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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Effects of via-conductor geometry in the electromigration failure of Al:Cu wires

Electromigration (EM) experiments conducted using two types of via/plug to conductor alignment indicate a geometrical dependence of electromigration failure in Al:Cu conductors. The resistance vs time curves show distinctive steps when the alignment is parallel. This is explained by a successive loss of conductivity through the plug due to void formation. In the perpendicular via/conductor arrangement, resistance increases by smaller and closely spaced steps. EM experiments without vias, found that the conductor life under stress increases by at least an order of magnitude. Kinetic studies at four temperatures between 180-240 C found activation energies to be 1.0 plus or minus 0.1eV.

Al:Cu accelerated testing electromigration activat↗
NASA NTRS1984

Test bed ion engine development

A test bed ion (TBI) engine was developed to serve as a tool in exploring the limits of electrostatic ion thruster performance. A description of three key ion engine components, the decoupled extraction and amplified current (DE-AC) accelerator system, field enhanced refractory metal (FERM) hollow cathode and divergent line cusp (DLC) discharge chamber, whose designs and operating philosophies differ markedly from conventional thruster technology is given. Significant program achievements were: (1) high current density DE-AC accelerator system operation at low electric field stress with indicated feasibility of a 60 mA/sq cm argon ion beam; (2) reliable FERM cathode start up times of 1 to 2 secs. and demonstrated 35 ampere emission levels; (3) DLC discharge chamber plasma potentials negative of anode potential; and (4) identification of an efficient high plasma density engine operating mode. Using the performance projections of this program and reasonable estimates of other parameter values, a 1.0 Newton thrust ion engine is identified as a realizable technology goal. Calculations show that such an engine, comparable in beam area to a J series 30 cm thruster, could, operating on Xe or Hg, have thruster efficiencies as high as 0.76 and 0.78 respectively, with a 100 eV/ion discharge loss.

Aston, G.↗
NASA NTRS1985

Turbulence characteristics of swirling flowfields

The time mean and turbulence properties of a confined swirling jet using the six orientation, single hot wire technique were obtained. The effect of swirl on a confined, expanding jet is to reduce the size of the corner recirculation zone and generate a central recirculation zone followed by a precessing vortex core. The effect of introducing a contraction nozzle of area ratio four, located two test section diameters downstream of the inlet, is to dramatically reduce the size and shape of the central recirculation zone for the swirling flows considered. The shear stresses are found to increase by an order of magnitude in the region of the contraction nozzle because of large radial gradients of axial velocity. Reduction of the expansion ratio to D/o = 1 causes the time mean flow field to be homogeneous throughout the entire test section with the tangential velocity dominating in the swirling cases. No recirculation zones were observed for these particular flows. Turbulence levels and dissipation rates were found to be low except in the entrance regions and in areas of acceleration in the swirling flow cases.

Jackson, T. W.↗
NASA NTRS1995

Measurements in Transitional Boundary Layers Under High Free-Stream Turbulence and Strong Acceleration Conditions

Measurements from transitional, heated boundary layers along a concave-curved test wall are presented and discussed. A boundary layer subject to low free-stream turbulence intensity (FSTI), which contains stationary streamwise (Gortler) vortices, is documented. The low FSTI measurements are followed by measurements in boundary layers subject to high (initially 8%) free-stream turbulence intensity and moderate to strong streamwise acceleration. Conditions were chosen to simulate those present on the downstream half of the pressure side of a gas turbine airfoil. Mean flow characteristics as well as turbulence statistics, including the turbulent shear stress, turbulent heat flux, and turbulent Prandtl number, are documented. A technique called "octant analysis" is introduced and applied to several cases from the literature as well as to data from the present study. Spectral analysis was applied to describe the effects of turbulence scales of different sizes during transition. To the authors'knowledge, this is the first detailed documentation of boundary layer transition under such high free-stream turbulence conditions.

