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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Characterization of Low-Velocity Impact Damage in Thermoplastic Laminated Composites

The impact damage response of two thermoplastic material systems were compared over a range of impact energies. Eight-inch-square impact specimens with a 24-ply quasi-isotropic layup were manufactured from TC1225 LMPAEK T700G from Toray Industries and APC AS4D/PEKK-FC from Solvay. The effect of the degree of crystallinity (DOC) on the damage response was also investigated using a third set of specimens from the Toray material manufactured with reduced crystallinity. Using a combination of data obtained from X-ray computed tomography (CT) scans and ultrasonic testing (UT), detailed damage maps were created for every interface and ply for selected specimens. Using these damage maps, the delamination size, shape, and area were evaluated at each interface. The presence of fractured fibers was also identified on each ply. The LMPAEK material was found to have fewer and smaller delaminations than the PEKK specimens for impacts at the same energy. However, the LMPAEK specimens contained a larger number of fiber breaks. A similar trend was observed when comparing the baseline LMPAEK specimens with the low-crystallinity LMPAEK specimens. The low-crystallinity specimens had very little delamination but had a large number of plies with fiber breaks. In addition, the LMPAEK specimens often contained lines of fiber fractures in near-surface plies emanating from the contact region that were not present in the PEKK specimens.

Composite Materials↗
NASA NTRSDate not supplied

Material Characterization and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

TPS↗
NASA NTRSDate not supplied

The NASA Open Science Data Repository: Biomedical Fair Data, Analysis Tools, User Communities, Publications, and Discoveries for Deep Space Missions

Increased biomedical risks and challenges associated with deep space missions require new knowledge discovery, new health countermeasures, and development of novel ecosystems, life support, crop production, and biomedical support capabilities. To meet NASA’s Moon to Mars strategic program goals for Human and Biological Sciences, findable, accessible, interoperable, reusable (FAIR), and maximally open-access data is going to be required to enable humanity to thrive in deep space. Indeed, this cornerstone perspective on FAIR and maximally open access data was also recommended in the recent 2023-2032 Decadal Survey from the National Academies of Sciences, Engineering, and Medicine. The NASA Open Science Data Repository (OSDR) is a maximally open access and FAIR database, and meets various scientific, technical, and operational spaceflight needs. It offers public users and submitters the ability to upload, download, search, share, analyze, and visualize data across ‘omics, physiological, phenotypic, behavioral, bioimaging, video, and environmental monitoring telemetry datasets. OSDR includes NASA GeneLab, NASA Ames Life Sciences Data Archive, and the NASA Biological Institutional Scientific Collection. OSDR has >455 studies with datasets from model organisms and non-NASA human astronauts. There are ~12 datasets from the Inspiration 4 (I4) mission, spanning metagenomics, comprehensive metabolic panels, clonal hematopoiesis, spatial transcriptomics, proteomics, and cytokine panels. In the interest of data privacy, two I4 datasets have raw FASTQ and FASTA files relating to the epitranscriptome, and a new request feature is live in OSDR (with a backend review process established) which was developed based on industry norms. OSDR also recently began a collaboration with the European Space Agency (ESA) to scientifically curate and make available >200 terabytes of human and model organism space-relevant data. The OSDR submission portal is designed to ingest and curate ~25 ‘omics assay data types, and ~50 physiological-phenotypic-imaging assay data types, spanning ultrasonography, micro-computed tomography, histology, morphometric photography, rebound tonometry, gait analysis, optical coherence tomography, novel object recognition, flow cytometry, and immunohistochemistry. A suite of analysis tools are available for OSDR users including: 1) an Environmental Data Application to compare radiation, CO2, relative humidity, temperature, and other telemetry across missions and subjects, 2) the RadLab database, a collaboration between NASA, ESA, the German and Italian Space Agencies, and the Bulgarian Academy of Sciences, which compiles radiation measurements relevant to human spaceflight and provides tools for accessing and manipulating the data, and 3) a Multi-study visualization tool which enables users to look across and combine GeneLab’s omics datasets across different experiments and missions. There are ~600 volunteer OSDR Analysis Working Group (AWG) members who: 1) provide feedback on scientific standards for reuse (subject and assay metadata; processing pipelines; dataset formats and uniformed structures for machine-readability), and 2) collaborate to mine-reuse OSDR data conducting scientific analysis. OSDR has enabled 60 publications as of September 2023, many directly from AWG collaborations most notably the Cell Press package in 2020. Lastly, there are at least 15 articles which mine OSDR data part of a package of ~50 articles across Nature Portfolio with research stemming from I4, the Japan Aerospace Exploration Agency, NASA Space Biology, and the NASA Human Research Program.

