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DOE OSTI2025

Summary of Graphite Data Stored within NDMAS

The Graphite Technology Development Project provides data to support the design of graphite core components within specific reactor service conditions of the next generation of high-temperature, gas-cooled nuclear reactors. Physical, mechanical, and thermal properties of nuclear grade graphite were characterized for specimens that were unirradiated, irradiated, and irradiated under various stress conditions. The material properties include diameter, length, mass, density, compressive strength, tensile strength, flexural strength, modulus, resistivity, thermal diffusivity, and thermal expansion coefficient. Baseline graphite specimens are unirradiated from different grades (2114, IG-110, NBG-17, NBG-18, and PCEA) and different types used in different characterization tests (compressive, flexural, tensile, one-inch cylinder, and quarter-inch cylinder). The Advanced Graphite Creep (AGC) irradiation specimens are from a much larger number of grades and cylinder types (creep, piggyback, and pencil). For baseline graphite, characterization data for 7,756 specimens extracted from thirteen graphite billets were captured to the NDMAS database. For AGC experiments, four irradiation campaigns have been completed: AGC-1, AGC-2, AGC-3, and AGC-4. The ongoing HDG-1 (High-Dose Graphite) experiment, which began irradiation with Cycle 168B on August 26, 2020, includes specimens previously irradiated in AGC-2 in addition to the specimens originally destined for AGC-5.. Besides the characterization data, the AGC data includes irradiation monitoring and physics data representing the irradiation conditions of AGC specimens. Currently, all data for AGC-1, AGC-2, and AGC-3 have been captured to the NDMAS database. Only AGC-4 pre-irradiation and irradiation monitoring data have been captured, and HDG-1 pre-irradiation data are in process of being captured for unirradiated specimens. To date, a total of 38,149 material property records have been captured into NDMAS database for baseline and AGC specimens. All characterization data are qualified for use according to their perspective data verification reports. For the AGC irradiation campaigns, a total of 41,502 qualified physics calculation records were added for AGC-1, AGC-2, and AGC-3. Finally, a total of 173,698,505 AGC irradiation monitoring data records (thermocouple temperature, gas flow rate, gas pressure, gas moisture, applied load, and specimen displacement) have been captured to NDMAS; the majority of those records (~94%) are qualified data records.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1996

Effect of Processing Variables on the Microstructure and Mechanical Properties of Microporous Carbon Materials

Microporous carbon materials with different pore and strut sizes have been fabricated by the pyrolysis of furfuryl alcohol resin, triethylene glycol, and p-toluene sulfonic acid mixtures. The resulting materials were characterized by scanning electron microscopy and density measurements. The room temperature flexural strength and modulus of these materials decreases with increasing amount of acid curing agent.

Singh, M.↗

NASA NTRS1992

Flexural analysis of uplifted rift flanks on Venus

Knowledge of the thermal structure of a planet is vital to a thorough understanding of its general scheme of tectonics. Since no direct measurements of heat flow or thermal gradient are available for Venus, most estimates have been derived from theoretical considerations or by analog with the Earth. The flexural response of the lithosphere to applied loads is sensitive to regional thermal structure. Under the assumption that the yield strength as a function of depth can be specified, the temperature gradient can be inferred from the effective elastic plate thickness. Previous estimates of the effective elastic plate thickness of Venus range from 11-18 km for the foredeep north of Uorsar Rupes to 30-60 km for the annular troughs around several coronae. Thermal gradients inferred for these regions are 14-23 K km(exp -1) and 4-9 K km(exp -1) respectively. In this study, we apply the same techniques to investigate the uplifted flanks of an extensional rift. Hypotheses for the origin of uplifted rift flanks on Earth include lateral transport of heat from the center of the rift, vertical transport of heat by small-scale convection, differential thinning of the lithosphere, dynamical uplift, and isostatic response to mechanical uploading of the lithosphere. The 1st hypothesis is considered the dominant contributor to terrestrial rift flanks lacking evidence for volcanic activity, particularly for rift structures that are no longer active. In this study, we model the uplifted flanks of a venusian rift as the flexural response to a vertical end load.

Evans, Susan A.↗

NASA NTRS1975

Effects of environment on the fatigue of graphite-epoxy composites

Torsional and flexural fatigue tests were performed on both uniaxial (0 deg) and crossplied (plus or minus 45 deg) graphite-epoxy materials at temperatures of 24 and 74 C in environments of air and water. The results of the torsion testing showed that the number of cycles required to cause an initial decrease in stiffness as well as the rate of stiffness loss was a function of temperature and environment; the most significant losses were noted for tests at the higher temperature in water. The torsional fatigue specimens were subsequently tested in four-point bending to determine the effect of torsional damage on longitudinal properties. This damage caused changes in the flexural stiffness, failure stress, and failure energy, depending on the stress and environmental histories. The flexural fatigue tests also showed a significant effect of water (at 24 C) on the material behavior. These results are compared with the results of previous investigations and are discussed in terms of proposed damage mechanisms.

