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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Status of Additive Manufacturing Capabilities for Processing Refractory Alloys Under the Mo-99 Program

The enriched 100 Mo target, denoted as aMo, that Northstar Medical Radioisotopes is developing to produce 99 Mo from an accelerator-based method is a disk-type geometry with a 0.5–0.715 mm thickness and a 29 mm outer diameter. A press and sinter method was adopted to fabricate these samples from aMo powder feedstock. Inherent porosity from the press and sinter method makes the disks more easily dissolvable during 99 Mo postprocessing. However, the disk-type geometry will be subject to thermal stresses due to temperature variations once the geometry is in line with the accelerated electron beam, causing warping and possible failure. Additive manufacturing (AM) processes such as laser powder bed fusion (LPBF) enable the manufacturing of custom, complex geometries that may otherwise be difficult to produce with more conventional methods (e.g., press and sinter approach). Therefore, the National Nuclear Security Administration’s Molybdenum-99 Program invested in developing an AM facility dedicated to processing and printing refractory powders. This report details the LPBF process, how irregular refractory powder can be prepared for LPBF, and the equipment that is available to support the program.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Development of boron epoxy rocket motor chambers.

A 71 cm diameter 74 cm length boron/epoxy composite rocket motor chamber was designed based on the geometric configuration of the JPL Applications Technology Satellite titanium alloy apogee motor chamber. Because analyses showed large stress concentrations in the domes, the configuration was modified using the same basic constraints for openings and attachments. The rocket motor chamber was then fabricated by filament winding with boron/epoxy tape and hydrostatically tested to failure at 264 N/sq cm, 57.2 N/sq cm above the design value. Two more rocket motor chambers were fabricated with the same basic constraints, but shortened to 57.6 cm for a smaller propellant load. The first of these short chambers failed in proof because of filament winding fabrication difficulties. The second chamber was successfully fabricated and passed the hydrostatic proof test.

Jensen, W. M.↗
NASA NTRS1941

Effect of alternately high and low repeated stresses upon the fatigue strength of 25S-T aluminum alloy

Fatigue tests were made on one lot of 3/4 inch diameter rolled-and-drawn 25S-T aluminum-alloy rod normal in composition and tensile properties. The specimens were tested at 3500 cycles per second in a rotating-beam fatigue test machine. Tests were made for three ratios (20:1, 50:1, and 200:1) of the number of cycles applied at low stress to the number applied at high stress. In general, failure occurred when the number of cycles at either the low or the high stress approached the ordinary fatigue curve for the material, regardless of the sequence in which the stresses were applied.

Stickley, G W↗
NASA NTRS1999

Production and Characterization of Carbon Nanotubes and Nanotube-Based Composites

The Nobel Prize winning discovery of the Buckuball (C60) in 1985 at Rice University by a group including Dr. Richard Smalley led to the whole new class of carbon allotropes including fullerenes and nanotubes. Especially interesting from many viewpoints are single-walled carbon nanotubes, which structurally are like a single graphitic sheet wrapped around a cylinder and capped at the ends. This cylinders have diameter as small as 0.5 - 2 nm (1/100,000th the diameter of a human hair) and are as long as 0.1 - 1 mm. Nanotubes are really individual molecules and believed to be defect-free, leading to high tensile strength despite their low density. Additionally, these fibers exhibit electrical conductivity as high as copper, thermal conductivity as high as diamond, strength 100 times higher than steel at one-sixth the weight, and high strain to failure. Thus it is believed that developments in the field of nanotechnology will lead to stronger and lighter composite materials for next generation spacecraft. Lack of a bulk method of production is the primary reason nanotubes are not used widely today. Toward this goal JSC nanotube team is exploring three distinct production techniques: laser ablation, arc discharge and chemical vapor deposition (CVD, in collaboration with Rice University). In laser ablation technique high-power laser impinges on the piece of carbon containing small amount of catalyst, and nanotubes self-assemble from the resulting carbon vapor. In arc generator similar vapor is created in arc discharge between carbon electrodes with catalyst. In CVD method nanotubes grow at much lower temperature on small catalyst particles from carbon-containing feedstock gas (methane or carbon monoxide). As of now, laser ablation produces cleanest material, but mass yield is rather small. Arc discharge produces grams of material, but purity is low. CVD technique is still in baby steps, but preliminary results look promising, as well as perspective of scaling the process up. We are also working on necessary purification of nanotubes. Applications of nanotubes are in such various fields as lightweight composites, molecular electronics, energy storage (electrodes in Li ion batteries), flat panel displays, conductive polymers, etc. JSC nanotube team is focused on development of lightweight materials. We work on the injection thermoset epoxies reinforced with nanotubes. Early results show good wetting of nanotube surface with epoxy, which is very important. More research will be possible as more nanotubes become available.