space biology↗
NASA NTRSDate not supplied

Correlations Between Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.

Qualification↗
NASA NTRSDate not supplied

Material Properties and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

PATO↗
NASA NTRSDate not supplied

Orion Artemis I As Flown MMOD Analysis

Introduction The Lockheed Martin Orion spacecraft conducted the Artemis I flight around the Moon from November 16 through December 11, 2022. After the flight, an engineer from the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group performed a Micrometeoroid and Orbital Debris MMOD analysis using the Bumper 3 risk assessment tool to predict the number of small impacts that would likely have occurred during the mission. Separately, a team from the same group inspected the Orion capsule for hypervelocity impact damage features. The results of the inspection were compared to those of the analysis to aid in improving the analysis, including the environment models. Scope of Work The spacecraft geometry model was created by Lockheed Martin during construction of the Artemis I Orion vehicle based on Computer Aided Design (CAD) models of the vehicle. New hypervelocity impact testing was performed to verify Ballistic Limit Equations (BLEs) used in the analysis to link impactor size and damage to the Thermal Protection System (TPS). The exact trajectory flown was recorded during the flight, including vehicle attitude. This data was used in conjunction with the ORDEM 3.2 and MEM 3 environment modeling tools to create models of particle flux impacting the spacecraft throughout the mission. Meteoroid shower forecast information was also included to account for additional particle flux associated with meteoroid showers. Inspection of the Orion capsule included the Backshell thermal tiles and the tape covering it, windows, fabric thermal materials, and small areas of other materials. Potential MMOD damage found was characterized using various techniques, including optical microscopy, computed tomography scanning, and X-ray spectroscopy. Findings The number of craters found in the Backshell tile, and their size distribution, matches well with the Bumper analysis prediction. Tape, window, and other material impacts recorded similarly align to Bumper analysis predictions. Conclusions and Recommendations This comparison of analysis with inspection of the hardware provides valuable insight into the MMOD environment and how accurately analysis tools assess the impact risk to spacecraft. As this was the first large, non-ablative returned surface from a lunar mission, this analysis extends the MMOD community’s insight beyond low Earth orbit into cis-lunar space.

MMOD↗
NASA NTRSDate not supplied

Developing Open-Source Training Materials for AI/ML and Space Biological Sciences Using NASA Cloud-Based Data

Artificial Intelligence (AI) and Machine Learning (ML) has gained significant traction in the biological and biomedical research fields, in part due to a culture of open data sharing and reuse. AI/ML methodology is well-suited to recognize and predict biological patterns from high-dimensional next-generation sequencing data (e.g. whole genome sequencing, transcriptomic sequencing), as well as from biological or medical imaging data (e.g. microscopy, computed tomography, ultrasound, magnetic resonance imaging, radiography). These methodologies hold particular promise for space biosciences research and automated space health monitoring systems. However, there are key considerations for properly training, validating, and testing a machine learning model in biological research or clinical application. Inexperienced researchers can produce models that perform poorly outside of the training dataset. Open Science principles such as data sharing and open-source code must go hand-in-hand with publicly available, high-quality training curricula in best practices, with modules centered on real-life scientific use cases and data so future AI/ML practitioners gain experience on real problems. Here we present the development of open-source training materials for AI/ML and space biosciences, as part of the NASA Transform to Open Science Training (TOPST) initiative. We develop 4 independent training programs, focused on the following topics: 1) Fundamentals of Machine Learning and Space Biosciences Domain, 2) Open Science, Artificial Intelligence, and Ethical Best Practices for Data Sharing and Analysis, 3) Using AI/ML Classification to Identify Gene Networks Affected By Space Exposure in Mouse Liver, and 4) Using Neural Networks to Find DNA Damage Patterns in Immune Cells after Radiation. All programs leverage cloud-based NASA biological datasets. The curriculum we present will enable worldwide access to training in AI/ML and scientific analysis.

