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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Mechanical Properties of T650-35/AFR-PE-4 at Elevated Temperatures for Lightweight Aeroshell Designs

Considerable efforts have been underway to develop multidisciplinary technologies for aeroshell structures that will significantly increase the allowable working temperature for the aeroshell components, and enable the system to operate at higher temperatures while sustaining performance and durability. As part of these efforts, high temperature polymer matrix composites and fabrication technologies are being developed for the primary load bearing structure (heat shield) of the spacecraft. New high-temperature resins and composite material manufacturing techniques are available that have the potential to significantly improve current aeroshell design. In order to qualify a polymer matrix composite (PMC) material as a candidate aeroshell structural material, its performance must be evaluated under realistic environments. Thus, verification testing of lightweight PMC's at aeroshell entry temperatures is needed to ensure that they will perform successfully in high-temperature environments. Towards this end, a test program was developed to characterize the mechanical properties of two candidate material systems, T650-35/AFR-PE-4 and T650-35/RP46. The two candidate high-temperature polyimide resins, AFR-PE-4 and RP46, were developed at the Air Force Research Laboratory and NASA Langley Research Center, respectively. This paper presents experimental methods, strength, and stiffness data of the T650-35/AFR-PE-4 material as a function of elevated temperatures. The properties determined during the research test program herein, included tensile strength, tensile stiffness, Poisson s ratio, compressive strength, compressive stiffness, shear modulus, and shear strength. Unidirectional laminates, a cross-ply laminate and two eight-harness satin (8HS)-weave laminates (4-ply and 10-ply) were tested according to ASTM standard methods at room and elevated temperatures (23, 316, and 343 C). All of the relevant test methods and data reduction schemes are outlined along with mechanical data. These data contribute to a database of material properties for high-temperature polyimide composites that will be used to identify the material characteristics of potential candidate materials for aeroshell structure applications.

Whitley, Karen S.↗
NASA NTRS1963

The spacecraft test and evaluation program

Considerations guiding the planning and execution of environmental tests in the development, design qualification and flight acceptance phases of the Telstar satellite program are discussed. Specific test procedures are covered and highlights of test results involving mechanical, thermal and magnetic properties of the spacecraft are reviewed.

TELSTAR SATELLITE↗
DOE OSTI2022

A correlation-based approach for evaluating mechanical properties of nuclear fuel cladding tubes

The present work offers and evaluates a correlation-based approach to determine the tensile properties of nuclear fuel cladding tubes. A set of model materials with known properties (i.e., austenitic and ferritic steels, fcc- and hcp-alloys) were tested to build a correlation between conventional tensile tests and ring (hoop) and tube (axial) tests. It was shown that close-to-linear relationships exist for the basic mechanical properties (i.e., yield and ultimate stress, uniform and total elongation) between the uniaxial tensile test data and the ring and tube test data. Using the ring and tube specimen geometries, the feasibility of the approach was demonstrated via manufacturing and testing specimens from irradiated Zr and FeCrAl nuclear fuel cladding tubes. Limitations caused by specific deformation mechanisms (e.g., high ductility of 304L steel) were discussed in detail. The approach can be extended to other tubular products with different geometry and dimensions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

