SEARCH · Engineering Papers

Results for “SHRINKAGE”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 271 records · Page 15

All sources NASA NTRS DOE OSTI

NASA NTRS2012

Three-Dimensional Structure and Evolution of Extreme-Ultraviolet Bright Points Observed by STEREO/SECCHI/EUVI

We unveil the three-dimensional structure of quiet-Sun EUV bright points and their temporal evolution by applying a triangulation method to time series of images taken by SECCHI/EUVI on board the STEREO twin spacecraft. For this study we examine the heights and lengths as the components of the three-dimensional structure of EUV bright points and their temporal evolutions. Among them we present three bright points which show three distinct changes in the height and length: decreasing, increasing, and steady. We show that the three distinct changes are consistent with the motions (converging, diverging, and shearing, respectively) of their photospheric magnetic flux concentrations. Both growth and shrinkage of the magnetic fluxes occur during their lifetimes and they are dominant in the initial and later phases, respectively. They are all multi-temperature loop systems which have hot loops (approx. 10(exp 6.2) K) overlying cooler ones (approx 10(exp 6.0) K) with cool legs (approx 10(exp 4.9) K) during their whole evolutionary histories. Our results imply that the multi-thermal loop system is a general character of EUV bright points. We conclude that EUV bright points are flaring loops formed by magnetic reconnection and their geometry may represent the reconnected magnetic field lines rather than the separator field lines.

Sun: UV Radiation↗

NASA NTRS2014

Thermal Model Predictions of Advanced Stirling Radioisotope Generator Performance

This paper presents recent thermal model results of the Advanced Stirling Radioisotope Generator (ASRG). The three-dimensional (3D) ASRG thermal power model was built using the Thermal Desktop(trademark) thermal analyzer. The model was correlated with ASRG engineering unit test data and ASRG flight unit predictions from Lockheed Martin's (LM's) I-deas(trademark) TMG thermal model. The auxiliary cooling system (ACS) of the ASRG is also included in the ASRG thermal model. The ACS is designed to remove waste heat from the ASRG so that it can be used to heat spacecraft components. The performance of the ACS is reported under nominal conditions and during a Venus flyby scenario. The results for the nominal case are validated with data from Lockheed Martin. Transient thermal analysis results of ASRG for a Venus flyby with a representative trajectory are also presented. In addition, model results of an ASRG mounted on a Cassini-like spacecraft with a sunshade are presented to show a way to mitigate the high temperatures of a Venus flyby. It was predicted that the sunshade can lower the temperature of the ASRG alternator by 20 C for the representative Venus flyby trajectory. The 3D model also was modified to predict generator performance after a single Advanced Stirling Convertor failure. The geometry of the Microtherm HT insulation block on the outboard side was modified to match deformation and shrinkage observed during testing of a prototypic ASRG test fixture by LM. Test conditions and test data were used to correlate the model by adjusting the thermal conductivity of the deformed insulation to match the post-heat-dump steady state temperatures. Results for these conditions showed that the performance of the still-functioning inboard ACS was unaffected.

radioisotope power system↗

NASA NTRS2015

Synthesis and Characterization of Poly(maleic Anhydride)s Cross-linked Polyimide Aerogels

With the development of technology for aerospace applications, new thermal insulation materials are required to be flexible and capable of surviving high heat flux. For instance, flexible insulation is needed for inflatable aerodynamic decelerators which are used to slow spacecraft for entry, descent and landing (EDL) operations. Polyimide aerogels have low density, high porosity, high surface area, and better mechanical properties than silica aerogels and can be made into flexible thin films, thus they are potential candidates for aerospace needs. The previously reported cross-linkers such as octa(aminophenyl)silsesquioxane (OAPS) and 1,3,5-triaminophenoxybenzene (TAB) are either expensive or not commercially available. Here, we report the synthesis of a series of polyimide aerogels cross-linked using various commercially available poly(maleic anhydride)s, as seen in Figure 1. The amine end capped polyimide oligomers were made with 3,3,4,4-biphenyltetracarboxylic dianhydride (BPDA) and diamine combinations of dimethylbenzidine (DMBZ) and 4, 4-oxydianiline (ODA). The resulting aerogels have low density (0.12 gcm3 to 0.16 gcm3), high porosity (90) and high surface area (380-554 m2g). The effect of the different poly(maleic anhydride) cross-linkers and polyimide backbone structures on density, shrinkage, porosity, surface area, mechanical properties, moisture resistance and thermal properties will be discussed.