James Casaletto↗
NASA NTRSDate not supplied

XRF Characterization of MMOD Impact Damage

Introduction The Hypervelocity Impact Technology (HVIT) Group at the NASA Johnson Space Center (JSC) has performed over 150 post flight MMOD inspections on returned space-ex-posed hardware and collected over 1,600 samples. Determination of the impactor source typically requires an analysis of the projectile residue in the damage feature. At this time, about 20% of the samples have been processed. Types of Samples Samples in the HVIT group collection can be classified into two types. Indirect (non-destructive) samples are produced when a pliable material (e.g., adhesive tape or dental mold) is inserted into an impact feature. With this type of sampling technique, crater material and (hopefully) projectile residue material is embedded in the sample media and can detected using further chemical characterizing techniques. Direct (destructive) sampling involves the in-tact extraction of material from the spacecraft and is done in a manner that the entire impact feature can be excised intact. This technique provides the greatest chance of successfully determining impactor source due to the entirety of the projectile remnants being present within the collected sample. Updated Projectile Residue Detection Techniques Previous assessments of projectile provenance have involved the use of samples that are first mounted in epoxy, sectioned to expose the crater interior, imaged with a scanning electron microscope (SEM), then any observed impactor residue was then analyzed using an energy dispersive spectrometer (EDS). This technique, while proven, may be supplemented with other types of elemental analysis techniques that can observe major element chemistry, in order to improve throughput of sample analysis. The Astromaterials Research and Exploration Science (ARES) Division at JSC, for example, operates a Bruker M4 Tornado micro-X-Ray fluorescence (XRF) spectrometer, capable of creating elemental maps of areas around these small impact features in a couple of hours, with a spot size <20 μm. The potential advantage with this technique lies in sample preparation, as no polishing or conductive coatings are needed. Early trials attempted to deter-mine impactor composition by collecting spectra from intact samples by aiming the X-Rays directly into the impact feature, but the signal:noise ratio was too low for confident material identification. Sample preparation for XRF then relies on sectioning the samples parallel to the impactor trajectory in order to expose the largest area of subsurface damage possible, thus maximizing the signal from any small impactor remnants. Complementary to the use of XRF for sample analysis, ARES also houses a Nikon XTH 320 micro-X-Ray computed tomography (XCT). This instrument can be used to create 3D visualizations of impact damage for the determination of crater volumes and dimensions, as well as for the determination of the best place to section each sample for the subsequent XRF analysis.

J L Hyde↗
NASA NTRSDate not supplied

Characterization Of Early Solar System Aqueous Fluids

The most direct and convincing evidence for the presence of water and organic molecules on protoplanetary bodies is provided by fluid inclusions trapped in secondary minerals. Our research has demonstrated that early solar system fluids have survived as fluid inclusions in a few astromaterials that escaped significant shock, terrestrial alteration, and invasive sample handling. Our long-term goal is to measure bulk molecular and isotopic composition of individual fluid inclusions in meteorites and samples collected directly from asteroids to provide ground truth regarding the nature and evolution of aqueous fluids in the early solar system. Our current protocol is to locate candidate fluid inclusions using X-Ray Computed Tomography, and then make compositional measurements of individual fluid inclusions by coordinated Raman spectrometry, Transmission Electron Microscopy and, most recently, Time of Flight – Secondary Ion Mass Spectrometry.

