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NASA NTRS2011

Three-Dimensional Finite Element Ablative Thermal Response and Thermostructural Design of Thermal Protection Systems

A finite element ablation and thermal response program is presented for simulation of three-dimensional transient thermostructural analysis. The three-dimensional governing differential equations and finite element formulation are summarized. A novel probabilistic design methodology for thermal protection systems is presented. The design methodology is an eight step process beginning with a parameter sensitivity study and is followed by a deterministic analysis whereby an optimum design can determined. The design process concludes with a Monte Carlo simulation where the probabilities of exceeding design specifications are estimated. The design methodology is demonstrated by applying the methodology to the carbon phenolic compression pads of the Crew Exploration Vehicle. The maximum allowed values of bondline temperature and tensile stress are used as the design specifications in this study.

Dec, John A.↗

NASA NTRS1988

Methods for heat transfer and temperature field analysis of the insulated diesel, phase 3

Work during Phase 3 of a program aimed at developing a comprehensive heat transfer and thermal analysis methodology for design analysis of insulated diesel engines is described. The overall program addresses all the key heat transfer issues: (1) spatially and time-resolved convective and radiative in-cylinder heat transfer, (2) steady-state conduction in the overall structure, and (3) cyclical and load/speed temperature transients in the engine structure. These are all accounted for in a coupled way together with cycle thermodynamics. This methodology was developed during Phases 1 and 2. During Phase 3, an experimental program was carried out to obtain data on heat transfer under cooled and insulated engine conditions and also to generate a database to validate the developed methodology. A single cylinder Cummins diesel engine was instrumented for instantaneous total heat flux and heat radiation measurements. Data were acquired over a wide range of operating conditions in two engine configurations. One was a cooled baseline. The other included ceramic coated components (0.050 inches plasma sprayed zirconia)-piston, head and valves. The experiments showed that the insulated engine has a smaller heat flux than the cooled one. The model predictions were found to be in very good agreement with the data.

Morel, Thomas↗

NASA NTRS1984

Solid lubrication design methodology

A single element traction rig was used to measure the traction forces at the contact of a ball against a flat disc at room temperature under combined rolling and sliding. The load and speed conditions were selected to match those anticipated for bearing applications in adiabatic diesel engines. The test program showed that the magnitude of traction forces were almost the same for all the lubricants tested; a lubricant should, therefore, be selected on the basis of its ability to prevent wear of the contact surfaces. Traction vs. slide/roll ratio curves were similar to those for liquid lubricants but the traction forces were an order of magnitude higher. The test data was used to derive equations to predict traction force as a function of contact stress and rolling speed. Qualitative design guidelines for solid lubricated concentrated contacts are proposed.

Aggarwal, B. B.↗

NASA NTRS2011

International Space Station Environmental Control and Life Support System Acceptance Testing for Node 1 Temperature and Humidity Control Subsystem

The International Space Station (ISS) Node 1 Environmental Control and Life Support (ECLS) System is comprised of five subsystems: Atmosphere Control and Storage (ACS), Atmosphere Revitalization (AR), Fire Detection and Suppression (FDS), Temperature and Humidity Control (THC), and Water Recovery and Management (WRM). This paper will provide a summary of the Node 1 ECLS THC subsystem design and a detailed discussion of the ISS ECLS Acceptance Testing methodology utilized for this subsystem.The International Space Station (ISS) Node 1 Environmental Control and Life Support (ECLS) System is comprised of five subsystems: Atmosphere Control and Storage (ACS), Atmosphere Revitalization (AR), Fire Detection and Suppression (FDS), Temperature and Humidity Control (THC), and Water Recovery and Management (WRM). This paper will provide a summary of the Node 1 ECLS THC subsystem design and a detailed discussion of the ISS ECLS Acceptance Testing methodology utilized for this subsystem.

Williams, David E.↗

NASA NTRS2014

Cure Cycle Design Methodology for Fabricating Reactive Resin Matrix Fiber Reinforced Composites: A Protocol for Producing Void-free Quality Laminates

For the fabrication of resin matrix fiber reinforced composite laminates, a workable cure cycle (i.e., temperature and pressure profiles as a function of processing time) is needed and is critical for achieving void-free laminate consolidation. Design of such a cure cycle is not trivial, especially when dealing with reactive matrix resins. An empirical "trial and error" approach has been used as common practice in the composite industry. Such an approach is not only costly, but also ineffective at establishing the optimal processing conditions for a specific resin/fiber composite system. In this report, a rational "processing science" based approach is established, and a universal cure cycle design protocol is proposed. Following this protocol, a workable and optimal cure cycle can be readily and rationally designed for most reactive resin systems in a cost effective way. This design protocol has been validated through experimental studies of several reactive polyimide composites for a wide spectrum of usage that has been documented in the previous publications.