Volino, Ralph J.↗
NASA NTRS2012

Prognostics Approach for Power MOSFET Under Thermal-Stress

The prognostic technique for a power MOSFET presented in this paper is based on accelerated aging of MOSFET IRF520Npbf in a TO-220 package. The methodology utilizes thermal and power cycling to accelerate the life of the devices. The major failure mechanism for the stress conditions is dieattachment degradation, typical for discrete devices with leadfree solder die attachment. It has been determined that dieattach degradation results in an increase in ON-state resistance due to its dependence on junction temperature. Increasing resistance, thus, can be used as a precursor of failure for the die-attach failure mechanism under thermal stress. A feature based on normalized ON-resistance is computed from in-situ measurements of the electro-thermal response. An Extended Kalman filter is used as a model-based prognostics techniques based on the Bayesian tracking framework. The proposed prognostics technique reports on preliminary work that serves as a case study on the prediction of remaining life of power MOSFETs and builds upon the work presented in [1]. The algorithm considered in this study had been used as prognostics algorithm in different applications and is regarded as suitable candidate for component level prognostics. This work attempts to further the validation of such algorithm by presenting it with real degradation data including measurements from real sensors, which include all the complications (noise, bias, etc.) that are regularly not captured on simulated degradation data. The algorithm is developed and tested on the accelerated aging test timescale. In real world operation, the timescale of the degradation process and therefore the RUL predictions will be considerable larger. It is hypothesized that even though the timescale will be larger, it remains constant through the degradation process and the algorithm and model would still apply under the slower degradation process. By using accelerated aging data with actual device measurements and real sensors (no simulated behavior), we are attempting to assess how such algorithm behaves under realistic conditions.

Power MOSFET PHM↗
NASA NTRS1981

Mission load dynamic tests of two undensified Space shuttle thermal protection system tiles

Two tests of undensified Space Shuttle thermal protection tiles under combined static and dynamic loads were conducted. The tiles had a density of approximately 144 Kg/cum (LI900 tiles) and were mounted on a strain isolation pad which was 0.41 cm (.160 inch) thick. A combined static and dynamic mission stress histogram representative of the W-3 area of the wing of the orbiter vehicle was applied. The stress histogram was provided by the space shuttle project. Results presented include: tabulation of measured peak and root-mean-square (RMS) accelerations in both compression and tension; peak SIP stress in compression and tension, peak and RMS amplitude response ratios; lateral to vertical response ratios; response time histories; peak stress distributions (histograms), and SIP extension measured both with and without static tension at various mission times.

Leatherwood, J. D.↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt.% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF/HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damages at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, were observed especially for the combined LCF/HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
NASA NTRS2016

Hall Thruster Thermal Modeling and Test Data Correlation

HERMeS - Hall Effect Rocket with Magnetic Shielding. Developed through a joint effort by NASA/GRC and the Jet Propulsion Laboratory (JPL). Design goals: High power (12.5 kW) high Isp (3000 sec), high efficiency (> 60%), high throughput (10,000 kg), reduced plasma erosion and increased life (5 yrs) to support Asteroid Redirect Robotic Mission (ARRM). Further details see "Performance, Facility Pressure Effects and Stability Characterization Tests of NASAs HERMeS Thruster" by H. Kamhawi and team. Hall Thrusters (HT) inherently operate at elevated temperatures approx. 600 C (or more). Due to electric magnetic (E x B) fields used to ionize and accelerate propellant gas particles (i.e., plasma). Cooling is largely limited to radiation in vacuum environment.Thus the hardware components must withstand large start-up delta-T's. HT's are constructed of multiple materials; assorted metals, non-metals and ceramics for their required electrical and magnetic properties. To mitigate thermal stresses HT design must accommodate the differential thermal growth from a wide range of material Coef. of Thermal Expansion (CTEs). Prohibiting the use of some bolted/torqued interfaces.Commonly use spring loaded interfaces, particularly at the metal-to-ceramic interfaces to allow for slippage.However most component interfaces must also effectively conduct heat to the external surfaces for dissipation by radiation.Thus contact pressure and area are important.