Michael Zolensky↗
NASA NTRSDate not supplied

NASA Open Science Data Repository: Biomedical FAIR Data, Analysis Tools, User Communities, and Discoveries for Deep Space Missions

Increased biomedical risks and challenges associated with deep space missions require new knowledge discovery, new health countermeasures, and development of novel ecosystems, life support, crop production, and biomedical support capabilities. To meet NASA’s Moon to Mars strategic program goals for Human and Biological Sciences, findable, accessible, interoperable, reusable (FAIR), and maximally open-access data is going to be required to enable humanity to thrive in deep space. Indeed, this cornerstone perspective on FAIR and maximally open access data was also recommended in the recent 2023-2032 Decadal Survey from the National Academies of Sciences, Engineering, and Medicine. The NASA Open Science Data Repository (OSDR) is a maximally open access and FAIR database, and meets various scientific, technical, and operational spaceflight needs. It offers public users and submitters the ability to upload, download, search, share, analyze, and visualize data across ‘omics, physiological, phenotypic, behavioral, bioimaging, video, and environmental monitoring telemetry datasets. OSDR includes NASA GeneLab, NASA Ames Life Sciences Data Archive, and the NASA Biological Institutional Scientific Collection. OSDR has >455 studies with datasets from model organisms and non-NASA human astronauts. There are ~12 datasets from the Inspiration 4 (I4) mission, spanning metagenomics, comprehensive metabolic panels, clonal hematopoiesis, spatial transcriptomics, proteomics, and cytokine panels. In the interest of data privacy, two I4 datasets have raw FASTQ and FASTA files relating to the epitranscriptome, and a new request feature is live in OSDR (with a backend review process established) which was developed based on industry norms. OSDR also recently began a collaboration with the European Space Agency (ESA) to scientifically curate and make available >200 terabytes of human and model organism space-relevant data. The OSDR submission portal is designed to ingest and curate ~25 ‘omics assay data types, and ~50 physiological-phenotypic-imaging assay data types, spanning ultrasonography, micro-computed tomography, histology, morphometric photography, rebound tonometry, gait analysis, optical coherence tomography, novel object recognition, flow cytometry, and immunohistochemistry. A suite of analysis tools are available for OSDR users including: 1) an Environmental Data Application to compare radiation, CO2, relative humidity, temperature, and other telemetry across missions and subjects, 2) the RadLab database, a collaboration between NASA, ESA, the German and Italian Space Agencies, and the Bulgarian Academy of Sciences, which compiles radiation measurements relevant to human spaceflight and provides tools for accessing and manipulating the data, and 3) a Multi-study visualization tool which enables users to look across and combine GeneLab’s omics datasets across different experiments and missions. There are ~600 volunteer OSDR Analysis Working Group (AWG) members who: 1) provide feedback on scientific standards for reuse (subject and assay metadata; processing pipelines; dataset formats and uniformed structures for machine-readability), and 2) collaborate to mine-reuse OSDR data conducting scientific analysis. OSDR has enabled 60 publications as of September 2023, many directly from AWG collaborations most notably the Cell Press package in 2020. Lastly, there are at least 15 articles which mine OSDR data part of a package of ~50 articles across Nature Portfolio with research stemming from I4, the Japan Aerospace Exploration Agency, NASA Space Biology, and the NASA Human Research Program.

open access↗
NASA NTRSDate not supplied

Mineralogical, Elemental, and Tomographic Reconnaissance Investigation for CLPS (METRIC): A Payload Designed for Exploration of Terrestrial Planetary Bodies