Sumsion, H. T.↗

NASA NTRS1990

Vibration transmission through rolling element bearings. I - Bearing stiffness formulation. II - System studies

How vibratory motion can be transmitted from the rotating shaft to the casing and other connecting structures in rotating mechanical equipment is addressed here by developing a new mathematical model of precision rolling element bearings. A new grating stiffness matrix is proposed in order to demonstrate a coupling between the shaft bending motion and the flexural motion of the casing plate. It is shown that the translational bearing stiffness coefficients currently used in rotor dynamic models are a small subset of the proposed matrix. The theory is validated by examples, and the proposed bearing formulation is then extended to demonstrate its superiority over existing models in vibration transmission analyses. It is shown that the model can easily be incorporated into analytical or numerical models typically used for dynamic analyses.

Lim, T. C.↗

NASA NTRS1992

Nondestructive evaluation of a ceramic matrix composite material

Monolithic ceramic materials have proven their usefulness in many applications, yet, their potential for critical structural applications is limited because of their sensitivity to small imperfections. To overcome this extreme sensitivity to small imperfections, ceramic matrix composite materials have been developed that have the ability to withstand some distributed damage. A borosilicate glass reinforced with several layers of silicon-carbide fiber mat has been studied. Four-point flexure and tension tests were performed not only to determine some of the material properties, but also to initiate a controlled amount of damage within each specimen. Acousto-ultrasonic (AU) measurements were performed periodically during mechanical testing. This paper will compare the AU results to the mechanical test results and data from other nondestructive methods including acoustic emission monitoring and X-ray radiography. It was found that the AU measurements were sensitive to the damage that had developed within the material.

Grosskopf, Paul P.↗

NASA NTRS2004

Reducing the Cation Exchange Capacity of Lithium Clay to Form Better Dispersed Polymer-Clay Nanocomposites

Polymer-clay nanocomposites have exhibited superior strength and thermo- oxidative properties as compared to pure polymers for use in air and space craft; however, there has often been difficulty completely dispersing the clay within the matrices of the polymer. In order to improve this process, the cation exchange capacity of lithium clay is first lowered using twenty-four hour heat treatments of no heat, 130 C, 150 C, or 170 C to fixate the lithium ions within the clay layers so that they are unexchangeable. Generally, higher temperatures have generated lower cation exchange capacities. An ion exchange involving dodecylamine, octadecylamine, or dimethyl benzidine (DMBZ) is then employed to actually expand the clay galleries. X-ray diffraction and transmission electron microscopy can be used to determine whether the clay has been successfully exfoliated. Finally, resins of DMBZ with clay are then pressed into disks for characterization using dynamic mechanical analyzer and oven- aging techniques in order to evaluate their glass transition, modulus strength, and thermal-oxidative stability in comparison to neat DMBZ. In the future, they may also be tested as composites for flexural and laminar shear strength.

Liang, Maggie↗

DOE OSTI2021

Phase evolution and mechanical performance of an ettringite-based binder during hydrothermal aging

Little is known about the performance of ettringite-based binders in hydrothermal conditions. This investigation aims to gain insights into the phase evolution and corresponding mechanical performance of an ettringite-based binder considering crystallization pressure caused by late-reaction products. Additionally, the role of fiber reinforcement on the strength retention of the binder was investigated. When aged at an elevated temperature under water-saturated conditions, hard-burned MgO hydrated to form brucite. The precipitation and growth of the brucite crystals led to a crystallization pressure of approximately 200 MPa calculated using thermodynamic modelling. Damage was observed after 4 months of aging with cracks in the microstructure and eventually a failure at the macro scale. Ettringite remained stable at 60 °C due to the water-saturated conditions. Polypropylene fiber delayed crack propagation and thus reduced the damage caused by crystallization pressure. The fiber improved the flexural performance of composite attaining deflection-hardening behavior regardless of aging conditions.

