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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Evaluation of thermal and mechanical loading effects on the structural behavior of a SiC/titanium composite

Composite specimens of titanium-15-3 matrix reinforced with continuous SCS-6 silicon carbide fibers were tested under a variety of thermal and mechanical loadings. A combined experimental/finite element approach was used to estimate the effective in-situ modulus of the matrix material and to evaluate changes in modulus due to the applied loads. Several fiber orientations were tested. Results indicate that the effect of the thermal loads on composite stiffness varies with fiber orientation. Applications of this method to test specimens damaged by uniaxial tension, thermal cycling, and isothermal fatigue loadings are used to illustrate that by monitoring overall structural behavior, changes in stiffness caused by thermomechanical loading can be detected.

Grady, Joseph E.↗
NASA NTRS1990

Evaluation of thermal and mechanical loading effects on the structural behavior of a SIC/titanium composite

Composite specimens of titanium-15-3 matrix reinforced with continuous SCS-6 silicon carbide fibers were tested under a variety of thermal and mechanical loadings. A combined experimental/finite element approach was used to estimate the effective in situ modulus of the matrix material and to evaluate changes in modulus due to the applied loads. Several fiber orientations were tested. Results indicate that the effect of thermal loads on composite stiffness varies with fiber orientation. Applications of this method to test specimens damaged by uniaxial tension, thermal cycling, and isothermal fatigue loadings are used to illustrate that by monitoring overall structural behavior, changes in stiffness caused by thermomechanical loading can be detected.

Grady, J. E.↗
NASA NTRS2005

Damage Accumulation and Failure of Plasma-Sprayed Thermal Barrier Coatings under Thermal Gradient Cyclic Conditions

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. A fundamental understanding of the sintering and thermal cycling induced delamination of thermal barrier coating systems under engine-like heat flux conditions will potentially help to improve the coating temperature capability. In this study, a test approach is established to emphasize the real-time monitoring and assessment of the coating thermal conductivity, which can initially increase under the steady-state high temperature thermal gradient test due to coating sintering, and later decrease under the thermal gradient cyclic test due to coating cracking and delamination. Thermal conductivity prediction models have been established for a ZrO2-(7- 8wt%)Y2O3 model coating system in terms of heat flux, time, and testing temperatures. The coating delamination accumulation is then assessed based on the observed thermal conductivity response under the combined steady-state and cyclic thermal gradient tests. The coating thermal gradient cycling associated delaminations and failure mechanisms under simulated engine heat-flux conditions will be discussed in conjunction with the coating sintering and fracture testing results.

Zhu, Dongming↗
NASA NTRS2014

Physics-based Entry, Descent and Landing Risk Model

A physics-based risk model was developed to assess the risk associated with thermal protection system failures during the entry, descent and landing phase of a manned spacecraft mission. In the model, entry trajectories were computed using a three-degree-of-freedom trajectory tool, the aerothermodynamic heating environment was computed using an engineering-level computational tool and the thermal response of the TPS material was modeled using a one-dimensional thermal response tool. The model was capable of modeling the effect of micrometeoroid and orbital debris impact damage on the TPS thermal response. A Monte Carlo analysis was used to determine the effects of uncertainties in the vehicle state at Entry Interface, aerothermodynamic heating and material properties on the performance of the TPS design. The failure criterion was set as a temperature limit at the bondline between the TPS and the underlying structure. Both direct computation and response surface approaches were used to compute the risk. The model was applied to a generic manned space capsule design. The effect of material property uncertainty and MMOD damage on risk of failure were analyzed. A comparison of the direct computation and response surface approach was undertaken.

descent and landing↗
DOE OSTI2025

ARC-DPA 1-MeV Neutron Fluence Equivalence Model for GaAs

Here, the legacy data used in the production of the American Society for Testing and Materials (ASTM) E722 standard for gallium arsenide (GaAs) were fit with the athermal recombination corrected-displacements per atom (ARC-DPA) model for the development of a novel 1-MeV neutron equivalent fluence metric. Improving on previous work, the coefficients for the ARC-DPA model were optimized using a conjugate gradient method, and the uncertainties in the observed damage in different benchmark neutron fields were sampled to quantify their contribution to the damage metric. The optimized parameters of −0.474 ± 0.03 for b arcdpa and 0.016 ± 0.002 for c arcdpa provided good agreement and indicated that the solution is not sensitive to the corresponding fluence uncertainties. Compared to the current 1-MeV neutron fluence equivalence standard for displacement damage in GaAs, our results indicate that for a thermal reactor neutron environment, displacement damage has been underestimated by around 25% and that the saturation value for the damage efficiency had been higher than previously modeled.

