Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Thermal damage”

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.

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

At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Aero-Heating of Shallow Cavities in Hypersonic Freestream Flow

The purpose of these experiments and analysis was to augment the heating database and tools used for assessment of impact-induced shallow-cavity damage to the thermal protection system of the Space Shuttle Orbiter. The effect of length and depth on the local heating disturbance of rectangular cavities tested at hypersonic freestream conditions has been globally assessed using the two-color phosphor thermography method. These rapid-response experiments were conducted in the Langley 31-Inch Mach 10 Tunnel and were initiated immediately prior to the launch of STS-114, the initial flight in the Space Shuttle Return-To-Flight Program, and continued during the first week of the mission. Previously-designed and numerically-characterized blunted-nose baseline flat plates were used as the test surfaces. Three-dimensional computational predictions of the entire model geometry were used as a check on the design process and the two-dimensional flow assumptions used for the data analysis. The experimental boundary layer state conditions were inferred using the measured heating distributions on a no-cavity test article. Two test plates were developed, each containing 4 equally-spaced spanwise-distributed cavities. The first test plate contained cavities with a constant length-to-depth ratio of 8 with design point depth-to-boundary-layer-thickness ratios of 0.1, 0.2, 0.35, and 0.5. The second test plate contained cavities with a constant design point depth-to-boundary-layer-thickness ratio of 0.35 with length-to-depth ratios of 8, 12, 16, and 20. Cavity design parameters and the test condition matrix were established using the computational predictions. Preliminary results indicate that the floor-averaged Bump Factor (local heating rate nondimensionalized by upstream reference) at the tested conditions is approximately 0.3 with a standard deviation of 0.04 for laminar-in/laminar-out conditions when the cavity length-to-boundary-layer thickness is between 2.5 and 10 and for cavities in the depth-to-boundary-layer-thickness range of 0.3 to 0.8. Over this same range of conditions and parameters, preliminary results also indicate that the maximum Bump Factor on the cavity centerline falls between 2.0 and 2.75, as long as the cavity-exit conditions remain laminar. Cavities with length-to-boundary-layer-thickness ratio less than 2.5 can not be easily classified with this approach and require further analysis.

Everhart, Joel L.↗
NASA NTRS2015

On Possible Arc Inception on Low Voltage Solar Array

Recent analysis of spacecraft failures during the period of 1990-2013 demonstrated clearly that electrostatic discharges caused more than 8 of all registered failures and anomalies, and comprised the most costly losses (25) for operating companies and agencies. The electrostatic discharges on spacecraft surfaces are the results of differential charging above some critical (threshold) voltages. The mechanisms of differential charging are well known, and various methods have been developed to prevent a generation of significant electric fields in areas of triple junctions. For example, low bus voltages in Low Earth Orbit plasma environment and slightly conducting layer over coverglass (ITO) in Geosynchronous Orbit surroundings are believed to be quite reliable measures to prevent discharges on respective surfaces. In most cases, the vulnerable elements of spacecraft (solar arrays, diode boards, etc.) go through comprehensive ground tests in vacuum chambers. However, tests articles contain the miniscule fragments of spacecraft components such as 10-30 solar cells of many thousands deployed on spacecraft in orbit. This is one reason why manufacturing defects may not be revealed in ground tests but expose themselves in arcing on array surface in space. The other reason for ineffectiveness of discharge preventive measures is aging of all materials in harsh orbital environments. The expected life time of modern spacecraft varies within the range of five-fifteen years, and thermal cycling, radiation damages, and mechanical stresses can result in surface erosion on conductive layers and microscopic cracks in coverglass sheets and adhesive films. These possible damages may cause significant increases in local electric field strengths and subsequent discharges. The primary discharges may or may not be detrimental to spacecraft operation, but they can produce the necessary conditions for sustained arcs initiation. Multiple measures were developed to prevent sustained discharges between adjacent strings, and many ground tests were performed to determine threshold parameters (voltage and current) for sustained arcs. And again, manufacturing defects and aging in space environments may result in considerable decrease of critical threshold parameters. This paper is devoted to the analysis of possible reasons behind arcing on spacecraft with low bus voltages.