Geological materials (indeed, all solid objects) are characterized by their crystal structure, elemental composition, and morphology. The Mineralogical, Elemental, and Tomographic Reconnaissance Investigation for CLPS (METRIC) instrument suite quantifies all three. These measurements address fundamental science questions (e.g., the origin and evolution of planetary bodies) and support the human exploration of space (e.g., the characterization of regolith for ISRU and the constraint of its geotechnical properties). METRIC comprises an X-ray Diffraction/X-ray Fluorescence instrument (XRD: mineral structure and XRF: elemental composition), an X-ray micro-Computed Tomography instrument (XCT: 3D internal micromorphology), and a hyperspectral imaging infrared spectrometer (IRS) to provide local/regional mineralogic context for these measurements. METRIC XRD/F draws heritage from the highly successful Mars Science Laboratory CheMin instrument. The METRIC XRD/F employs two separate sample cells, one optimized for XRD and one for XRF, resulting in more rapid XRD analysis (tens of minutes vs. tens of hours for CheMin) and an orders-of-magnitude improvement in XRF detection. XCT has not been deployed in space, so the METRIC XCT represents a new capability for solar system exploration. The XCT uses the same basic high-TRL components as METRIC XRD/F, decreasing its development cost for flight. The METRIC IRS is a derivative of the NASA Earth Science Technology Office funded Hyperspectral Thermal Imager instrument and utilizes the NASA Technology Transfer Program to incorporate a commercial-of-the-shelf infrared camera ruggedized for space by NASA Marshall Space Flight Center. The IRS spectral range (8–14 µm) and resolution (10.8 cm -1 ) are tailored to quantify mineralogy in rocks using their characteristic Reststrahlen bands and to characterize mineralogy of soils using the position of the Christensen Feature. The METRIC payload is currently designed for deployment to the Moon on a Commercial Lunar Payload Services (CLPS) mission, where the XRD/F and XCT would be located on a lander and the IRS would be on deployed on a companion rover to evaluate the mineralogical diversity of the landing site. A pneumatic drill designed by Honeybee Robotics would excavate regolith up to 50 cm below the lander and deliver multiple aliquots of regolith to the XRD/F and XCT. The METRIC payload could also be deployed on a rover. In this case, a sample handling system on a robotic arm could scoop regolith and/or drill rocks and deliver powder to the XRD/F and XCT located in the rover’s interior. Alternatively, METRIC instruments could be used singly or in combination on human space missions. The XRD/F and XCT could be used to characterize samples in a rover or in a science laboratory within a habitat. These data could help astronauts identify resource-enriched rocks and regolith and triage geologic samples to return samples of high interest for analysis in terrestrial laboratories. The IRS could be attached to a human-navigated rover to collect mineralogical data along a traverse and identify high-priority science samples.

E. B. Rampe↗
NASA NTRSDate not supplied

Orion Artemis I As Flown MMOD Analysis

Introduction The Lockheed Martin Orion spacecraft conducted the Artemis I flight around the Moon from November 16 through December 11, 2022. After the flight, an engineer from the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group performed a Micrometeoroid and Orbital Debris MMOD analysis using the Bumper 3 risk assessment tool to predict the number of small impacts that would likely have occurred during the mission. Separately, a team from the same group inspected the Orion capsule for hypervelocity impact damage features. The results of the inspection were compared to those of the analysis to aid in improving the analysis, including the environment models. Scope of Work The spacecraft geometry model was created by Lockheed Martin during construction of the Artemis I Orion vehicle based on Computer Aided Design (CAD) models of the vehicle. New hypervelocity impact testing was performed to verify Ballistic Limit Equations (BLEs) used in the analysis to link impactor size and damage to the Thermal Protection System (TPS). The exact trajectory flown was recorded during the flight, including vehicle attitude. This data was used in conjunction with the ORDEM 3.2 and MEM 3 environment modeling tools to create models of particle flux impacting the spacecraft throughout the mission. Meteoroid shower forecast information was also included to account for additional particle flux associated with meteoroid showers. Inspection of the Orion capsule included the Backshell thermal tiles and the tape covering it, windows, fabric thermal materials, and small areas of other materials. Potential MMOD damage found was characterized using various techniques, including optical microscopy, computed tomography scanning, and X-ray spectroscopy. Findings The number of craters found in the Backshell tile, and their size distribution, matches well with the Bumper analysis prediction. Tape, window, and other material impacts recorded similarly align to Bumper analysis predictions. Conclusions and Recommendations This comparison of analysis with inspection of the hardware provides valuable insight into the MMOD environment and how accurately analysis tools assess the impact risk to spacecraft. As this was the first large, non-ablative returned surface from a lunar mission, this analysis extends the MMOD community’s insight beyond low Earth orbit into cis-lunar space.