Hou, Tan-Hung↗

NASA NTRS1988

An internal variable constitutive model for the large deformation of metals at high temperatures

The advent of large deformation finite element methodologies is beginning to permit the numerical simulation of hot working processes whose design until recently has been based on prior industrial experience. Proper application of such finite element techniques requires realistic constitutive equations which more accurately model material behavior during hot working. A simple constitutive model for hot working is the single scalar internal variable model for isotropic thermal elastoplasticity proposed by Anand. The model is recalled and the specific scalar functions, for the equivalent plastic strain rate and the evolution equation for the internal variable, presented are slight modifications of those proposed by Anand. The modified functions are better able to represent high temperature material behavior. The monotonic constant true strain rate and strain rate jump compression experiments on a 2 percent silicon iron is briefly described. The model is implemented in the general purpose finite element program ABAQUS.

Brown, Stuart↗

NASA NTRS1997

Low Temperature Creep of a Titanium Alloy Ti-6Al-2Cb-1Ta-0.8Mo

This paper presents a methodology for the analysis of low temperature creep of titanium alloys in order to establish design limitations due to the effect of creep. The creep data on a titanium Ti-6Al-2Cb-1Ta-0.8Mo are used in the analysis. A creep equation is formulated to determine the allowable stresses so that creep at ambient temperatures can be kept within an acceptable limit during the service life of engineering structures or instruments. Microcreep which is important to design of precision instruments is included in the discussion also.

Chu, H. P.↗

NASA NTRS1996

The Study of the Relationship between Probabilistic Design and Axiomatic Design Methodology

The structural design, or the design of machine elements, has been traditionally based on deterministic design methodology. The deterministic method considers all design parameters to be known with certainty. This methodology is, therefore, inadequate to design complex structures that are subjected to a variety of complex, severe loading conditions. A nonlinear behavior that is dependent on stress, stress rate, temperature, number of load cycles, and time is observed on all components subjected to complex conditions. These complex conditions introduce uncertainties; hence, the actual factor of safety margin remains unknown. In the deterministic methodology, the contingency of failure is discounted; hence, there is a use of a high factor of safety. It may be most useful in situations where the design structures are simple. The probabilistic method is concerned with the probability of non-failure performance of structures or machine elements. It is much more useful in situations where the design is characterized by complex geometry, possibility of catastrophic failure, sensitive loads and material properties. Also included: Comparative Study of the use of AGMA Geometry Factors and Probabilistic Design Methodology in the Design of Compact Spur Gear Set.

Onwubiko, Chin-Yere↗

NASA NTRS2006

Designing Cure Cycles for Matrix/Fiber Composite Parts

A methodology has been devised for designing cure cycles to be used in the fabrication of matrix/fiber composite parts (including laminated parts). As used here, cure cycles signifies schedules of elevated temperature and pressure as functions of time, chosen to obtain desired rates of chemical conversion of initially chemically reactive matrix materials and to consolidate the matrix and fiber materials into dense solids. Heretofore, cure cycles have been designed following an empirical, trial-and-error approach, which cannot be relied upon to yield optimum results. In contrast, the present methodology makes it possible to design an optimum or nearly optimum cure cycle for a specific application. Proper design of a cure cycle is critical for achieving consolidation of a reactive matrix/fiber layup into a void-free laminate. A cure cycle for a composite containing a reactive resin matrix usually consists of a two-stage ramp-and-hold temperature profile. The temperature and the duration of the hold for each stage are unique for a given composite material. The first, lower-temperature ramp-and hold stage is called the B stage in composite- fabrication terminology. At this stage, pressure is not applied, and volatiles (solvents and reaction by-products) are free to escape. The second, higher-temperature stage is for final forced consolidation.

Hou, Tan-Hung↗

NASA NTRS2017

Environmental Barrier Coating Fracture, Fatigue and High-Heat-Flux Durability Modeling and Stochastic Progressive Damage Simulation

Advanced environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect emerging light-weight SiC/SiC ceramic matrix composite (CMC) engine components, further raising engine operating temperatures and performance. Because the environmental barrier coating systems are critical to the performance, reliability and durability of these hot-section ceramic engine components, a prime-reliant coating system along with established life design methodology are required for the hot-section ceramic component insertion into engine service. In this paper, we have first summarized some observations of high temperature, high-heat-flux environmental degradation and failure mechanisms of environmental barrier coating systems in laboratory simulated engine environment tests. In particular, the coating surface cracking morphologies and associated subsequent delamination mechanisms under the engine level high-heat-flux, combustion steam, and mechanical creep and fatigue loading conditions will be discussed. The EBC compostion and archtechture improvements based on advanced high heat flux environmental testing, and the modeling advances based on the integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program will also be highlighted. The stochastic progressive damage simulation successfully predicts mud flat damage pattern in EBCs on coated 3-D specimens, and a 2-D model of through-the-thickness cross-section. A 2-parameter Weibull distribution was assumed in characterizing the coating layer stochastic strength response and the formation of damage was therefore modeled. The damage initiation and coalescence into progressively smaller mudflat crack cells was demonstrated. A coating life prediction framework may be realized by examining the surface crack initiation and delamination propagation in conjunction with environmental degradation under high-heat-flux and environment load test conditions.