Model↗
NASA NTRSDate not supplied

Particle Impact Simulation and Ignition Prediction

An experimentally calibrated tool is needed to predict if a system is susceptible to failure by particle impact ignition (PI) based on use conditions, materials, and flow geometry. This tool will accelerate new components, evaluating existing hardware, and help disposition anomalies. Conduct particle impact testing with in-situ diagnostics and complementary simulations on subset of key engineering materials (IN718, M400, 316L, 6061, Ti64, Zr) to develop a proof-of-concept predictive tool for assessing the risk of PI for idealized geometries (spherical particles) in realistic environments. Assess particle/target interactions (coefficient of restitution, ignition, kindling) using instrumented particle impact rigs while systematically varying key parameters (materials, particle size, environment, target configuration). Determine key field variables (temperature, strain, stress) in particle impacts using Multiphysics finite element and hydrocode simulations validated through comparison with experimental measurements and observations. Synthesize experiments and simulations into constitutive models for PI that can be integrated with existing computational fluid dynamics (CFD) and Debris Transport Analysis (DTA) tools in future efforts

particle impact↗
NASA NTRS2024

Particle Impact Simulation and Ignition Prediction

An experimentally calibrated tool is needed to predict if a system is susceptible to failure by particle impact ignition (PI) based on use conditions, materials, and flow geometry. This tool will accelerate new components, evaluating existing hardware, and help disposition anomalies. - Conduct particle impact testing with in-situ diagnostics and complementary simulations on subset of key engineering materials (IN718, M400, 316L, 6061, Ti64, Zr) to develop a proof-of-concept predictive tool for assessing the risk of PI for idealized geometries (spherical particles) in realistic environments. - Assess particle/target interactions (coefficient of restitution, ignition, kindling) using instrumented particle impact rigs while systematically varying key parameters (materials, particle size, environment, target configuration). - Determine key field variables (temperature, strain, stress) in particle impacts using Multiphysics finite element and hydrocode simulations validated through comparison with experimental measurements and observations. - Synthesize experiments and simulations into constitutive models for PI that can be integrated with existing computational fluid dynamics (CFD) and Debris Transport Analysis (DTA) tools in future efforts.

Jonathan Tylka↗
NASA NTRS1994

The effects of pitting on fatigue crack nucleation in 7075-T6 aluminum alloy

A high-strength aluminum alloy, 7075-T6, was studied to quantitatively evaluate chemical pitting effects of its corrosion fatigue life. The study focused on pit nucleation, pit growth, and fatigue crack nucleation. Pitting corrosion fatigue experiments were conducted in 3.5 percent NaCl aqueous solution under constant amplitude sinusoidal loading at two frequencies, 5 and 20 Hz. Smooth and unnotched specimens were used in this investigation. A video recording system was developed to allow in situ observation of the surface changes of the specimens during testing. The results indicated that pitting corrosion considerably reduces the fatigue strength by accelerating fatigue crack nucleation. A metallographic examination was conducted on the specimens to evaluate the nature of corrosion pits. First, the actual shapes of the corrosion pits were evaluated by cross-sectioning the pits. Secondly, the relation between corrosion pits and microstructure was also investigated. Finally, the possibility of another corrosion mechanism that might be involved in pitting was explored in this investigation. The fractography of the tested specimens showed that corner corrosion pits were responsible for fatigue crack nucleation in the material due to the associated stress concentration. The pits exhibited variance of morphology. Fatigue life for the experimental conditions appeared to be strongly dependent on pitting kinetics and the crack nucleation stage.

Ma, LI↗
NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF-HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damage at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, was observed especially for the combined LCF-HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗
NASA NTRS2011

The Effect of Dose Rate on Composite Durability When Exposed to a Simulated Long-Term Lunar Radiation Environment

Human exploration of space beyond low Earth orbit (LEO) requires a safe living and working environment for crew. Composite materials are one type of material being investigated by NASA as a multi-functional structural approach to habitats for long-term use in space or on planetary surfaces with limited magnetic fields and atmosphere. These materials provide high strength with the potential for decreased weight and increased radiation protection of crew and electronics when compared with conventional aluminum structures. However, these materials have not been evaluated in a harsh radiation environment, as would be experienced outside of LEO or on a planetary surface. Thus, NASA has been investigating the durability of select composite materials in a long-term radiation environment. Previously, NASA exposed composite samples to a simulated, accelerated 30-year radiation treatment and tensile stresses similar to those of a habitat pressure vessel. The results showed evidence of potential surface oxidation and enhanced cross-linking of the matrix. As a follow-on study, we performed the same accelerated exposure alongside an exposure with a decreased dose rate. The slower dose ]rate is comparable to a realistic scenario, although still accelerated. Strain measurements were collected during exposure and showed that with a fastdose rate, the strain decreased with time, but with a slow ]dose rate, the strain increased with time. After the radiation exposures, samples were characterized via tensile tests, flexure tests, Fourier Transform Infrared Spectroscopy (FTIR), and Differential Scanning Calorimetry (DSC). The results of these tests will be discussed.