poly(maleic anhydride)↗

NASA NTRS2015

Out-of-Autoclave Cure Composites

As the size of aerospace composite parts exceeds that of even the largest autoclaves, the development of new out-of-autoclave processes and materials is necessary to ensure quality and performance. Many out-of-autoclave prepreg systems can produce high-quality composites initially; however, due to long layup times, the resin advancement commonly causes high void content and variations in fiber volume. Applied Poleramic, Inc. (API), developed an aerospace-grade benzoxazine matrix composite prepreg material that offers more than a year out-time at ambient conditions and provides exceptionally low void content when out-of-autoclave cured. When compared with aerospace epoxy prepreg systems, API's innovation offers significant improvements in terms of out-time at ambient temperature and the corresponding tack retention. The carbon fiber composites developed with the optimized matrix technology have significantly better mechanical performance in terms of hot-wet retention and compression when compared with aerospace epoxy matrices. These composites also offer an excellent overall balance of properties. This matrix system imparts very low cure shrinkage, low coefficient of thermal expansion, and low density when compared with most aerospace epoxy prepreg materials.

Hayes, Brian S.↗

NASA NTRS2016

Composite Cure Process Modeling and Simulations using COMPRO(Registered Trademark) and Validation of Residual Strains using Fiber Optics Sensors

Composite cure process induced residual strains and warping deformations in composite components present significant challenges in the manufacturing of advanced composite structure. As a part of the Manufacturing Process and Simulation initiative of the NASA Advanced Composite Project (ACP), research is being conducted on the composite cure process by developing an understanding of the fundamental mechanisms by which the process induced factors influence the residual responses. In this regard, analytical studies have been conducted on the cure process modeling of composite structural parts with varied physical, thermal, and resin flow process characteristics. The cure process simulation results were analyzed to interpret the cure response predictions based on the underlying physics incorporated into the modeling tool. In the cure-kinetic analysis, the model predictions on the degree of cure, resin viscosity and modulus were interpreted with reference to the temperature distribution in the composite panel part and tool setup during autoclave or hot-press curing cycles. In the fiber-bed compaction simulation, the pore pressure and resin flow velocity in the porous media models, and the compaction strain responses under applied pressure were studied to interpret the fiber volume fraction distribution predictions. In the structural simulation, the effect of temperature on the resin and ply modulus, and thermal coefficient changes during curing on predicted mechanical strains and chemical cure shrinkage strains were studied to understand the residual strains and stress response predictions. In addition to computational analysis, experimental studies were conducted to measure strains during the curing of laminated panels by means of optical fiber Bragg grating sensors (FBGs) embedded in the resin impregnated panels. The residual strain measurements from laboratory tests were then compared with the analytical model predictions. The paper describes the cure process procedures and residual strain predications, and discusses pertinent experimental results from the validation studies.