plasma interaction↗
NASA NTRS2015

On Possible Arc Inception on Low Voltage Solar Array

Recent analysis of spacecraft failures during the period of 1990-2013 demonstrated clearly that electrostatic discharges caused more than 8 percent of all registered failures and anomalies, and comprised the most costly losses (25 percent) for operating companies and agencies. The electrostatic discharges on spacecraft surfaces are the results of differential charging above some critical (threshold) voltages. The mechanisms of differential charging are well known, and various methods have been developed to prevent a generation of significant electric fields in areas of triple junctions. For example, low bus voltages in Low Earth Orbit plasma environment and slightly conducting layer over cover-glass (ITO) in Geosynchronous Orbit surroundings are believed to be quite reliable measures to prevent discharges on respective surfaces. In most cases, the vulnerable elements of spacecraft (solar arrays, diode boards, etc.) go through comprehensive ground tests in vacuum chambers. However, tests articles contain the miniscule fragments of spacecraft components such as 10-30 solar cells of many thousands deployed on spacecraft in orbit. This is one reason why manufacturing defects may not be revealed in ground tests but expose themselves in arcing on array surface in space. The other reason for ineffectiveness of discharge preventive measures is aging of all materials in harsh orbital environments. The expected life time of modern spacecraft varies within the range of five-fifteen years, and thermal cycling, radiation damages, and mechanical stresses can result in surface erosion on conductive layers and microscopic cracks in cover-glass sheets and adhesive films. These possible damages may cause significant increases in local electric field strengths and subsequent discharges. The primary discharges may or may not be detrimental to spacecraft operation, but they can produce the necessary conditions for sustained arcs initiation. Multiple measures were developed to prevent sustained discharges between adjacent strings, and many ground tests were performed to determine threshold parameters (voltage and current) for sustained arcs. And again, manufacturing defects and aging in space environments may result in considerable decrease of critical threshold parameters. This paper is devoted to the analysis of possible reasons behind arcing on spacecraft with low bus voltages.

low voltage solar array↗
NASA NTRSDate not supplied

Space Launch System Core Stage Green Run Base Heating: Anomaly, Mitigation and Flight Redesign

The NASA Space Launch System (SLS) vehicle is composed of four RS-25 liquid oxygen and hydrogen rocket engines in the Core Stage (CS). The SLS Core Stage went through Green Run hot-fire testing at NASA Stennis Space Center’s B-2 test facility in 2021. The main goal of this testing was to confirm Core Stage tanking, propulsion and thrust vector control systems operations and performance to verify with predicted models. Two hot-fire (HF) test sequences were performed with the first one (HF1) in January for a test duration of 70 seconds and the second (HF2) testing completed in March for a test duration of 500 seconds. This paper focuses on the base heating anomalies observed during HF1 and HF2 where an extensive fire was observed along the Core Stage base heat shield during test operations. This environment was not anticipated and led to extensive unplanned damage to the thermal protection system which was augmented for flight. Green Run observations also led to a reassessment of flight environments for Artemis I. This paper discusses the potential cause of the anomalies, the flow physics, the reconstructed base environments, and mitigation plans for HF2 and flight.

aerothermodynamics↗
NASA NTRSDate not supplied

Space Launch System Core Stage Green Run Base Heating: Anomaly, Mitigation and Flight Redesign

The NASA Space Launch System (SLS) vehicle is composed of four RS-25 liquid oxygen and hydrogen rocket engines in the Core Stage (CS). The SLS Core Stage went through Green Run hotfire testing at NASA Stennis Space Center’s B-2 test facility in 2021. The main goal of this testing was to confirm Core Stage tanking, propulsion and thrust vector control systems operations and performance to verify with predicted models. Two hot-fire (HF) test sequences were performed with the first one (HF1) in January for a test duration of 70 seconds and the second (HF2) testing completed in March for a test duration of 500 seconds. This paper focuses on the base heating anomalies observed during HF1 and HF2 where an extensive fire was observed along the Core Stage base heat shield during test operations. This environment was not anticipated and led to extensive unplanned damage to the thermal protection system which was augmented for flight. Green Run observations also led to a reassessment of flight environments for Artemis I. This paper discusses the potential cause of the anomalies, the flow physics, the reconstructed base environments, and mitigation plans for HF2 and flight.

aerothermodynamics↗
DOE OSTI2024

A Multiphysics Thermoelastoviscoplastic Damage Internal State Variable Constitutive Model including Magnetism