Nikolaev, Pavel↗
DOE OSTI2024

High throughput battery failure experimental platform

Addressing the need to increase the sample set to understand the causes of lithium battery thermal runaway, we conceived of an experimental platform with capability to increase the number of runaway experiments (currently 3-5 per week), while also collecting detailed electrochemical impedance spectroscopy measurements (EIS). Once expanded, the platform would enable data collection on 10s to 100s of cells that all experience runaway, thereby creating a statistical database necessary to identify early indication of risk. A primary containment unit to house cylindrical cells of variety NMC811 and of size 21700 (21 mm diameter by 70 mm length) was designed with features such as debris containment, preloaded cells in an exchangeable port, nitrogen ventilation, and exhaust containment. We performed the first overcharge abuse experiments of several 21700 cells, handpicked because of different initial EIS, and demonstrated that EIS changes dramatically during early stages of overcharge, but in a different manner than previous pouch cell experiments. The abuse experiments also revealed the discharge pattern and debris field created during runaway, as well as the cell temperature control and overheat, that must be considered in the primary containment apparatus. We designed and built a switching relay system to permit measurement of EIS without an active charging circuit, and created instrument control software for charging, EIS, and cell temperature control. The late-start funding was insufficient to fully construct the primary containment unit, but the foundational design and knowhow is available for any future work.

25 ENERGY STORAGE↗
DOE OSTI2019

Bearing Fault Detection and Wear Estimation Using Machine Learning

Unpredicted bearings failures can be costly and dangerous. Current methods have been examining the use of machine learning algorithms to automatically detect bearing faults. Vibration specialists must react daily, as the sheer number of bearings and the machines they operate are critical and any downtime will result in loss of productivity and endanger personal. The method presented in this paper utilizes a novel approach to detect and determine bearings fault diameters. The detection algorithm uses the cubic support vector machine (SVM) for high accuracy inner and outer race fault detection. After detecting the type of fault, the data is then passed through a second layer that uses a modified K-means clustering and a linear interpolation to accurately estimate the diameter of the fault that was detected.

42 ENGINEERING↗
NASA NTRS1972

Development of manufacturing process for large-diameter composite monofilaments by pyrolysis of resin-impregnated carbon-fiber bundles

Large diameter, carbon-carbon composite, monofilaments were produced from the pyrolysis of organic precursor resins reinforced with high-strenght carbon fibers. The mechanical properties were measured before and after pyrolysis and the results were correlated with the properties of the constituents. The composite resulting from the combination of Thornel 75 and GW-173 resin precursor produced the highest tensile strength. The importance of matching strain-to-failure of fibers and matrix to obtain all the potential reinforcement of fibers is discussed. Methods are described to reduce, within the carbonaceous matrix, pyrolysis flaws which tend to reduce the composite strength. Preliminary studies are described which demonstrated the feasibility of fiber-matrix copyrolysis to alleviate matrix cracking and provide an improved matrix-fiber interfacial bonding.

Bradshaw, W. G.↗
NASA NTRS1987

Strength of a thick graphite/epoxy rocket motor case after impact by a blunt object

The National Aeronautics and Space Administration is developing graphite/epoxy filament-wound cases (FWC) for the solid rocket motors of the Space Shuttle. The membrane region is about 36 mm thick. A study was made to determine the reduction in strength of the FWC due to accidental damage caused by low-velocity impacts. Two 76.2 cm diameter by 30.5 cm long cylinders were impacted every 5 cm of circumference with 1.27 cm radius impacters of various mass. The impacters represented tools and equipment dropped from various heights. One cylinder was empty and the other was filled with inert propellant. Five cm wide test specimens were cut from the cylinder. Each was centered on an impact sight. The specimens were X-rayed and loaded to failure in uniaxial tension. The strengths and depths of impact damage were analyzed in terms of maximum impact force. Rigid body mechanics and the Hertz law were used to derive an equation for impact force in terms of kinetic energy and the masses of the impacter and target. The depth of damage was predicted in terms of impact force using Love's solution of pressure applied on part of the boundary of a semi-infinite body.