Sreekantamurthy, Thammaiah↗

NASA NTRS2017

Tutorial on Atomic Oxygen Effects and Contamination

Atomic oxygen is the most predominant specie in low Earth orbit (LEO) and is contained in the upper atmosphere of many other planetary bodies. Formed by photo-dissociation of molecular oxygen, it is highly reactive and energetic enough to break chemical bonds on the surface of many materials and react with them to form either stable or volatile oxides. The extent of the damage for spacecraft depends a lot on how much atomic oxygen arrives at the surface, the energy of the atoms, and the reactivity of the material that is exposed to it. Oxide formation can result in shrinkage, cracking, or erosion which can also result in changes in optical, thermal, or mechanical properties of the materials exposed. The extent of the reaction can be affected by mechanical loading, temperature, and other environmental components such as ultraviolet radiation or charged particles. Atomic oxygen generally causes a surface reaction, but it can scatter under coatings and into crevices causing oxidation much farther into a spacecraft surface or structure than would be expected. Contamination can also affect system performance. Contamination is generally caused by arrival of volatile species that condense on spacecraft surfaces. The volatiles are typically a result of outgassing of materials that are on the spacecraft. Once the volatiles are condensed on a surface, they can then be fixed on the surface by ultraviolet radiation andor atomic oxygen reaction to form stable surface contaminants that can change optical and thermal properties of materials in power systems, thermal systems, and sensors. This tutorial discusses atomic oxygen erosion and contaminate formation, and the effect they have on typical spacecraft materials. Scattering of atomic oxygen, some effects of combined environments and examples of effects of atomic oxygen and contamination on spacecraft systems and components will also be presented.

Earth orbital environments↗

NASA NTRS2017

Macrosegregation Resulting from Directional Solidification Through an Abrupt Change in Cross-Sections

Simulations of the directional solidification of two hypoeutectic alloys (Al-7Si alloy and Al-19Cu) and resulting macrosegregation patterns are presented. The casting geometries include abrupt changes in cross-section from a larger width of 9.5 mm to a narrower 3.2 mm width then through an expansion back to a width of 9.5 mm. The alloys were chosen as model alloys because they have similar solidification shrinkages, but the effect of Cu on changing the density of the liquid alloy is about an order of magnitude greater than that of Si. The simulations compare well with experimental castings that were directionally solidified in a graphite mold in a Bridgman furnace. In addition to the simulations of the directional solidification in graphite molds, some simulations were effected for solidification in an alumina mold. This study showed that the mold must be included in numerical simulations of directional solidification because of its effect on the temperature field and solidification. For the model alloys used for the study, the simulations clearly show the interaction of the convection field with the solidifying alloys to produce a macrosegregation pattern known as "steepling" in sections with a uniform width. Details of the complex convection- and segregation-patterns at both the contraction and expansion of the cross-sectional area are revealed by the computer simulations. The convection and solidification through the expansions suggest a possible mechanism for the formation of stray grains. The computer simulations and the experimental castings have been part of on-going ground-based research with the goal of providing necessary background for eventual experiments aboard the ISS. For casting practitioners, the results of the simulations demonstrate that computer simulations should be applied to reveal interactions between alloy solidification properties, solidification conditions, and mold geometries on macrosegregation. The simulations also presents the possibility of engineering the mold-material to avoid, or mitigate, the effects of thermosolutal convection and macrosegregation by selecting a mold material with suitable thermal properties, especially its thermal conductivity.