GEN3D Experimental and Numerical Development of GEN3 Durability Models

Understanding of the high temperature durability of particles and the materials that contain them is critical to next generation of concentrating solar power (CSP) technology. Here we studied the durability of particles and their containment materials under extreme UV cycling, thermal cycling, and in low-speed high temperature mechanical wear situations. The optical stability of seven candidate particles has been determined following exposure to the high temperature conditions present in a generation 3 particle-based CSP technology. Particle solar weighted absorptance and emittance measured periodically during 10,000 high solar irradiance exposure cycles and up to 400 hours of isothermal aging has been documented. The particle aging due to repeated exposure to concentrated solar flux represented the 30-year lifetime of a power plant. Models were fit to the absorptivity and emissivity data following the isothermal aging provides the projected optical degradation of the particles as a function of temperature. Mechanical wear was studied through the use of custom developed wear testing facilities for measuring high temperature impact wear, abrasion wear, and particle attrition. Additionally, a novel technique for measuring the high temperature mechanical properties of single particles was developed. Through these tests it was observed that high nickel alloys generally showed lower wear than comparable iron based steels, particularly at elevated temperatures of 800°C. Mechanical wear at these temperatures is a highly complex phenomenon combining both mechanical wear and oxidation. Additionally, the containment materials wear rates are influenced by the particles (both hardness and roundness), making the wear mechanisms complex. The initial wear test conducted in the abrasion test rig revealed a substantial amount of oxide materials in the particle bed after testing (in relative to later tests), and substantially more wear, likely indicating a need for concern in startup operation of particle facilities to not incur high wear from the presence of oxides. Particle attrition experiments have only been conducted for a single material but increase size distribution, reduction in circularity, and particle diameter is observed. Efforts to develop predictive models was limited due to a testing campaign that prioritized testing materials for particle pathway developers over building a comprehensive design of experiments. The results discussed in this report inform future CSP developers and researchers further de risking the technology and assisting in its future development. ParticleBased CSP development provides a path to dispatchable solar power generation with storage at a price competitive in the current energy market. Lowering the cost of CSP technology provides a carbon free power generation solution that can assist in the transition from fossil fuels to renewable sources of electricity.

14 SOLAR ENERGY↗
NASA NTRS1978

Nitronic 60: a new alloy

Report presents test demonstrations of mechanical and stress-corrosion properties at very low temperatures. Included are design details of alloy specimens and test procedures.

Montano, J. W.↗
NASA NTRS1982

Mechanical properties of low tantalum alloys

The mechanical property behavior of equiaxed cast B-1900 + Hf alloy as a function of tantalum content was studied. Tensile and stress rupture characterization was conducted on cast to size test bars containing tantalum at the 4.3% (standard level), 2.2% and 0% levels. Casting parameters were selected to duplicate conditions used to prepare test specimens for master metal heat qualification. The mechanical property results as well as results of microstructural/phase analysis of failed test bars are presented.

Kortovich, C. S.↗
DOE OSTI2024

Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

The manufacturing of carbon fiber-reinforced polymer (CFRP) composites demands rapid and energy-efficient strategies. Frontal polymerization (FP) enables the manufacturing of CFRP using dicyclopentadiene (DCPD) thermoset polymer which meets these requirements. In this work, we introduce reactive extrusion of CFRP (RE-CFRP), where two rollers provide localized heat and pressure to sustain the curing reaction and the consolidation of a continuous carbon fiber tow pre-impregnated with DCPD. We study the effect of the extrusion speed, temperature, and compaction force on the properties of the produced CFRP. Mechanical testing confirms that the resulting fiber volume fraction and the elastic modulus are similar to bulk cured tows. A homogenized thermo-chemical model is developed to study the effect of the process parameters on the polymerization reaction. The process produces hollow woven composite tubes directly via extrusion and in situ curing. Overall, this process offers advantages in curing, tooling, speed, and energy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure and mechanical behavior of laser remelted amorphous Al-Ni-La welds

To explore the feasibility of using laser powder bed fusion systems to print bulk amorphous Al alloys, a single autogenous weld produced by laser remelting on a cast Al-5La-9Ni (at.%) alloy was studied for its microstructure and mechanical behavior. The solidification rates experienced by material within the welds were high enough to produce entirely amorphous regions within the welds. Welds were characterized using SEM, STEM, and APT and were found to contain Ni-rich amorphous clusters. Micropillar compression tests were used to assess mechanical properties of the welds and found that all of the amorphous regions exhibited yield strengths around 1 GPa. In conclusion, these results are discussed in the context of diffusivity of Ni and rare earth elements in liquid, glass forming ability, thermodynamic driving force for phase formation during solidification, free volume concentrations in bulk metallic glasses, and cluster-related softening.