1-MeV equivalent fluence↗
NASA NTRS2006

Boundary Layer Transition Results From STS-114

The tool for predicting the onset of boundary layer transition from damage to and/or repair of the thermal protection system developed in support of Shuttle Return to Flight is compared to the STS-114 flight results. The Boundary Layer Transition (BLT) Tool is part of a suite of tools that analyze the aerothermodynamic environment of the local thermal protection system to allow informed disposition of damage for making recommendations to fly as is or to repair. Using mission specific trajectory information and details of each damage site or repair, the expected time of transition onset is predicted to help determine the proper aerothermodynamic environment to use in the subsequent thermal and stress analysis of the local structure. The boundary layer transition criteria utilized for the tool was developed from ground-based measurements to account for the effect of both protuberances and cavities and has been calibrated against flight data. Computed local boundary layer edge conditions provided the means to correlate the experimental results and then to extrapolate to flight. During STS-114, the BLT Tool was utilized and was part of the decision making process to perform an extravehicular activity to remove the large gap fillers. The role of the BLT Tool during this mission, along with the supporting information that was acquired for the on-orbit analysis, is reviewed. Once the large gap fillers were removed, all remaining damage sites were cleared for reentry as is. Post-flight analysis of the transition onset time revealed excellent agreement with BLT Tool predictions.

Berry, Scott A.↗
NASA NTRS2000

Hubble Space Telescope Thermal Blanket Repair Design and Implementation

Substantial damage to the outer layer of Hubble Space Telescope (HST) thermal blankets was observed during the February 1997 servicing mission. After six years in LEO, many areas of the aluminized Teflon(R) outer blanket layer had significant cracks, and some material was peeled away to expose inner layers to solar flux. After the mission, the failure mechanism was determined, and repair materials and priorities were selected for follow-on missions. This paper focuses on the thermal, mechanical, and EVA design requirements for the blanket repair, the creative solutions developed for these unique problems, hardware development, and testing.

Ousley, Wes↗
NASA NTRS2005

Implementing Recommendations of the Columbia Accident Investigation Board - Development of on-Orbit RCC Thermography

One of NASA s Space Shuttle Return-to-Flight (RTF) efforts has been to develop thermography for the on-orbit inspection of the Reinforced Carbon Carbon (RCC) portion of the Orbiter Wing Leading Edge (WLE). This paper addresses the capability of thermography to detect cracks in RCC by using in-plane thermal gradients that naturally occur on-orbit. Crack damage, which can result from launch debris impact, is a detection challenge for other on-orbit sensors under consideration for RTF, such as the Intensified Television Camera and Laser Dynamic Range Imager. We studied various cracks in RCC, both natural and simulated, along with material characteristics, such as emissivity uniformity, in steady-state thermography. Severity of crack, such as those likely and unlikely to cause burn through were tested, both in-air and in-vacuum, and the goal of this procedure was to assure crew and vehicle safety during re-entry by identification and quantification of a damage condition while on-orbit. Expected thermal conditions are presented in typical shuttle orbits, and the expected damage signatures for each scenario are presented. Finally, through statistical signal detection, our results show that even at very low in-plane thermal gradients, we are able to detect damage at or below the threshold for fatality in the most critical sections of the WLE, with a confidence exceeding 1 in 10,000 probability of false negative.