Lauer, M.↗

NASA NTRS2012

The Origin and Evolution of Saturn's 2011-2012 Stratospheric Vortex

The planet-encircling springtime storm in Saturn's troposphere (December 2010-July 2011, Fletcher, L.N. et al. [2011]. Science 332, 1413-1414; Sánchez-Lavega, A. et al. [2011]. Nature 475, 71-74; Fischer, G. et al. [2011]. Nature 475, 75-77) produced dramatic perturbations to stratospheric temperatures, winds and composition at mbar pressures that persisted long after the tropospheric disturbance had abated. Thermal infrared (IR) spectroscopy from the Cassini Composite Infrared Spectrometer (CIRS), supported by ground-based IR imaging from the VISIR instrument on the Very Large Telescope and the MIRSI instrument on NASA's IRTF, is used to track the evolution of a large, hot stratospheric anticyclone between January 2011 and March 2012. The evolutionary sequence can be divided into three phases: (I) the formation and intensification of two distinct warm airmasses near 0.5 mbar between 25 and 35degN (B1 and B2) between January-April 2011, moving westward with different zonal velocities, B1 residing directly above the convective tropospheric storm head; (II) the merging of the warm airmasses to form the large single 'stratospheric beacon' near 40degN (B0) between April and June 2011, disassociated from the storm head and at a higher pressure (2 mbar) than the original beacons, a downward shift of 1.4 scale heights (approximately 85 km) post-merger; and (III) the mature phase characterised by slow cooling (0.11 +/- 0.01 K/day) and longitudinal shrinkage of the anticyclone since July 2011. Peak temperatures of 221.6 +/- 1.4 K at 2 mbar were measured on May 5th 2011 immediately after the merger, some 80 K warmer than the quiescent surroundings. From July 2011 to the time of writing, B0 remained as a long-lived stable stratospheric phenomenon at 2 mbar, moving west with a near-constant velocity of 2.70 +/- 0.04 deg/day (24.5 +/- 0.4 m/s at 40degN relative to System III longitudes). No perturbations to visible clouds and hazes were detected during this period. With no direct tracers of motion in the stratosphere, we use thermal windshear calculations to estimate clockwise peripheral velocities of 200-400 m/s at 2 mbar around B0. The peripheral velocities of the two original airmasses were smaller (70-140 m/s). In August 2011, the size of the vortex as defined by the peripheral collar was 65deg longitude (50,000 km in diameter) and 25deg latitude. Stratospheric acetylene (C2H2) was uniformly enhanced by a factor of three within the vortex, whereas ethane (C2H6) remained unaffected. The passage of B0 generated a new band of warm stratospheric emission at 0.5 mbar at its northern edge, and there are hints of warm stratospheric structures associated with the beacons at higher altitudes (p < 0.1 mbar) than can be reliably observed by CIRS nadir spectroscopy. Analysis of the zonal windshear suggests that Rossby wave perturbations from the convective storm could have propagated vertically into the stratosphere at this point in Saturn's seasonal cycle, one possible source of energy for the formation of these stratospheric anticyclones.

evolution↗

NASA NTRS2014

Magnetic Field Amplification in the Thin X-Ray Rims of SN 1006

Several young supernova remnants, including SN 1006, emit synchrotron X-rays in narrow filaments, hereafter thin rims, along their periphery. The widths of these rims imply 50–100 μG fields in the region immediately behind the shock, far larger than expected for the interstellar medium compressed by unmodified shocks, assuming electron radiative losses limit rim widths. However, magnetic field damping could also produce thin rims. Here we review the literature on rim width calculations, summarizing the case for magnetic field amplification. We extend these calculations to include an arbitrary power-law dependence of the diffusion coefficient on energy, D ∝ Eμ. Loss-limited rim widths should shrink with increasing photon energy, while magnetic-damping models predict widths almost independent of photon energy. We use these results to analyze Chandra observations of SN 1006, in particular the southwest limb. We parameterize the FWHM in terms of energy as FWHM ∝ EmE γ. Filament widths in SN 1006 decrease with energy; mE ∼ −0.3 to −0.8, implying magnetic field amplification by factors of 10–50, above the factor of four expected in strong unmodified shocks. For SN 1006, the rapid shrinkage rules out magnetic damping models. It also favors short mean free paths (small diffusion coefficients) and strong dependence of D on energy (μ ≥ 1).

MAGNETIC FIELD AMPLIFICATION IN THE THIN X-RAY RIM↗

NASA NTRS2019

Computational Materials Techniques for Thermal Protection Solutions: Materials and Process Design

Integrated computational materials techniques that span the atomistic and continuum scales have the potential to aid the design and manufacturing of thermal protection materials. Two cases demonstrating the practical application of these methods are discussed. Case one examines the selection of a high temperature coating for carbon/carbon, with the target application being a solar thermal propulsion heat exchanger. The performance of various refractory metal and metal-carbide coatings is characterized considering extreme thermal (3500 K) and chemical (hydrogen flows) conditions. The recession rate, hydrogen leakage, and likelihood of mechanical failure are characterized and provide directions for further experimental investigation. Case two examines the process optimization of a heat shield material composed of a woven silica fiber preform and cyanate ester resin. Frequently, internal voids were found to be present in this composite after the resin infusion and curing stages of manufacturing. Using the manufacturing conditions, computations indicate that both water adsorption and resin cure shrinkage are contributing factors to void formation. The results suggest an alternative process configuration for curing that would mitigate voids.