APT↗
NASA NTRS1972

Development and Design Application of Rigidized Surface Insulation Thermal Protection Systems, Volume 1

Materials and design technology of the all-silica LI-900 rigid surface insulation (RSI) thermal protection system (TPS) concept for the shuttle spacecraft is presented. All results of contract development efforts are documented. Engineering design and analysis of RSI strain arrestor plate material selections, sizing, and weight studies are reported. A shuttle prototype test panel was designed, analyzed, fabricated, and delivered. Thermophysical and mechanical properties of LI-900 were experimentally established and reported. Environmental tests, including simulations of shuttle loads represented by thermal response, turbulent duct, convective cycling, and chemical tolerance tests are described and results reported. Descriptions of material test samples and panels fabricated for testing are included. Descriptions of analytical sizing and design procedures are presented in a manner formulated to allow competent engineering organizations to perform rational design studies. Results of parametric studies involving material and system variables are reported. Material performance and design data are also delineated.

Source record↗
NASA NTRS1984

Mechanical property measurements of plasma-sprayed thermal-barrier coatings subjected to oxidation

Techniques have been developed for measuring the tensile properties of plasma-sprayed coatings which are used in thermal barrier applications. The measurements have included the average Young's modulus, bond strength and elongation at failure. The oxidation behavior of the bond coat plays an important role in the integrity and adhesion of plasma-sprayed thermal barrier coatings. This work studies the nature of the high temperature degradation on the mechanical properties of the coating. Furnace tests have been carried out on U-700 alloy with bond coats of NiCrAlY or NiCrAlZr and an overlay of ZrO2-8 percent Y2O3. Weight gain measurements on the coatings have been examined with relation to the adhesion strength and failure observations. The results from an initial study are reported in this work.

Berndt, C. C.↗
NASA NTRS1987

Mechanical properties of high gradient and hot isostatically pressed PWA 1480

This program has been designed to evaluate the potential benefits to alloy 1480 material properties due to high thermal gradient casting, hot isostatic pressing, and alternative heat treatment. Alloy 1480 castings have been obtained from vendors representing the extremes of commercial casting thermal gradients. Quantitative characterization of the dendrite arm spacing (DAS) and pore distributions has been conducted. A hot isostatic pressing (HIP) schedule, which avoids the many pitfalls of single crystal HIP has been devised for alloy 1480. In addition, an alternate heat treatment for alloy 1480 has been devised which provides benefits in mechanical properties. The standard gradient cast test material is being evaluated in the standard heat treat condition as a baseline and in the HIP plus alternate heat treated condition. The fhigh gradient cast material is being evaluated in alternate heat treat and HIP plus alternate heat treated conditions. Evaluations focus on demonstration of the benefits due to the applied processes, especially in the area of cyclic life.

Fritzemeier, L. G.↗
NASA NTRS1995

Micro-mechanics of micro-composites

The Structural Dynamics branch at NASA LaRC is working on developing an active passive mount system for vibration control. Toward this end a system utilizing piezoelectric actuators is currently being utilized. There are limitations to the current system related to space applications under which it is desired to eliminate deformations in the actuators associated with thermal effects. In addition, a material that is readily formable into complex shapes and whose mechanical properties can be optimized with regards to vibration control would be highly desirable. Microcomposite material are currently under study to service these needs. Microcomposite materials are essentially materials in which particles on the scale of microns are bound together with a polyimide (LaRC Si) that has been developed at LaRC. In particular a micro-composite consisting of LaRC Si binder and piezoelectric ceramic particles shows promise in satisfying the needs of the active passive mount project. The LaRC/ Si microcomposite has a unique combination of piezoelectric properties combined with a near zero coefficient of thermal expansion and easy machinability. The goal of this ASEE project is to develop techniques to analytically determine important material properties necessary to characterize the dynamic properties of actuators and mounts made from the LaRC Si / ceramic microcomposite. In particular, a generalized method of cells micromechanics originally developed at NASA Lewis is employed to analyze the microstructural geometry of the microcomposites and predict the overall mechanical properties of the material. A testing program has been established to evaluate and refine the GMC approach to these materials. In addition, a theory of mixtures analysis is being developed that utilizes the GMC micromechanics information to analyze complex behavior of the microcomposite material which has a near zero CTE.