Ottens, Brian↗
NASA NTRS2005

Implementing Recommendations of the Columbia Accident Investigation Board: Development of On-Orbit IR Thermography

One of NASA's Space Shuttle Return-to-Flight (RTF) efforts has been to develop thermography for the on-orbit inspection of the Reinforced Carbon Carbon (RCC) portion of the Orbiter Wing Leading Edge (WLE). This paper addresses the capability of thermography to detect cracks in RCC by using in-plane thermal gradients that naturally occur on-orbit. Crack damage, which can result from launch debris impact, is a detection challenge for other on-orbit sensors under consideration for RTF, such as the Intensified Television Camera and Laser Dynamic Range Imager. We studied various cracks in RCC, both natural and simulated, along with material characteristics, such as emissivity uniformity, in steady-state thermography. Severity of crack, such as those likely and unlikely to cause burn through were tested, both in-air and in-vacuum, and the goal of this procedure was to assure crew and vehicle safety during reentry by identification and quantification of a damage condition while on-orbit. Expected thermal conditions are presented in typical shuttle orbits, and the expected damage signatures for each scenario are presented. Finally, through statistical signal detection, our results show that even at very low in-plane thermal gradients, we are able to detect damage at or below the threshold for fatality in the most critical sections of the WLE, with a confidence exceeding 1 in 10,000 probability of false negative.

Ottens, Brian P.↗
NASA NTRSDate not supplied

Analysis of Hypervelocity-Impacted Thin Films for Space Applications

Exposure to the harsh space environment and hypervelocity impacts from micrometeoroids and small orbital debris can affect space operations through long-term degradation of spacecraft materials, surfaces, or systems. Multi-layer insulation (MLI) and coated polyimide films are space-craft materials commonly found on the external surfaces of spacecraft for thermal control and protection. Characterizing the damage to these exposed materials with in-situ and laboratory measurements can better inform spacecraft designers and operators in understanding and mitigating surface or system degradation. In this paper, we examine flown Hubble Space Telescope (HST) Electronic Bay 5 MLI and coated polyimide ground test articles to characterize hyper-velocity impact damage. Impact feature cavities are inspected to identify damage, which can validate long-term degradation models, improve thermal management systems, or improve accuracy of damage predictions. An overview of the impact characterization using optical microscopy, narrow-band spectroscopy, and scanning election microscopy/energy dispersive x-ray (SEM/EDX) of the two materials is presented. Observations of robustness in the space environment, as well as a detailed assessment of cratering and penetration statistics for the space-exposed sample, also are discussed.

Melissa A Ward↗
NASA NTRSDate not supplied

Analysis of Hypervelocity-Impacted Thin Films for Space Applications

Exposure to the harsh space environment and hypervelocity impacts from micrometeoroids and small orbital debris can affect space operations through long-term degradation of spacecraft materials, surfaces, or systems. Multi-layer insulation (MLI) and coated, polyimide films are spacecraft materials commonly found on the external surfaces of spacecraft for thermal control and protection. Characterizing the damage to these exposed materials with in situ and laboratory measurements can better inform spacecraft designers and operators in understanding and mitigating surface or system degradation. In this paper, we examine flown Hubble Space Telescope (HST) Equipment Bay 5 MLI and coated, polyimide ground test articles to characterize hypervelocity impact damage. Impact feature cavities are inspected to identify damage, which can validate long-term degradation models, improve thermal management systems, or improve accuracy of damage predictions. An overview of the impact characterization using optical microscopy, narrowband spectroscopy, and Scanning Election Microscopy/Energy Dispersive X- ray (SEM/EDX) of the two materials is presented. Observations of robustness in the space environment, as well as a detailed assessment of cratering and penetration statistics for the space-exposed sample, also are discussed.

Melissa A. Ward↗
NASA NTRS2006

Overview of Boundary Layer Transition Research in Support of Orbiter Return To Flight

A predictive tool for estimating the onset of boundary layer transition resulting from damage to and/or repair of the thermal protection system was developed in support of Shuttle Return to Flight. The boundary layer transition tool is part of a suite of tools that analyze the aerothermodynamic environment to the local thermal protection system to allow informed disposition of damage for making recommendations to fly as is or to repair. Using mission specific trajectory information and details of each damage site or repair, the expected time (and thus Mach number) at transition onset is predicted to help define the aerothermodynamic environment to use in the subsequent thermal and stress analysis of the local thermal protection system and structure. The boundary layer transition criteria utilized for the tool was developed from ground-based measurements to account for the effect of both protuberances and cavities and has been calibrated against select flight data. Computed local boundary layer edge conditions were used to correlate the results, specifically the momentum thickness Reynolds number over the edge Mach number and the boundary layer thickness. For the initial Return to Flight mission, STS-114, empirical curve coefficients of 27, 100, and 900 were selected to predict transition onset for protuberances based on height, and cavities based on depth and length, respectively.