thermal protection↗

NASA NTRS2018

Atomic Oxygen Environments, Effects, and Mitigation

Oxygen atoms↗

NASA NTRS2019

Computational Materials Techniques for Thermal Protection Solutions: Materials and Process Design

Integrated computational materials techniques that span the atomistic and continuum scales have the potential to aid the design and manufacturing of thermal protection materials. Two cases demonstrating the practical application of these methods are discussed. Case one examines the selection of a high temperature coating for carbon/carbon, with the target application being a solar thermal propulsion heat exchanger. The performance of various refractory metal and metal-carbide coatings is characterized considering extreme thermal (3500 degrees Kelvin) and chemical (hydrogen flows) conditions. The recession rate, hydrogen leakage, and likelihood of mechanical failure are characterized and provide directions for further experimental investigation. Case two examines the process optimization of a heat shield material composed of a woven silica fiber preform and cyanate ester resin. Frequently, internal voids were found to be present in this composite after the resin infusion and curing stages of manufacturing. Using the manufacturing conditions, computations indicate that both water adsorption and resin cure shrinkage are contributing factors to void formation. The results suggest an alternative process configuration for curing that would mitigate voids.

Thermal Protection↗

NASA NTRS2018

Computational Materials Techniques for Thermal Protection Solutions: Materials and Process Design

Haskins, Justin↗

NASA NTRS2018

Numerical and Experimental Study of Local Resin Pressure for the Manufacturing of Composite Structures and Their Effect on Porosity

Porosity can have significant impact on the mechanical performance of composite structures. The primary sources of voids during the cure of composites include air entrapped during lay-up, bag or tool leaks, and the off gassing of volatiles. Capturing the physics of void evolution during composite processing is a challenge due to the number of sources and changing phenomena that give rise to voids as the resin cures. Local changes in resin pressure due to geometric features or cure shrinkage have been experimentally linked to a higher likelihood of void formation. In this work, a preliminary model was developed to predict local resin pressure which can be used to identify regions more susceptible to porosity. Experiments were conducted to validate the model accuracy. Ultimately, this model can be used as a tool to minimize the likelihood of porosity by optimizing the material selection, part design, layup, and cure process.

Bedayat, Houman↗

NASA NTRS2020

Flexible Polyimide Aerogels Derived From Use of Neopentyl Spacer in Backbone

Polyimide aerogels have gained much attention in the last decade due to their highly porous structure with low density, low dielectric constant, good mechanical properties and thermal stability. They are desirable for many aerospace and commercial applications including lightweight substrates for antennas for aerospace vehicles, due to the low dielectric constant, approaching one as density decreases. However, with only aromatic diamines in the backbone, the aerogels are flexible only as very thin films, nominally 0.5 mm thick. A more flexible aerogel substrate would allow them to be used as conformal antennas, which would reduce drag and also save space in aerospace vehicles. In this research, we demonstrate that the flexibility can be increased by substituting the aromatic diamines typically used in polyimide aerogels with 1,3-bis(4-aminophenoxy)-2, 2-dimethylpropane (BAPN), which contains a flexible neopentyl spacer group. Using the aliphatic diamine, BAPN, leads to aerogels with a high bend radius even when the aerogels are 2-3 mm thick. Twenty different formulations of polyimide aerogels were synthesized from 3,3’,4,4’-biphenyltetracarboxylic dianhydride (BPDA) and a combination of BAPN and 2,2’-dimethylbenxidine (DMBZ), and cross-linked with 1,3,5-triaminophenoxybenzene (TAB) to understand the effect of polymer concentration, oligomer chain length and concentration of BAPN on the properties of the aerogels. Aerogels made using 50 mol % BAPN with n of 45 and 7 wt % polymer possessed the best combination of properties conducive to use as a flexible substrate for conformal antennas, including low density, good hydrophobicity, low shrinkage with high surface area, a one-inch bend radius in aerogels up to 3 mm thickness, and a dielectric constant of 1.11.