We present a macroscale constitutive model that couples magnetism with thermal, elastic, plastic, and damage effects in an Internal State Variable (ISV) theory. Previous constitutive models did not include an interdependence between the internal magnetic (magnetostriction and magnetic flux) and mechanical fields. Although constitutive models explaining the mechanisms behind mechanical deformations caused by magnetization changes have been presented in the literature, they mainly focus on nanoscale structure–property relations. A fully coupled multiphysics macroscale ISV model presented herein admits lower length scale information from the nanoscale and microscale descriptions of the multiphysics behavior, thus capturing the effects of magnetic field forces with isotropic and anisotropic magnetization terms and moments under thermomechanical deformations. For the first time, this ISV modeling framework internally coheres to the kinematic, thermodynamic, and kinetic relationships of deformation using the evolving ISV histories. For the kinematics, a multiplicative decomposition of deformation gradient is employed including a magnetization term; hence, the Jacobian represents the conservation of mass and conservation of momentum including magnetism. The first and second laws of thermodynamics are used to constrain the appropriate constitutive relations through the Clausius–Duhem inequality. The kinetic framework employs a stress–strain relationship with a flow rule that couples the thermal, mechanical, and magnetic terms. Experimental data from the literature for three different materials (iron, nickel, and cobalt) are used to compare with the model’s results showing good correlations.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A Multiphysics Thermoelastoviscoplastic Damage Internal State Variable Constitutive Model including Magnetism

We present a macroscale constitutive model that couples magnetism with thermal, elastic, plastic, and damage effects in an Internal State Variable (ISV) theory. Previous constitutive models did not include an interdependence between the internal magnetic (magnetostriction and magnetic flux) and mechanical fields. Although constitutive models explaining the mechanisms behind mechanical deformations caused by magnetization changes have been presented in the literature, they mainly focus on nanoscale structure–property relations. A fully coupled multiphysics macroscale ISV model presented herein admits lower length scale information from the nanoscale and microscale descriptions of the multiphysics behavior, thus capturing the effects of magnetic field forces with isotropic and anisotropic magnetization terms and moments under thermomechanical deformations. For the first time, this ISV modeling framework internally coheres to the kinematic, thermodynamic, and kinetic relationships of deformation using the evolving ISV histories. For the kinematics, a multiplicative decomposition of deformation gradient is employed including a magnetization term; hence, the Jacobian represents the conservation of mass and conservation of momentum including magnetism. The first and second laws of thermodynamics are used to constrain the appropriate constitutive relations through the Clausius–Duhem inequality. The kinetic framework employs a stress–strain relationship with a flow rule that couples the thermal, mechanical, and magnetic terms. Experimental data from the literature for three different materials (iron, nickel, and cobalt) are used to compare with the model’s results showing good correlations.

36 MATERIALS SCIENCE↗
NASA NTRS2008

Advanced Low Conductivity Thermal Barrier Coatings: Performance and Future Directions (Invited paper)

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and performance will be emphasized. Advanced thermal barrier coatings have been developed using a multi-component defect clustering approach, and shown to have improved thermal stability and lower conductivity. The coating systems have been demonstrated for high temperature combustor applications. For thermal barrier coatings designed for turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability. Erosion resistant thermal barrier coatings are being developed, with a current emphasis on the toughness improvements using a combined rare earth- and transition metal-oxide doping approach. The performance of the toughened thermal barrier coatings has been evaluated in burner rig and laser heat-flux rig simulated engine erosion and thermal gradient environments. The results have shown that the coating composition optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic durability. The erosion, impact and high heat-flux damage mechanisms of the thermal barrier coatings will also be described.

Zhu, Dongming↗
NASA NTRS2008

Advanced Low Conductivity Thermal Barrier Coatings: Performance and Future Directions

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and performance will be emphasized. Advanced thermal barrier coatings have been developed using a multi-component defect clustering approach, and shown to have improved thermal stability and lower conductivity. The coating systems have been demonstrated for high temperature combustor applications. For thermal barrier coatings designed for turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability. Erosion resistant thermal barrier coatings are being developed, with a current emphasis on the toughness improvements using a combined rare earth- and transition metal-oxide doping approach. The performance of the toughened thermal barrier coatings has been evaluated in burner rig and laser heat-flux rig simulated engine erosion and thermal gradient environments. The results have shown that the coating composition optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic durability. The erosion, impact and high heat-flux damage mechanisms of the thermal barrier coatings will also be described.