MMOD↗
NASA NTRSDate not supplied

Three-Dimensional Reconstruction of Defects and Structures in Additively Manufactured Parts with Automated Serial Sectioning

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with complex components for space flight applications. Laser powderbed fusion (L-PBF) is a commonly used AM technology due to the ability to produce complex parts with fine feature resolution in a wide variety of alloys and applications. L-PBF, like many other manufacturing processes, can produce minor flaws in parts when in nominal operation as well as process-escape defects when process abnormalities occur. The effects of the flaws and methods of detecting the flaws are a subject of interest to understand the difficulties in detecting these flaws with current technology and how much risk the flaws or defects pose to potential flight parts. Using a RoboMet.3D automated serial sectioning system, seeded defects as well as minor process flaws can be imaged and reconstructed in three dimensions to compare to non-destructive evaluation (NDE) techniques, such as x-ray computed tomography (CT), neutron CT, and in-situ monitoring. The RoboMet automates the metallography process by automatically grinding, polishing, and imaging samples in a single system and providing the control data for NDE comparisons to know the real size of defects built into coupons. These comparisons provide an understanding behind the technological limitations of the NDE techniques for different alloys. The same serial sectioning methods have also been utilized to characterize the surfaces of parts to reconstruct the surfaces and take measurements of internal features not easily examined with non-destructive methods. Using the RoboMet, fine lattice structures built with L-PBF have been characterized to determine the actual thicknesses of struts and density of the lattice structures. These structures have been used as finer build supports for the L-PBF process, designs for fine catalysts, and other design considerations for small components. The RoboMet data helps to inform the modeling and design efforts around these fine components.

additive manufacturing↗
NASA NTRSDate not supplied

Bond Line Thickness Estimation in Composite Structures Using Multiple Inspection Techniques

Imaging and other nondestructive evaluation techniques are commonly used for material characterization and defect recognition in safety critical aerospace applications, with data fusion providing the framework for uncertainty quantification in these contexts. Most commonly, forward physics-based modeling predicts the response conditioned on material properties and defect assumptions, and probabilistic methods are used to infer the hidden state of subject of the inspection from a combination of prior information, likelihoods, and inspection data. In this paper Bayesian methods are used to estimate bond thickness in lap joints comprised of aluminum adherends using a combination of infrared thermography, digital radiography, and ultrasound. The accuracy of the fused estimates are validated against data generated from synthetic specimens, and by comparison against high resolution X-ray computed tomography inspections of built specimens.

thermal nondestructive evaluation↗
NASA NTRSDate not supplied

MSR Curation Technology Development – Developing Protocols for Pre-Basic Characterization Measurements

The joint NASA/ESA Mars Sample Return (MSR) campaign could deliver to Earth the first pristine Mar-tian rock and regolith samples, collected by the Mars2020 science mission, Perseverance. In preparation for their arrival, the NASA/ESA Joint Curation Office (JCO) within the Sample Receiving Project (SRP) is developing curation technology needed to perform initial characterization of the samples while isolating samples from the Earth’s biosphere and protecting the samples from terrestrial contamination. (RSTA; Fig. 1). The Mars Sample Return Planning Group 2 (MSPG2) identified methods for achieving an array of potential science objectives for MSR outlined by the International MSR Objectives and Samples Team (iMOST) [1]. One category of methods, called Pre-Basic Characterization, recommends potential analyses that would happen before the Returnable Sample Tube Assemblies (RSTA; Figure 1) are opened: 1) Magnetometer & Magnetic Susceptibility; 2) X-ray Computed Tomography (XCT) Scanner [2]. To be in compliance with planetary protection requirements, and to limit the amount of time sample tubes are out-side of an isolated contamination-controlled environment, secondary containment is necessary. A Sample Tube Isolation Container (STIC) and Secondary Outer Containment Case (SOCC) is currently being developed at NASA JPL under the direction of the SRP JCO.