Mechanical creep and fatigue loading condition↗

NASA NTRS1998

Continuum Damage Mechanics Used to Predict the Creep Life of Monolithic Ceramics

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated temperature applications. High-temperature and long-duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. An analytical methodology in the form of the integrated design program-Ceramics Analysis and Reliability Evaluation of Structures/Creep (CARES/Creep) has been developed by the NASA Lewis Research Center to predict the life of ceramic structural components subjected to creep rupture conditions. This program utilizes commercially available finite element packages and takes into account the transient state of stress and creep strain distributions (stress relaxation as well as the asymmetric response to tension and compression). The creep life of a component is discretized into short time steps, during which the stress distribution is assumed constant. Then, the damage is calculated for each time step on the basis of a modified Monkman-Grant (MMG) creep rupture criterion. The cumulative damage is subsequently calculated as time elapses in a manner similar to Miner's rule for cyclic fatigue loading. Failure is assumed to occur when the normalized cumulative damage at any point in the component reaches unity. The corresponding time is the creep rupture life for that component.

Powers, Lynn M.↗

NASA NTRS2005

Fully Associative, Nonisothermal, Potential-Based Unified Viscoplastic Model for Titanium-Based Matrices

A number of titanium matrix composite (TMC) systems are currently being investigated for high-temperature air frame and propulsion system applications. As a result, numerous computational methodologies for predicting both deformation and life for this class of materials are under development. An integral part of these methodologies is an accurate and computationally efficient constitutive model for the metallic matrix constituent. Furthermore, because these systems are designed to operate at elevated temperatures, the required constitutive models must account for both time-dependent and time-independent deformations. To accomplish this, the NASA Lewis Research Center is employing a recently developed, complete, potential-based framework. This framework, which utilizes internal state variables, was put forth for the derivation of reversible and irreversible constitutive equations. The framework, and consequently the resulting constitutive model, is termed complete because the existence of the total (integrated) form of the Gibbs complementary free energy and complementary dissipation potentials are assumed a priori. The specific forms selected here for both the Gibbs and complementary dissipation potentials result in a fully associative, multiaxial, nonisothermal, unified viscoplastic model with nonlinear kinematic hardening. This model constitutes one of many models in the Generalized Viscoplasticity with Potential Structure (GVIPS) class of inelastic constitutive equations.

Source record↗

NASA NTRS1998

Deterministic Multiaxial Creep and Creep Rupture Enhancements for CARES/Creep Integrated Design Code

High temperature and long duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. A previous model advanced by the authors described a methodology by which the creep rupture life of a loaded component can be predicted. That model was based on the life fraction damage accumulation rule in association with the modified Monkman-Grant creep rupture criterion. However, that model did not take into account the deteriorating state of the material due to creep damage (e.g., cavitation) as time elapsed. In addition, the material creep parameters used in that life prediction methodology, were based on uniaxial creep curves displaying primary and secondary creep behavior, with no tertiary regime. The objective of this paper is to present a creep life prediction methodology based on a modified form of the Kachanov-Rabotnov continuum damage mechanics (CDM) theory. In this theory, the uniaxial creep rate is described in terms of sum, temperature, time, and the current state of material damage. This scalar damage state parameter is basically an abstract measure of the current state of material damage due to creep deformation. The damage rate is assumed to vary with stress, temperature, time, and the current state of damage itself. Multiaxial creep and creep rupture formulations of the CDM approach are presented in this paper. Parameter estimation methodologies based on nonlinear regression analysis are also described for both, isothermal constant stress states and anisothermal variable stress conditions This creep life prediction methodology was preliminarily added to the integrated design code CARES/Creep (Ceramics Analysis and Reliability Evaluation of Structures/Creep), which is a postprocessor program to commercially available finite element analysis (FEA) packages. Two examples, showing comparisons between experimental and predicted creep lives of ceramic specimens, are used to demonstrate the viability of Ns methodology and the CARES/Creep program.