Poe, C. C., Jr.↗
NASA NTRS1989

Strength of a thick graphite/epoxy rocket motor case after impact by a blunt object

The National Aeronautics and Space Administration is developing graphite/epoxy filament-wound cases (FWC) for the solid rocket motors of the Space Shuttle. The membrane region is about 36 mm thick. A study was made to determine the reduction in strength of the FWC due to accidental damage caused by low-velocity impacts. Two 76.2 cm diameter by 30.5 cm long cylinders were impacted every 5 cm of circumference with 1.27 cm radius impacters of various mass. The impacters represented tools and equipment dropped from various heights. One cylinder was empty and the other was filled with inert propellant. Five cm wide test specimens were cut from the cylinder. Each was centered on an impact site. The specimens were X-rayed and loaded to failure in uniaxial tension. The strengths and depths of impact damage were analyzed in terms of maximum impact force. Rigid body mechanics and the Hertz law were used to derive an equation for impact force in terms of kinetic energy and the masses of the impacter and target. The depth of damage was predicted in terms of impact force using Love's solution of pressure applied on part of the boundary of a semi-infinite body.

Poe, Clarence C., Jr.↗
DOE OSTI2016

Detonation mode and frequency analysis under high loss conditions for stoichiometric propane-oxygen

In this paper, the propagation characteristics of galloping detonations were quantified with a high-time-resolution velocity diagnostic. Combustion waves were initiated in 30-m lengths of 4.1-mm inner diameter transparent tubing filled with stoichiometric propane–oxygen mixtures. Chemiluminescence from the resulting waves was imaged to determine the luminous wave front position and velocity every 83.3 μ. As the mixture initial pressure was decreased from 20 to 7 kPa, the wave was observed to become increasingly unsteady and transition from steady detonation to a galloping detonation. While wave velocities averaged over the full tube length smoothly decreased with initial pressure down to half of the Chapman–Jouguet detonation velocity (D CJ ) at the quenching limit, the actual propagation mechanism was seen to be a galloping wave with a cycle period of approximately 1.0 ms, corresponding to a cycle length of 1.3–2.0 m or 317–488 tube diameters depending on the average wave speed. The long test section length of 7300 tube diameters allowed observation of up to 20 galloping cycles, allowing for statistical analysis of the wave dynamics. In the galloping regime, a bimodal velocity distribution was observed with peaks centered near 0.4 D CJ and 0.95 D CJ . Decreasing initial pressure increasingly favored the low velocity mode. Galloping frequencies ranged from 0.8 to 1.0 kHz and were insensitive to initial mixture pressure. Wave deflagration-to-detonation transition and detonation failure trajectories were found to be repeatable in a given test and also across different initial mixture pressures. The temporal duration of wave dwell at the low and high velocity modes during galloping was also quantified. It was found that the mean wave dwell duration in the low velocity mode was a weak function of initial mixture pressure, while the mean dwell time in the high velocity mode depended exponentially on initial mixture pressure. Analysis of the velocity histories using dynamical systems ideas demonstrated trajectories that varied from stable to limit cycles to aperiodic motion with decreasing initial pressure. Finally, the results indicate that galloping detonation is a persistent phenomenon at long tube lengths.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Quantification of Changes in Fill Tube Curvature During Target Assembly

National Ignition Facility (NIF) targets used for inertial confinement fusion (ICF) experiments are precision-engineered assemblies composed of more than 100 components carefully and precisely assembled with accuracies no larger than a few micrometers in most cases. When individual components deviate from these strict specifications during the assembly process, they can induce target failure. An integral component essential to ICF targets is the capsule-fill-tube assembly. This assembly involves bonding the capsule to a fused silica tube less than 5 μm in thickness, through which the tritium and deuterium (T 2 + D 2 ) fuel mixture is injected into the capsule prior to the NIF shot. The filling tube is bonded to a larger fused silica capillary, about 130 μm in outer diameter, which is coated with a polymeric layer on the order of a 10-μm thickness or less. Only tubes exhibiting a deflection equivalent to less than 1% of their total length from a perfectly straight line are suitable for assembly. Slight curvatures on the order of 1 mm over 10 cm can induce unwanted stresses, potentially causing capsule misalignment and resulting in clogging or leaks during the filling process. Despite manually qualitatively sorting each tube for straightness prior assembly, it has been found that the treatments the tubes undergo once attached to the capsule can alter their curvature. Filling tubes that initially satisfy straightness tolerances can undergo geometric deformation, resulting in curvature deviations exceeding 1% of their total length and thus failing to meet target assembly requirements. Here, in this study, we propose a metric to assess the degree of curvature of the filling tubes and to gauge their changes in curvature caused by the standard thermal processing methods employed in target assembly. In addition, we suggest alternatives to mitigate tube curvature, ensuring they conform to specifications following assembly in the final targets.