V Tu↗
NASA NTRSDate not supplied

In-situ Imaging of Pyrolyzing Aerospace Materials

Tracking morphological changes of materials during heating is crucial to understand its response in fire protection, biofuel production, thermal protection systems (TPS) for hypersonic flight. As materials are heated, they undergo physical and chemical changes due to water loss, stretching or shrinking, pyrolysis and chemical reactions in the ambient environment. The effects of these changes can have a profound impact on the material’s performance, indicated by changes in on the porosity and volume. While materials such as wood shrink as they pyrolyze and lose mass, others swell due to their inherent characteristics when exposed to heat [1]. This study focuses on experiments conducted at the Advanced Light Source (ALS) beamline 8.3.2, where in situ micro-computed tomography (µ-CT) is performed on materials as they are being pyrolyzed. Through in situ µ-CT, the change in total volume and porosity can be obtained in real-time, allowing for better understanding of the underlying thermophysical and chemical processes as a function of temperature. This study also focuses on the implementation of the Porous Microstructure Analysis software (PuMA) [2] to obtain thermal conductivity, permeability, and other properties of the material from the 3D tomographies. The information gained from these tomographies will supplement microscale model development of material morphological change and will aid macroscale modeling for high-temperature applications. For this study, Room Temperature Vulcanizing silicone (RTV) [3-5] is heated from room temperature to 1000°C using an infrared lamp heating system, and tomographies are continuously collected as the sample is heated. The tomographies are then segmented to obtain solid and void phases, from which estimates of pore size, porosity and total volume are extracted as a function of temperature. PuMA is deployed on the segmented tomographies to obtain thermal conductivity, permeability, and other properties as a function of temperature. Preliminary results show that RTV first intumesces (swells) as pyrolysis begins, due to build-up of pyrolysis gases in closed pores, and then shrinks significantly as more open pores are formed and the pyrolysis gases outgas. Pore network visualization of the tomographies using OpenPNM [6] showed the increase in pore connectivity with increase in temperature. Future work will focus on using PuMA to obtain macroscopic properties of RTV as a function of temperature.

Tomography↗
NASA NTRS2024

Characterization of Low-Velocity Impact Damage in Toughened Non-Crimp Fabric Laminates

The damage response of resin-infused composites was investigated using quasi-static indentation (QSI) and instrumented drop-weight impact testing. The test specimens were composed of six layers of non-crimp fabrics where each layer contained +45°, 90°, −45°, and 0° plies. The goals of the testing were to identify damage responses that may differ from traditional thermoset materials and provide damage characterization data to evaluate current damage prediction analyses and aid improvements to current damage models. The damage was characterized using X-ray computed tomography (CT) and ultrasonic testing (UT). Incremental QSI loading was used on a single specimen to investigate damage growth in nine steps at progressively higher loads. Realtime acoustic emission data were used to determine the unloading points. Unlike typical thermoset composites, the force-displacement was smooth and showed no obvious indications of damage. The primary damage consisted of large lines of fiber fracture on the plies near the impact surface and delaminations through the thickness. Nine specimens were impacted at nominal impact energies of 25 ft-lbs, 30 ft-lbs, and 35 ft-lbs. The force histories at each energy followed nearly identical paths. Again, no obvious signs of damage were observed in any of the force histories. The general damage response in the dynamic tests was similar to the QSI-loaded specimens. However, repeat specimens impacted with a given impact energy showed variations in the damage. Some characteristics of the damage response were different than those typically observed in thermoset composites and will need to be evaluated using current analysis methods.

Composite Materials↗
NASA NTRSDate not supplied

Open-Hole Testing of Resin Infused Carbon Composite Laminates to Facilitate Damage Growth and Failure Analysis Tools for Structural Design

In manufacturing of carbon-fiber reinforced composite aircraft structures, resin infusion offers a highly repeatable process for manufacturing structural components with resin content control, low labor requirements, and complex curvatures. To further understand the structural capabilities of res-in infused composites (RIC), this study – as part of the NASA-led Hi-Rate Composite Aircraft Manufacturing project efforts – performed open hole tension (OHT) and open hole compression (OHC) testing on RIC laminates. This testing provides information on the damage morphology and growth characteristics of RICs, which fuels the development and evaluation of analysis tools for progressive damage growth and failure responses. X-ray computed tomography (XCT) was implemented on each OHC and OHT specimen prior to mechanical testing to identify preexisting damage and/or defects. Two OHT and OHC specimens were loaded monotonically to failure and an additional OHT and OHC specimen were loaded intermittently at defined conditions and XCT scanned after each run. From the data obtained in this study, damage mechanisms leading to failure were identified, damage morphology and size were assessed, and damage initiation and failure loads were measured.

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