Zhu, Dongming↗
NASA NTRS2017

Simulated Space Environment Effects on a Candidate Solar Sail Material

For long duration missions of solar sail vehicles, the sail material needs to survive the harsh space environment as the degradation of the sail material determines its operational lifetime. Therefore, understanding the effects of the space environment on the sail membrane is essential for mission success. In this study, the effect of simulated space environments of ionizing radiation and thermal aging were investigated. In order to assess some of the potential damage effects on the mechanical, thermal and optical properties of a commercial off the shelf (COTS) polyester solar sail membrane. The solar sail membrane was exposed to high energy electrons [about 70 keV and 10 nA/cm(exp. 2)], and the physical properties were characterized. After about 8.3 Grad dose, the tensile modulus, tensile strength and failure strain of the sail membrane decreased by 20 to 95%. The aluminum reflective layer was damaged and partially delaminated but it did not show any significant change in solar absorbance or thermal emittance. The mechanical properties of a precracked sample, simulating potential impact damage of the sail membrane, as well as thermal aging effects on metallized PEN (polyethylene naphthalate) film, will be discussed.

Kang, Jin Ho↗
NASA NTRS2011

Limiting Future Collision Risk to Spacecraft: An Assessment of NASA's Meteoroid and Orbital Debris Programs

Over the past 50 years, various NASA communities have contributed significantly to maturing NASA s meteoroid and orbital debris (MMOD)1 programs to their current state. As a result of these community efforts, and to NASA s credit, NASA s MMOD programs and models are now widely used and respected by the providers and users of both government and commercial satellites, nationally as well as internationally. Satellites have been redesigned to protect critical components from MMOD damage by moving critical components from exterior surfaces to deep inside a satellite s structure. Orbits are monitored and altered to minimize the risk of collision with tracked orbital debris. MMOD shielding added to the International Space Station (ISS) protects critical components and astronauts from potentially catastrophic damage that might result from smaller, untracked debris and meteoroid impacts. The space shuttle, as it orbited Earth, and whether docked to the ISS or not, was optimally oriented to protect its fragile thermal protection and thermal radiation systems from MMOD damage. In addition, astronauts inspected its thermal protection system for MMOD damage before the shuttle reentered Earth s atmosphere; Orion, NASA s capsule to carry astronauts to low Earth orbit, includes designs to mitigate the threat of MMOD damage and provide increased safety to the crew. When a handful of reasonable assumptions are used in NASA s MMOD models, scenarios are uncovered that conclude that the current orbital debris environment has already reached a "tipping point." That is, the amount of debris - in terms of the population of large debris objects, as well as overall mass of debris in orbit - currently in orbit has reached a threshold where it will continually collide with itself, further increasing the population of orbital debris. This increase will lead to corresponding increases in spacecraft failures, which will only create more feedback into the system, increasing the debris population growth rate. The increase thus far has been most rapid in low Earth orbit (LEO), with geosynchronous Earth orbits (GEOs) potentially suffering the same fate, but over a much longer time period. The exact timing and pace of this exponential growth are uncertain, but the serious implications of such a scenario require careful attention because of the strategic importance of U.S. space operations. The Office of Science and Technology Policy and the Office of Management and Budget contracted with the National Research Council for a study to perform three tasks: review NASA s MMOD programs and efforts, recommend in which of those NASA should increase or decrease its effort or change focus, and determine whether NASA should pursue work in any new MMOD areas. The official letter requesting the study and the full statement of task for the Committee for the Assessment of NASA s Orbital Debris Programs are in Appendixes A and B, respectively.

Source record↗
DOE OSTI2020

Improvised Electrsopinning Set Up for Thicker Ceramic Nanofiber Mat for High Power Targets

In high energy particle physics there is a demand for multi-MW high performance particle production targets. Nanofiber microstructure will have better performance than current solid targets in mitigating increased thermal tress waves, radiation damage. The objective is to fabricate thicker ceramic/metallic nano-fiber with high strength, thermal shock resistance using low cost electrospinning process.