Berry, Scott A.↗
NASA NTRS2007

Investigation of MMOD Impact on STS-115 Shuttle Payload Bay Door Radiator

The Orbiter radiator system consists of eight individual 4.6 m x 3.2 m panels located with four on each payload bay door. Forward panels #1 and #2 are 2.3 cm thick while the aft panels #3 and #4 have a smaller overall thickness of 1.3 cm. The honeycomb radiator panels consist of 0.028 cm thick Aluminum 2024-T81 facesheets and Al5056-H39 cores. The face-sheets are topped with 0.005 in. (0.127 mm) silver-Teflon tape. The radiators are located on the inside of the shuttle payload bay doors, which are closed during ascent and reentry, limiting damage to the on-orbit portion of the mission. Post-flight inspections at the Kennedy Space Center (KSC) following the STS-115 mission revealed a large micrometeoroid/orbital debris (MMOD) impact near the hinge line on the #4 starboard payload bay door radiator panel. The features of this impact make it the largest ever recorded on an orbiter payload bay door radiator. The general location of the damage site and the adjacent radiator panels can be seen in Figure 2. Initial measurements of the defect indicated that the hole in the facesheet was 0.108 in. (2.74 mm) in diameter. Figure 3 shows an image of the front side damage. Subsequent observations revealed exit damage on the rear facesheet. Impact damage features on the rear facesheet included a 0.03 in. diameter hole (0.76 mm), a approx.0.05 in. tall bulge (approx.1.3 mm), and a larger approx.0.2 in. tall bulge (approx.5.1 mm) that exhibited a crack over 0.27 in. (6.8 mm) long. A large approx.1 in. (25 mm) diameter region of the honeycomb core was also damaged. Refer to Figure 4 for an image of the backside damage to the panel. No damage was found on thermal blankets or payload bay door structure under the radiator panel. Figure 5 shows the front facesheet with the thermal tape removed. Ultrasound examination indicated a maximum facesheet debond extent of approximately 1 in. (25 mm) from the entry hole. X-ray examinations revealed damage to an estimated 31 honeycomb cells with an extent of 0.85 in. x 1.1 in. (21.6 x 27.9 mm). Pieces of the radiator at and surrounding the impact site were recovered during the repair procedures at KSC. They included the thermal tape, front facesheet, honeycomb core, and rear facesheet. These articles were examined at JSC using a scanning electron microscope (SEM) with an energy dispersive x-ray spectrometer (EDS). Figure 6 shows SEM images of the entry hole in the facesheet. The asymmetric height of the lip may be attributed to projectile shape and impact angle. Numerous instances of a glass-fiber organic matrix composite were observed in the facesheet tape sample. The fibers were approximately 10 micrometers in diameter and variable lengths. EDS analysis indicated a composition of Mg, Ca, Al, Si, and O. Figures 7 and 8 present images of the fiber bundles, which were believed to be circuit board material based on similarity in fiber diameter, orientation, consistency, and composition. A test program was initiated in an attempt to simulate the observed damage to the radiator facesheet and honeycomb. Twelve test shots were performed using projectiles cut from a 1.6 mm thick fiberglass circuit board substrate panel. Results from test HITF07017, shown in figures 9 and 10, correlates with the observed impact features reasonably well. The test was performed at 4.14 km/sec with an impact angle of 45 degrees using a cylindrical projectile with a diameter and length of 1.25 mm. The fiberglass circuit board material had a density of 1.65 g/cu cm, giving a projectile mass of 2.53 mg. An analysis was performed using the Bumper code to estimate the probability of impact to the shuttle from a 1.25 mm diameter particle. Table 1 shows a 1.6% chance (impact odds = 1 in 62) of a 1.25 mm or larger MMOD impact on the radiators of the vehicle during a typical ISS mission. There is a 0.4% chance (impact odds = 1 in 260) that a 1.25 mm or larger MMOD particle would impact the RCC wing leading edge and nose cap during a typical miion. Figure 11 illustrates the vulnerable areas of the wing leading edge reinforced carbon-carbon (RCC), an area of the vehicle that is very sensitive to impact damage. The highlighted red, orange, yellow, and light green areas would be expected to experience critical damage if impacted by an OD particle such as the one that hit the RH4 radiator panel on STS-115.