Jadaan, Osama M.↗

NASA NTRS1990

Expert systems for superalloy studies

There are many areas in science and engineering which require knowledge of an extremely complex foundation of experimental results in order to design methodologies for developing new materials or products. Superalloys are an area which fit well into this discussion in the sense that they are complex combinations of elements which exhibit certain characteristics. Obviously the use of superalloys in high performance, high temperature systems such as the Space Shuttle Main Engine is of interest to NASA. The superalloy manufacturing process is complex and the implementation of an expert system within the design process requires some thought as to how and where it should be implemented. A major motivation is to develop a methodology to assist metallurgists in the design of superalloy materials using current expert systems technology. Hydrogen embrittlement is disasterous to rocket engines and the heuristics can be very complex. Attacking this problem as one module in the overall design process represents a significant step forward. In order to describe the objectives of the first phase implementation, the expert system was designated Hydrogen Environment Embrittlement Expert System (HEEES).

Workman, Gary L.↗

NASA NTRSDate not supplied

LOFTID Aeroshell Thermal Response Uncertainty Analysis Utilizing the End-to-End Monte Carlo Approach

A probabilistic thermal margin process has been performed to design the flexible thermal protection system (FTPS) and select entry trajectory constraints given an acceptable risk level for the Low-Earth Orbit Flight Test of and Inflatable Decelerator (LOFTID) project. Uncertainties exist in atmospheric entry aeroheating environments and the predicted thermal response of thermal protection system (TPS) material. Entry vehicle TPS is often over-sized to mitigate uncertainty by combining conservative bounding scenarios together. The probabilistic thermal margin process allows engineers to make informed aeroshell design, flight design, and FTPS performance risk trades while preventing excessive FTPS margin from being applied. This paper describes the uncertainty analysis methodology used to carry out a probabilistic thermal margin process used for LOFTID’s aeroshell and explains how the calculated probability of exceeding flight allowable temperatures is used to design the FTPS and establish nominal flight design constraints. This probabilistic thermal margin process had never been applied to entry, decent, and landing design for a flown entry vehicle and it is one of the LOFTID project’s goals to demonstrate its merits.

Steven Andrew Tobin↗

NASA NTRS2008

High Temperature, Permanent Magnet Biased, Fault Tolerant, Homopolar Magnetic Bearing Development

This paper summarizes the development of a magnetic bearing designed to operate at 1,000 F. A novel feature of this high temperature magnetic bearing is its homopolar construction which incorporates state of the art high temperature, 1,000 F, permanent magnets. A second feature is its fault tolerance capability which provides the desired control forces with over one-half of the coils failed. The construction and design methodology of the bearing is outlined and test results are shown. The agreement between a 3D finite element, magnetic field based prediction for force is shown to be in good agreement with predictions at room and high temperature. A 5 axis test rig will be complete soon to provide a means to test the magnetic bearings at high temperature and speed.

Palazzolo, Alan↗

NASA NTRS2020

Burning Embers: Towards More Transparent and Robust Climate-change Risk Assessments

The Intergovernmental Panel on Climate Change (IPCC) reports provide policy-relevant insights about climate impacts, vulnerabilities and adaptation through a process of peer-reviewed literature assessments underpinned by expert judgement. An iconic output from these assessments is the burning embers diagram, first used in the Third Assessment Report to visualize reasons for concern, which aggregate climate-change-related impacts and risks to various systems and sectors. These burning embers use colour transitions to show changes in the assessed level of risk to humans and ecosystems as a function of global mean temperature. In this Review, we outline the history and evolution of the burning embers and associated reasons for concern framework, focusing on the methodological approaches and advances. While the assessment framework and figure design have been broadly retained over time, refinements in methodology have occurred, including the consideration of different risks, use of confidence statements, more formalized protocols and standardized metrics. Comparison across reports reveals that the risk level at a given temperature has generally increased with each assessment cycle, reflecting accumulating scientific evidence. For future assessments, an explicit, transparent and systematic process of expert elicitation is needed to enhance comparability, quality and credibility of burning embers.

burning embers diagram↗

NASA NTRS2017

Development of Advanced Environmental Barrier Coatings for SiC/SiC Composites at NASA GRC: Prime-Reliant Design and Durability Perspectives

Environmental barrier coatings (EBCs) are considered technologically important because of the critical needs and their ability to effectively protect the turbine hot-section SiC/SiC ceramic matrix composite (CMC) components in harsh engine combustion environments. The development of NASA's advanced environmental barrier coatings have been aimed at significantly improved the coating system temperature capability, stability, erosion-impact, and CMAS resistance for SiC/SiC turbine airfoil and combustors component applications. The NASA environmental barrier coating developments have also emphasized thermo-mechanical creep and fatigue resistance in simulated engine heat flux and environments. Experimental results and models for advanced EBC systems will be presented to help establishing advanced EBC composition design methodologies, performance modeling and life predictions, for achieving prime-reliant, durable environmental coating systems for 2700-3000 F engine component applications. Major technical barriers in developing environmental barrier coating systems and the coating integration with next generation composites having further improved temperature capability, environmental stability, EBC-CMC fatigue-environment system durability will be discussed.

Environmental barrier coatings (EBCs)↗