43 PARTICLE ACCELERATORS↗
NASA NTRSDate not supplied

Design of a Thermal Testbed for Metrology of Active Antennas

NASA mission requirements have driven an increased interest in active phased array antennas (APAA) for space-based user communication terminals. Recent advancements in 5G technology have driven down the cost of APAA development and manufacturing all while providing a technology solution that covers many existing Ka-Band satellite communication spectrum bands. While these developments have provided ample opportunities to leverage new chips and arrays for use in space, there is also a need to evaluate these antennas in a relevant environment. Active arrays, as designed for use in 5G, require thermal management to avoid damage to the device as well as to maintain performance. Measured performance under various thermal conditions is essential both for understanding overall APAA performance and ensuring operation is within required tolerances. To address these measurement needs, the SmallSat Ka-band Operations User Terminal (SKOUT) project at the NASA Glenn Research Center (GRC) developed a test environment that combines traditional antenna and communication system metrology with a conduction cooling/heating thermal control system to simulate the space thermal environment. This paper will address the metrologysystem design and performance specifications as well as test article setup and operation. Tests that are typically performed at ambient temperature can now be performed over the typical temperature range of a Low Earth Orbit (LEO) mission. These tests include error vector magnitude (EVM), gain to noise temperature (G/T), antenna patterns, and non-linear characterization. The paper will cover the configuration for each test and provide results from a recent test campaign. Results illustrate the importance of higher fidelity environmental testing when evaluating the performance of an APAA.

active phased array↗
DOE OSTI2022

High power targets: Challenges of next-generation high-intensity neutrino beams

High power target systems are crucial elements in enabling future neutrino and other rare particle beams. These systems transform intense source of protons into secondary particles of interest to enable new scientific discoveries. As primary beam intensities increase in next-generation multi-megawatt accelerator facilities, high power target systems face key challenges. Thermal shock and radiation damage effects in beam-intercepting devices were identified as the leading cross-cutting challenges of high-power target facilities. Target materials R&D to address these challenges are therefore essential to enable and ensure reliable operation of future accelerator target facilities. This paper provides an overview of the R&D activities underway to help support high power target systems development for next-generation multi-MW facilities.

43 PARTICLE ACCELERATORS↗
NASA NTRS1988

Hubble Space Telescope Metallized Teflon(registered trademark) FEP Thermal Control Materials: On-Orbit Degradation and Post-Retrieval Analysis

During the Hubble Space Telescope (HST) Second Servicing Mission (SM2), degradation of unsupported Teflon(Registered Trademark) FEP (fluorinated ethylene propylene), used as the outer layer of the multilayer insulation (MLI) blankets, was evident as large cracks on the telescope light shield. A sample of the degraded outer layer was retrieved during the mission and returned to Earth for ground testing and evaluation. The results of the Teflon(Registered Trademark) FEP sample evaluation and additional testing of pristine Teflon(Registered Trademark) FEP led the investigative team to theorize that the HST damage was caused by thermal cycling with deep-layer damage from electron and proton radiation which allowed the propagation of cracks along stress concentrations , and that the damage increased with the combined total dose of electrons, protons, UV and x-rays along with thermal cycling. This paper discusses the testing and evaluation of the retrieved Teflon(Registered Trademark) FEP.

Townsend, Jacqueline A.↗
NASA NTRS1980

Effects of moisture, residual thermal curing stresses and mechanical load on the damage development in quasi-isotropic laminates

Classical laminate theory and a finite element model were used to predict stress states prior to the first formation of damage in laminates fabricated from T/300/5208. Crack patterns characteristic of the laminate in a wet or dry condition were also predicted using a shear lag model. Development of edge damage was recorded and observed during the test by transferring an image of the damage from the edge surface on to a thin acetate sheet such that the damage imprinted could be immediately viewed on a microfiche card reader. Moisture was shown to significantly alter the interior and edge dry stress states due to swelling and a reduction of elastic properties and to reduce the transverse strength in 90 deg plies. A model was developed in order to predict changes in first ply failure laminate loads due to differences in stacking sequence together with a wet or dry environmental condition.

Kriz, R. D.↗
NASA NTRS1982

Effects of moisture, residual thermal curing stresses, and mechanical load on the damage development in quasi-isotropic laminates

This investigation demonstrates how moisture absorbed in (0/+ or - 45/90)s and (0/90/+ or - 45)s graphite epoxy laminates significantly alters the stress state and chronology of damage development along the laminate edge during static tension and tension-tension cyclic loading. Emphasis is placed on using reasonable approximations for wet and dry elastic properties, including out-of-plane properties (nu sub 23 and G sub 23), since these properties are required by finite element and shear lag models to predict the stress state at the laminate edge. Moisture was observed to alter the dry edge stress state in the 90-deg plies of the (0/+ or - 45/90)s laminate such that delaminations occurred at a lower load and transverse cracks occurred at a higher load. A model was developed which predicted the differences in loads required to initiate damage in the 90-deg plies of the two laminates in the wet and dry conditions. Although moisture can alter the chronology of damage development, the damage state in each laminate observed prior to fracture appeared to be independent of moisture content.

Kriz, R. D.↗