Materials science↗
NASA NTRS2020

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗
DOE OSTI2014

A novel pillar indentation splitting test for measuring fracture toughness of thin ceramic coatings

Fracture toughness is an important material property that plays a role in determining the in-service mechanical performance and adhesion of thin ceramic films. Unfortunately, measuring thin film fracture toughness is affected by influences from the substrate and the large residual stresses that can exist in the films. In this paper, we explore a promising new technique that potentially overcomes these problems based on nanoindentation testing of micro-pillars produced by focused ion beam milling of the films. By making the pillar diameter approximately equal to its length, the residual stress in the pillar’s upper portion is almost fully relaxed, and when indented with a sharp Berkovich indenter, the pillars fracture by splitting at reproducible loads that are readily quantified by a sudden displacement excursion in the load displacement behavior. Cohesive finite element simulations are used to analyze and develop, for a given material, a simple relation between the critical load at failure, pillar radius, and fracture toughness. The main novel aspect of this work is that neither crack geometries nor crack sizes need to be measured post test. Furthermore, the residual stress can be measured at the same time with toughness, by comparing the indentation results from the stress-free pillars and the as-deposited film. The method is tested on three different hard coatings formed by physical vapor deposition: titanium nitride, chromium nitride, and a CrAlN/Si 3 N 4 nanocomposite. Results compare well to independently measured values of fracture toughness for the three brittle films. The technique offers several benefits over existing methods.

42 ENGINEERING↗
NASA NTRS1986

Deformation and damage of composite plates under impact loading

Transient deformation and damage were studied in impacted graphite/epoxy plates. The plates were 8-ply and 16-ply quasi-isotropic laminates clamped around a 12.7 cm diameter circumference. They were instrumented with surface and embedded strain gages and loaded by a 202 gr mass dropped from a height of 1.8 m. The load history and imparted energy were obtained by means of an accelerometer attached to the impactor. Transient strains at various locations through the thickness and at various distances from the loading point were obtained. The characteristic features of the strain records are associated with specific failure modes in the laminate. The deformation history was also correlated with the induced damage as detected by X-radiography and ultrasonics. Impact damage is more extensive in the thicker laminate. Damage takes the form of delaminated strips parallel to the fiber direction in each ply and increasing in length from top to bottom.

Daniel, I. M.↗
NASA NTRS2015

Buckling Test Results from the 8-Foot-Diameter Orthogrid-Stiffened Cylinder Test Article TA01

Results from the testing of cylinder test article SBKF-P2-CYLTA01 (referred to herein as TA01) are presented. The testing was conducted at the Marshall Space Flight Center (MSFC), November 19‒21, 2008, in support of the Shell Buckling Knockdown Factor (SBKF) Project.i The test was used to verify the performance of a newly constructed buckling test facility at MSFC and to verify the test article design and analysis approach used by the SBKF project researchers. TA01 is an 8-foot-diameter (96-inches), 78.0-inch long, aluminum-lithium (Al-Li), orthogrid-stiffened cylindrical shell similar to those used in current state-of-the-art launch vehicle structures and was designed to exhibit global buckling when subjected to compression loads. Five different load sequences were applied to TA01 during testing and included four sub-critical load sequences, i.e., loading conditions that did not cause buckling or material failure, and one final load sequence to buckling and collapse. The sub-critical load sequences consisted of either uniform axial compression loading or combined axial compression and bending and the final load sequence subjected TA01 to uniform axial compression. Traditional displacement transducers and strain gages were used to monitor the test article response at nearly 300 locations and an advanced digital image correlation system was used to obtain low-speed and high-speed full-field displacement measurements of the outer surface of the test article. Overall, the test facility and test article performed as designed. In particular, the test facility successfully applied all desired load combinations to the test article and was able to test safely into the postbuckling range of loading, and the test article failed by global buckling. In addition, the test results correlated well with initial pretest predictions.