Rojdev, Kristina↗
NASA NTRS1959

Flight Investigation of Effects of Transition, Landing Approaches, Partial-Power Vertical Descents, and Droop-Stop Pounding on the Bending and Torsional Moments Encountered by a Helicopter Rotor Blade

Flight tests have been conducted with a single-rotor helicopter, one blade of which was equipped at 14 percent and 40 percent of the blade radius with strain gages calibrated to measure moments rather than stresses, to determine the effects of transition, landing approaches, and partial-power vertical descents on the rotor-blade bending and torsional moments. In addition, ground tests were conducted to determine the effects of static droop-stop pounding on the rotor-blade moments. The results indicate that partial-power vertical descents and landing approaches produce rotor-blade moments that are higher than the moments encountered in any other flight condition investigated to date with this equipment. Decelerating through the transition region in level flight was found to result in higher vibratory moments than accelerating through this region. Deliberately induced static droop-stop pounding produced flapwise bending moments at the 14-percent-radius station which were as high as the moments experienced in landing approaches and partial-power vertical descents.

Ludi, LeRoy H.↗
NASA NTRS1981

Degradation of a two-layer thermal barrier coating under thermal cycling

A two-layer plasma-sprayed thermal barrier coating on a directionally solidified nickel-base eutectic alloy substrate was characterized prior to and after thermal cycling to 1095 C in an accelerated furnace test. The coating was comprised of an inner layer of Ni-16.4Cr-5.1Al-0.15Y (wt%) bond coat and an outer layer of ZrO2-7.9Y2O3 (wt%) thermal barrier. Characterization of the bond coat revealed that substantial amounts of yttrium and aluminum were oxidized during plasma-spraying in air. The oxidation of these elements reduced the protective capacity of the bond coat so that, on thermal exposure, severe degradation of the bond coat resulted and large amounts of nickel oxide formed. This nickel oxide was demonstrated to grow outward into the thermal barrier, which appears to have increased the stresses in the thermal barrier and contributed to its failure near the thermal barrier-bond coat interface.

Maier, R. D.↗
NASA NTRS2023

Modeling and Simulation for Exercise Vibration Isolation and Stabilization System Design

The microgravity environment that crew members experience on orbit presents a well-known health challenge, particularly when it comes to loss of muscle and bone mass. To counteract these negative effects, exercise countermeasures play a critical role in the daily routine of the crew on the International Space Station (ISS). To help inform requirements for upcoming exploration missions such as the Gateway Program, a new device, called the European Enhanced Exploration Exercise Device (E4D), is being built by the European Space Agency through their contractor, the Danish Aerospace Company. The E4D is being demonstrated on the ISS and is unique from other current exercise devices in that it provides four separate modalities in a single device: resistive, cycle ergometry, seated aerobic rowing, and rope pulling. To support the integration of E4D on ISS, a passive Vibration Isolation and Stabilization (VIS) system was required by NASA, and this responsibility was given to the Johnson Space Center. This paper describes the end-to-end process of modeling, simulation, and analysis used to inform the mechanical design of the VIS system. The process begins with the collection of representative exerciser motion capture (MoCap) through ground-based testing with the developmental E4D in both the Prototype Immersive Technology (PIT) Laboratory and the Active Response Gravity Offload System (ARGOS) facility at the Johnson Space Center. These collected MoCap data are processed through human biomechanics modeling to create forcing functions as input to a multibody dynamics simulation of the combined E4D/VIS system, with numerous resulting outputs. These outputs include microgravity accelerations, overall system displacements, internal and transmitted loads, as well as collisions. Microgravity accelerations are compared for compliance against ISS requirements while displacements are used for sway space determinations on the design and volumetric constraints within the targeted module. Internal loads are supplied to the supporting stress analysis teams and external loads for structural loads and dynamics teams, both at NASA and ESA. Finally, contact and clearance analysis is performed using the simulation to eliminate potential design issues. To ensure that the elements of the multibody simulation were verified and validated, correlation against multiple VIS related ground hardware testbeds was performed and characterized. In addition to the isolation part of the VIS problem, stabilization is also key to the integrated performance and evaluation. Due to the difficulty in defining ISS requirements in this area, the stability of the exerciser was inspected via analysis. Loss of balance was defined analytically as occurring when the resultant force vector acting on the exerciser lies outside the base of support of the feet. Both the VIS and E4D teams have recently gone through their Critical Design Reviews (CDRs) and the iterative model-based approach has been integral to inform mechanical design, particularly in the case of the VIS. This same end-to-end approach is now being applied for the Gateway Program, where an Exploration Exercise Device (EED) derived from the E4D and notional VIS for the device are under concept development.

