiffness. The varying sizing concentration is simulated by introducing an interface of varying thickness between fibers and matrix. Simulation results confirm that a thicker interface, corresponding to a higher sizing concentration, decreases interfacial shear stress, enhancing material strength while decreasing stiffness. The reverse trend in strength and stiffness with the sizing concentration aligns with experimental observations. In conclusion, the present study emphasizes the importance of sizing concentration for mechanical properties and provide a design criterion for customized high-strength and high-stiffness applications.

Porosity↗