polyimide aerogels↗

NASA NTRSDate not supplied

RESIDUAL DEFORMATION ANALYSIS IN COMPOSITE SHELL STRUCTURES MANUFACTURED USING AUTOMATED FIBER PLACEMENT

The manufacturing of composites typically produces residual stresses that can significantly affect the final shape of the structure. The process of automated fiber placement (AFP) has become a prominent manufacturing technique in developing layups with tailored, variable stiffness morphology. The steered patterns of fiber tows with and without overlaps produce residual deformations that are distinctive from traditional layups. Digital image correlation was used to measure the AFP lamina coefficients of thermal expansion, which were incorporated into finite element analyses (FEA) to model the cooling phase of the cure cycle. The effects of nonlinear analysis and temperature-dependent lamina properties calculated using self-consistent field micromechanics, on the resulting residual deformation of shells, were also modeled. The predicted residual deformation was analyzed by considering out-of-roundness in cylindrical shells and compared to the experimental results. The shell FEA results were well-correlated with the overall deformed shape of the AFP cylinder with overlaps, while the shell FEA model of the AFP cylinder without overlaps did not show as good of qualitative match of the deformation pattern. Analytical correlation with measured results were insensitive to material softening at elevated temperatures, geometric nonlinearities, and variations in measured lamina thermal properties. To improve the accuracy of the residual deformation analysis, these results suggest that the thermo-chemical shrinkages preceding the cooldown should be considered, as well as possible variations in ply level microstructure due to the presence of the embedded fiber tow gaps and overlaps.

Composites↗

NASA NTRS2021

Residual Stresses Induced due to Curing of the Bulk Matrix in a Simplified Three-Dimensional (3D) Woven Repeating Unit Cell

It has been observed that 3D woven materials are highly susceptible to processes induced defects including tow misalignment, intratow and intertow cracking and/or voids. Adequate process modeling of 3D woven Polymer Matrix Composites (PMCs) is necessary to predict and estimate the effects of the manufacturing process on these defects. A preliminary step towards this is achieved with the commercial Finite Element Analysis (FEA) tool Abaqus complemented with written user subroutines to account for the effect of shrinkage and thermoelastic properties evolution as a function of the degree of cure of the bulk matrix phase in a 3D woven composite repeating unit cell (RUC). As a pathfinder, the process modeling framework is demonstrated on a simplified 3D woven RUC of an AS4/RIMR 135 system. Curing simulations are performed on the 3D woven RUC to observe the processing induced residual stresses. The results of the analysis show that high stress concentrations, present within the 3D intertow matrix bordering the binder tow, coincide with X-Ray computed tomography (X-Ray-CT) scan data depicting cracking in the same location

3D Woven↗

NASA NTRSDate not supplied

Upscaling of 500 °C Durable SiC JFET-R Integrated Circuits

At HiTEC2018, NASA Glenn Research Center reported the first demonstration of yearlong 500°C operation of ceramic-packaged “Generation 10” ~200-transistor integrated circuits (ICs) based on two-level interconnect silicon carbide (4H-SiC) junction field effect transistors and resistors (JFET-R). This HiTEC 2021submissionupdateson-going efforts at NASA Glenn spanning two subsequent prototype IC generations “11 and 12” to increase both complexity and durability of these ICs. Increased chip complexities of around 1000 transistors/chip for Gen. 11and near 3000 transistors/chip for Gen. 12 aremade possibleby reductions in minimum layout feature sizes (including resistorwidth shrinkage from 6 μm to 2μm) coupled with enlarged die size (from 3x3 mm to 5x5mm). Gen. 11 ICs electrically tested to date include an 8-bit delta-sigma analog to digital converter (ADC) as well as upscaled random access memory (RAM)and nearly 1 kbit read only memory (ROM). However, Gen. 11 prototype ICs exhibited significantly lower yield and durability than Gen. 10 ICs. Development of revised processing is being investigated towards mitigating these issues in subsequentGen. 12 fabrication runcurrentlyin progress.

Silicon Carbide↗