36 MATERIALS SCIENCE↗

NASA NTRS2004

Making Precise Resonators for Mesoscale Vibratory Gyroscopes

An alternative approach to the design and fabrication of vibratory gyroscopes is founded on the use of fabrication techniques that yield best results in the mesoscopic size range, which is characterized by overall device dimensions of the order of a centimeter. This approach stands in contradistinction to prior approaches in (1) the macroscopic size range (the size range of conventional design and fabrication, characterized by overall device dimensions of many centimeters) and (2) the microscopic size range [the size range of microelectromechanical systems (MEMS), characterized by overall device dimensions of the order of a millimeter or less]. The mesoscale approach offers some of the advantage of the MEMS approach (sizes and power demands smaller than those of the macroscale approach) and some of the advantage of the macroscale approach (the possibility of achieving relative dimensional precision greater than that of the MEMS approach). Relative dimensional precision is a major issue in the operation of a vibratory gyroscope. The heart of a vibratory gyroscope is a mechanical resonator that is required to have a specified symmetry in a plane orthogonal to the axis about which rotation is to be measured. If the resonator could be perfectly symmetrical, then in the absence of rotation, a free vibration of the resonator could remain fixed along any orientation relative to its housing; that is, the gyroscope could exhibit zero drift. In practice, manufacturing imprecision gives rise to some asymmetry in mass, flexural stiffness or dissipation, resulting in a slight drift or beating motion of an initial vibration pattern that cannot be distinguished from rotation. In the mesoscale approach, one exploits the following concepts: For a given amount of dimensional error generated in manufacturing, the asymmetry and hence the rate-of-rotation drift of the gyroscope can be reduced by increasing the scale. The decrease in asymmetry also reduces coupling of vibrations to the external environment. Mechanical thermal noise and electronic measurement noise and drift can also be reduced by increasing the size of the resonator and its associated sensors.

Yang, Eui-Hyeok↗

NASA NTRS2012

Miniaturization of Planar Horn Motors

There is a great need for compact, efficient motors for driving various mechanisms including robots or mobility platforms. A study is currently underway to develop a new type of piezoelectric actuators with significantly more strength, low mass, small footprint, and efficiency. The actuators/motors utilize piezoelectric actuated horns which have a very high power density and high electromechanical conversion efficiency. The horns are fabricated using our recently developed novel pre-stress flexures that make them thermally stable and increases their coupling efficiency. The monolithic design and integrated flexures that pre-stresses the piezoelectric stack eliminates the use of stress bolt. This design allows embedding solid-state motors and actuators in any structure so that the only macroscopically moving parts are the rotor or the linear translator. The developed actuator uses a stack/horn actuation and has a Barth motor configuration, which potentially generates very large torque and speeds that do not require gearing. Finite element modeling and design tools were investigated to determine the requirements and operation parameters and the results were used to design and fabricate a motor. This new design offers a highly promising actuation mechanism that can potentially be miniaturized and integrated into systems and structures. It can be configured in many shapes to operate as multi-degrees of freedom and multi-dimensional motors/actuators including unidirectional, bidirectional, 2D and 3D. In this manuscript, we are reporting the experimental measurements from a bench top design and the results from the efforts to miniaturize the design using 2x2x2 mm piezoelectric stacks integrated into thin plates that are of the order of3 x 3x 0.2 cm.

horn actuation↗

DOE OSTI2022

Qualification of Continuous Fiber Reinforced 3D Printed Material for use in Hot Cell Environments

The ability to employ additively manufactured polymers in highly radioactive environments facilitates rapid prototyping as well as emergency replacement of various equipment components contained in-cell. A technical evaluation (TEV) exists seeking to qualify 3D printed polymers and carbon reinforcements for use in-cell, the data generated in this project seeks to support the TEV. The goal of the study is to determine if the loss in mechanical properties is low enough to justify semi-permanent use in-cell.

3D printing↗

NASA NTRS1991

Integration of mechanism and control for large-angle slew maneuvers of flexible structures

A rolling contact noncircular gear system is applied to assist a desired controller in the slewing of a flexible space structure. The varying gear ratio in cooperation with the controller results in lower feedback gains at the controller, as well as considerably reducing flexural vibrations of the space structure. The noncircular gears consist of a pair of convex noncircular cylinders with specially designed profiles that are synthesized in conjunction with the optimal controller gains for minimizing the flexural vibrations of flexible structure during a slew maneuver. Convexity of the cylindrical profiles for this noncircular gear device must be ensured to maintain rolling contact between the two cylinders. Simulations of slewing control tasks for two kinds of flexible space structures, such as a planar flexible beam and the planar articulated flexible beams, are presented.