Countermeasures↗
NASA NTRS1979

Some influences of vision on susceptibility to motion sickness

Two experiments were performed to evaluate the influence of vision on susceptibility to motion sickness during exposure to constant patterns of vestibular stimulation. The motion profile involved accelerating subjects at 20 deg/sec per sec to 300 deg/sec, maintaining them at that constant velocity for 30 sec, and decelerating them to a rapid stop in about 1.5 sec. The number of stops tolerated by a subject before reaching the motion sickness endpoint served as his score. In Experiment 1, subjects were tested twice with their eyes open and twice with their eyes blindfolded. They tolerated fewer sudden stops when permitted sight of the experimental chamber. In Experiment 2, the effect of having the eyes open or closed at different stages of the motion profile was evaluated. Having the eyes open during any stage of the test was more stressful than having the eyes closed, but this was especially true during the sudden stops. The findings are discussed in terms of their general implications for understanding (1) situations in which vision alone elicits symptoms of motion sickness, and (2) situations involving vestibular stimulation where vision heightens susceptibility.

Lackner, J. R.↗
NASA NTRS1969

Apollo 6, Anomaly Report No. 6: Abnormal Structural Performance During Launch Phase

Approximately 2 minutes 13 seconds after lift-off of the Apollo 6 mission, abrupt changes of strain, vibration, and acceleration measurements were indicated in the S-IVB, instrument unit, adapter, lunar module, and command and service modules; photographs showed objects coming from the area of the adapter. The adapter, however, continued to sustain the required loads with no impairment of the mission. The investigation was first focused upon the understanding of the coupled vibration modes and characteristics of the launch vehicle and spacecraft.' Extensive test programs were conducted. It was eventually concluded that the adapter failure was not caused by vibration. Extensive study of the airborne photography and other evidence indicated that a large area of the adapter had lost inner facesheet from the honeycomb sandwich panels. Loads and stresses resulting from vibration were determined to be insufficient to initiate such a failure. The investigation was then directed toward determining the range of pressures that could have been trapped in the Apollo 6 adapter sandwich panels, and toward determining the tolerance of the panels to withstand pressure with various degrees of flaws such as adhesive voids and facesheet dents. The degradation effects of moisture and heat exposure on the adhesive strength were also studied and tested. These tests and analyses led to the conclusion that pressure internal to the sandwich panels could have caused the failure, if a large flaw existed. The pressure buildup would have been caused by aerodynamic heating effects on air and moisture trapped in the panel. The probable cause of the failure was found in the original ultrasonic inspection scan record of the affected adapter panel. In the center of the region where the adapter failed, horizontally along the station 709 panel splice, the record contained two thick anomalous lines extending several feet. Without an X-ray record of this region, the significance of this particular scan record cannot be fully understood. However, since all other evidence had indicated that the adhesive had to be weakened in a rather large area to initiate the failure, the investigation was focused intently upon the station 709 splices of other adapters. Sufficient information was developed to verify that deficient assembly techniques have consistently resulted in abnormalities in the structure at this station. These abnormalities were identified in adapters 12, 13, 14, 15, and 16. Before the splice abnormalities were pinpointed, corrective action was taken to reduce pressure "buildup in the honeycomb panels and to reduce heat degrading effects on the adhesive. This was done by drilling vent holes in the inner facesheet and covering the outer facesheet with cork. The adapters having identified abnormalities in the station 709 splice are being repaired, and the contractor is investigating ways of avoiding these -abnormalities in panels yet to be bonded.

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