Hyde, J.↗
NASA NTRS1985

NASA space materials research

The effect of the space environment on: (1) thermal control coatings and thin polymer films; (2) radiation stability of 250 F and 350 F cured graphite/epoxy composites; and (3) the thermal mechanical stability of graphite/epoxy, graphite/glass composites are considered. Degradation in mechanical properties due to combined radiation and thermal cycling is highlighted. Damage mechanisms are presented and chemistry modifications to improve stability are suggested. The dimensional instabilities in graphite/epoxy composites associated with microcracking during thermal cycling is examined as well as the thermal strain hysteresis found in metal-matrix composites.

Tenney, D. R.↗
NASA NTRS1983

Burner liner thermal/structural load modelling

The objective of this program is to develop a thermal data transfer computer program module for the burner liner thermal structural load modeling program. This will be accomplished by (1) reviewing existing methodologies for thermal data transfer and selecting three heat transfer codes for application in this program; (2) evaluating the selected codes to establish criteria for developing a computer program module to transfer thermal data from the heat transfer codes to selected stress analysis codes; (3) developing the automated thermal load transfer module; and (4) verifying and documenting the module. In aircraft turbine engine hot section components, cyclic thermal stresses are the most important damage mechanism. Consequently, accurate and reliable prediction of thermal loads is essential to improving durability. To achieve this goal, a considerable effort over the past 20 years has been devoted to the acquisition of engine temperature test data, as well as the development of accurate, reliable, and efficient computer codes for the prediction of steady state and transient temperatures and for the calculation of elastic and inelastic cyclic stresses and strains in hot section components. There is a need for continued development of these codes, because the availability of more accurate analysis techniques for complex configurations has enabled engine designers to use more sophisticated designs to achieve higher cycle efficiency and reduce weight.

Maffeo, R. J.↗
NASA NTRS2001

Thermal Fatigue and Fracture Behavior of Ceramic Thermal Barrier Coatings

Thermal fatigue and fracture behavior of plasma-sprayed ceramic thermal barrier coatings has been investigated under high heat flux and thermal cyclic conditions. The coating crack propagation is studied under laser heat flux cyclic thermal loading, and is correlated with dynamic fatigue and strength test results. The coating stress response and inelasticity, fatigue and creep interactions, and interface damage mechanisms during dynamic thermal fatigue processes are emphasized.

Zhu, Dong-Ming↗
DOE OSTI2024

Vertical z-axis discontinuous carbon fibers for improved lightning strike performance of continuous fiber-reinforced polymer composites

Effective lightning strike protection for critical aerospace and wind applications requires high electrical conductivity to dissipate current efficiently. However, polymer matrix composites face a challenge due to their inherently insulating nature. While conventional carbon fiber-reinforced composites (CFRP) exhibit electrical conductivity in the planar direction, achieving through-thickness conductivity remains an ongoing challenge. In this work, we have undertaken the fabrication of CFRP interleaved with vertically oriented carbon fibers (Z-fiber) to impart higher electrical conductivity along the thickness direction. Two Z-fiber composite variations are prepared: Z-1 with a single layer of Z-fiber and Z-5 with five interleaved layers and compared with no Z-fiber layer (Z-0) composite. The composite panels were subjected to lab-scale lightning strike tests with a current magnitude of 100 kA. To emulate real-world service conditions, an aerospace-grade paint coating was applied to the composite laminates. Comparative analysis shows Z-1 reduces damage diameter to ∼22 mm compared to Z-0 (∼26 mm), while Z-5 exhibits the least damage (∼16.7 mm), confirmed by optical microscopy. Z-5 demonstrates nine times higher through-thickness electrical conductivity than Z-0, reducing electrical anisotropy substantially. Thermal-electric finite element damage modeling predicts surface damage within 6% of experimental values for both Z-0 and Z-5 composites. Flexural tests post-lightning reveal Z-5 retains 66% flexural strength and 86% modulus, significantly better than Z-0, which retains less than 40% for both properties. This study highlights the efficacy of Z-fiber composites in lightning strike protection, offering improved through-thickness conductivity and mechanical property retention.

36 MATERIALS SCIENCE↗