Chew, Meng-Sang↗

DOE OSTI2024

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

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

36 MATERIALS SCIENCE↗

NASA NTRS1998

Microstructure and Mechanical Properties of Reaction-Formed Joints in Reaction Bonded Silicon Carbide Ceramics

A reaction-bonded silicon carbide (RB-SiC) ceramic material (Carborundum's Cerastar RB-SIC) has been joined using a reaction forming approach. Microstructure and mechanical properties of three types of reaction-formed joints (350 micron, 50-55 micron, and 20-25 micron thick) have been evaluated. Thick (approximately 350 micron) joints consist mainly of silicon with a small amount of silicon carbide. The flexural strength of thick joints is about 44 plus or minus 2 MPa, and fracture always occurs at the joints. The microscopic examination of fracture surfaces of specimens with thick joints tested at room temperature revealed the failure mode to be typically brittle. Thin joints (<50-55 micron) consist of silicon carbide and silicon phases. The room and high temperature flexural strengths of thin (<50-55 micron) reaction-formed joints have been found to be at least equal to that of the bulk Cerastar RB-SIC materials because the flexure bars fracture away from the joint regions. In this case, the fracture origins appear to be inhomogeneities inside the parent material. This was always found to be the case for thin joints tested at temperatures up to 1350C in air. This observation suggests that the strength of Cerastar RB-SIC material containing a thin joint is not limited by the joint strength but by the strength of the bulk (parent) materials.

Singh, M.↗

NASA NTRS2015

Monolithic Flexure Pre-Stressed Ultrasonic Horns

A monolithic ultrasonic horn where the horn, backing, and pre-stress structures are combined in a single monolithic piece is disclosed. Pre-stress is applied by external flexure structures. The provision of the external flexures has numerous advantages including the elimination of the need for a pre-stress bolt. The removal of the pre-stress bolt eliminates potential internal electric discharge points in the actuator. In addition, it reduces the chances of mechanical failure in the actuator stacks that result from the free surface in the hole of conventional ring stacks. In addition, the removal of the stress bolt and the corresponding reduction in the overall number of parts reduces the overall complexity of the resulting ultrasonic horn actuator and simplifies the ease of the design, fabrication and integration of the actuator of the present invention into other structures.

Sherrit, Stewart↗

NASA NTRS2016

Monolithic Flexure Pre-Stressed Ultrasonic Horns

Sherrit, Stewart↗

DOE OSTI2021

Relationship between microstructure evolution and properties enhancement of carbon nanotubes‐filled polybutylene terephthalate/polypropylene blends induced by thermal annealing

Abstract Thermal annealing induced microstructure evolution and properties enhancement of polybutylene terephthalate/polypropylene/carbon nanotubes (PBT/PP/CNTs) nanocomposites was methodically investigated. The electrical conductive PBT/PP/CNTs nanocomposites with a low percolation threshold were obtained by simple melt blending due to the selective location of the CNTs in PBT phase and the formation of the double percolation structure. Thermal annealing further remarkably decreased the volume resistivity of the nanocomposites, with the maximum reduction of seven orders of magnitude. Scanning electron microscope observation and rheology tests demonstrated that the relatively large CNTs agglomerates were redistributed to build more homogeneous CNTs networks after annealing. The phase coalescence during annealing promoted the formation of the more perfect co‐continuous structure. These phenomena helped to enhance the electrical conductivity of the nanocomposites. Flexural properties of the nanocomposites were also enhanced after annealing, which might be due to the more effective stress transfer between the polymer and CNTs induced by the reconstructed CNTs networks. The nanocomposites obtained in this study possess excellent electrical and mechanical properties, which can be applied to the fields of sensors, electromagnetic interference shielding, anti‐static materials, and so forth.

Shang, Mengyao↗

NASA NTRS1991

Prototype high speed optical delay line for stellar interferometry

The long baselines of the next-generation ground-based optical stellar interferometers require optical delay lines which can maintain nm-level path-length accuracy while moving at high speeds. NASA-JPL is currently designing delay lines to meet these requirements. The design is an enhanced version of the Mark III delay line, with the following key features: hardened, large diameter wheels, rather than recirculating ball bearings, to reduce mechanical noise; a friction-drive cart which bears the cable-dragging forces, and drives the optics cart through a force connection only; a balanced PZT assembly to enable high-bandwidth path-length control; and a precision aligned flexural suspension for the optics assembly to minimize bearing noise feedthrough. The delay line is fully programmable in position and velocity, and the system is controlled with four cascaded software feedback loops. Preliminary performance is a jitter in any 5 ms window of less than 10 nm rms for delay rates of up to 28 mm/s; total jitter is less than 10 nm rms for delay rates up to 20 mm/s.

Colavita, M. M.↗