Hilburger, Mark W.↗
DOE OSTI2015

Medium-Term Outcomes Following Endovascular Repair of Infrarenal Abdominal Aortic Aneurysms with an Unfavourable Proximal Neck

PurposeThe purpose of this study was to evaluate medium-term outcomes following endovascular repair of abdominal aortic aneurysms (EVAR) with unfavourable neck anatomy using stent grafts with a 36 mm or larger proximal diameter.Materials and MethodsA retrospective review of 27 patients who underwent elective EVAR between 2006 and 2008 using a stent graft with a 36 mm or larger proximal diameter was carried out. All patients had computed tomography angiography (CTA) for procedure planning, and detailed assessment of the aneurysm neck was performed using a three-dimensional CTA workstation. Patients were followed up with CTA at 3 and 12 months and annual duplex thereafter.ResultsThe median aneurysm diameter was 7 cm, and the median aneurysm neck diameter was 31 mm. Cook Zenith stent grafts were used in all patients, with a proximal diameter of 36 mm (n = 25) and 40 mm (n = 2). Primary and assisted primary technical success rates were 74 and 93 %, respectively. The follow-up period ranged from 62 to 84 months, with a median of 72 months. 15 patients died during follow-up. Two patients died from aortic rupture, and the remaining patients died from cardiac disease (n = 4), chest sepsis (n = 6), cancer (n = 2) and renal failure (n = 1). Complications included type I endoleak (n = 5), limb occlusion (n = 2), limb stenosis (n = 2), limb kinking (n = 1), dissection of an artery (n = 1), occlusion of a femorofemoral cross-over graft (n = 1) and poor attachment of a distal limb (n = 1).ConclusionsEVAR using stent grafts in the presence of an unfavourable neck has a high risk of complications. Medium-term survival in this group is low but mainly due to patient co-morbidities.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2019

Numerical study of the ignition behavior of a post-discharge kernel in a turbulent stratified crossflow

Ensuring robust ignition is critical for the operability of aeronautical gas-turbine combustors. For ignition to be successful, an important aspect is the ability of the hot gas generated by the spark discharge to initiate combustion reactions, leading to the formation of a self-sustained ignition kernel. This study focuses on this phenomena by performing simulations of kernel ignition in a crossflow configuration that was characterized experimentally. First, inert simulations are performed to identify numerical parameters correctly reproducing the kernel ejection from the ignition cavity, which is here modeled as a pulsed jet. In particular, the kernel diameter and the transit time of the kernel to the reacting mixture are matched with measurements. Considering stochastic perturbations of the ejection velocity of the ignition kernel, the variability of the kernel transit time is also reproduced by the simulations. Subsequently, simulations of a series of ignition sequences are performed with varying equivalence ratio of the fuel-air mixture in the crossflow. The numerical results are shown to reproduce the ignition failure that occurs for the leanest equivalence ratio ($φ = 0.6$). For higher equivalence ratios, the simulations are shown to capture the sensitivity of the ignition to the equivalence ratio, and the kernel successfully transitions into a propagating flame. Significant stochastic dispersion of the ignition strength is observed, which relates to the variability of the transit time of the kernel to the re- active mixture. An analysis of the structure of the ignition kernel also highlights the transition towards a self-propagating flame for successful ignition conditions.

42 ENGINEERING↗
DOE OSTI2023

The combined effect of temperature and seawater on the compression properties of carbon fiber vinyl ester composites for sandwich structures

For naval applications, composite sandwich structures are of significant interest, and are often manufactured using thin (2 to 4 mm) composite facings made from carbon or glass fiber reinforcement, attached to a thick (25 to 50 mm) section of PVC cellular foam or balsa wood-based core materials using a suitable polymeric resin. In the present study, we focus on the hygrothermal effect on the fiber-dominated compression properties of carbon fiber reinforced vinyl ester resin based polymeric composite (CF/VE), used as “skin” for a polymeric composite sandwich material. Hygrothermal conditioning is achieved by saturating samples in simulated seawater at 40°C. Compression properties are evaluated for coupons extracted along warp and fill undergoing- no conditioning, conditioning till saturation (up to 6 months), and long-term conditioning (2 years). Sea-water saturation yields in up to 12% drop in compression strength with a further 3–4% drop resulting from long-term conditioning. No statistically significant modulus degradation is noticed due to short or long-term hygrothermal exposure. The failure mechanism of the warp extracted coupon, which fails in a splitting failure mode originating due to the delamination between the 0/90 interface, or the fill extracted coupon, which fails due to the instability caused by tow micro-buckling, remains unchanged due to combined exposure (short or long-term) of seawater and temperature. The loss in strength is attributed to the degradation of the fiber-matrix interface, which is validated via conducting single fiber push-in tests with a nominal diameter of 7 micron for conditioned and unconditioned coupons.

Engineering↗