Donovan, Richard P.↗
NASA NTRS1994

Scanning and Transmission Electron Microscopy of High Temperature Materials

Software and hardware updates to further extend the capability of the electron microscope were carried out. A range of materials such as intermetallics, metal-matrix composites, ceramic-matrix composites, ceramics and intermetallic compounds, based on refractory elements were examined under this research. Crystal structure, size, shape and volume fraction distribution of various phases which constitute the microstructures were examined. Deformed materials were studied to understand the effect of interfacial microstructure on the deformation and fracture behavior of these materials. Specimens tested for a range of mechanical property requirements, such as stress rupture, creep, low cycle fatigue, high cycle fatigue, thermomechanical fatigue, etc. were examined. Microstructural and microchemical stability of these materials exposed to simulated operating environments were investigated. The EOIM Shuttle post-flight samples were also examined to understand the influence of low gravity processing on microstructure. In addition, fractographic analyses of Nb-Zr-W, titanium aluminide, molybdenum silicide and silicon carbide samples were carried out. Extensive characterization of sapphire fibers in the fiber-reinforced composites made by powder cloth processing was made. Finally, pressure infiltration casting of metal-matrix composites was carried out.

Source record↗
NASA NTRS1998

Noncontact Determination of Antisymmetric Plate Wave Velocity in Ceramic Matrix Composites

High-temperature materials are of increasing importance in the development of more efficient engines and components for the aeronautics industry. In particular, ceramic matrix composite (CMC) and metal matrix composite (MMC) structures are under active development for these applications. The acousto-ultrasonic (AU) method has been shown to be useful for assessing mechanical properties in composite structures. In particular, plate wave analysis can characterize composites in terms of their stiffness moduli. It is desirable to monitor changes in mechanical properties that occur during thermomechanical testing and to monitor the health of components whose geometry or position make them hard to reach with conventional ultrasonic probes. In such applications, it would be useful to apply AU without coupling directly to the test surface. For a number of years, lasers have been under investigation as remote ultrasonic input sources and ultrasound detectors. The use of an ultrasonic transducer coupled through an air gap has also been under study. So far at the NASA Lewis Research Center, we have been more successful in using lasers as ultrasonic sources than as output devices. On the other hand, we have been more successful in using an air-coupled piezoelectric transducer as an output device than as an input device. For this reason, we studied the laser in/air-coupled-transducer out combination-using a pulsed NdYAG laser as the ultrasonic source and an air-coupled-transducer as the detector. The present work is focused on one of the AU parameters of interest, the ultrasonic velocity of the antisymmetric plate-wave mode. This easily identified antisymmetric pulse can be used to determine shear and flexure modulus. It was chosen for this initial work because the pulse arrival times are likely to be the most precise. The following schematic illustrates our experimental arrangement for using laser in/air-transducer out on SiC/SiC composite tensile specimens. The NdYAG pulse was directed downward by a 90 infrared prism to the top of the specimen, but at the edge of one end. An energy sensor measured a single pulse at 13 millijoules (mJ) before it passed through the prism, which attenuated 15 percent of its energy. It also provided an output trigger for the waveform time-delay synthesizer.

Kautz, Harold E.↗
NASA NTRS2003

Polymer/Silicate Nanocomposites Developed for Improved Strength and Thermal Stability

Over the past decade, polymer-silicate nanocomposites have been attracting considerable attention as a method of enhancing polymer properties. The nanometer dimensions of the dispersed silicate reinforcement can greatly improve the mechanical, thermal, and gas barrier properties of a polymer matrix. In a study at the NASA Glenn Research Center, the dispersion of small amounts (less than 5 wt%) of an organically modified layered silicate (OLS) into the polymer matrix of a carbon-fiber-reinforced composite has improved the thermal stability of the composite. The enhanced barrier properties of the polymer-clay hybrid are believed to slow the diffusion of oxygen into the bulk polymer, thereby slowing oxidative degradation of the polymer. Electron-backscattering images show cracking of a nanocomposite matrix composite in comparison to a neat resin matrix composite. The images show that dispersion of an OLS into the matrix resin reduces polymer oxidation during aging and reduces the amount of cracking in the matrix significantly. Improvements in composite flexural strength, flexural modulus, and interlaminar shear strength were also obtained with the addition of OLS. An increase of up to 15 percent in these mechanical properties was observed in composites tested at room temperature and 288 C. The best properties were seen with low silicate levels, 1 to 3 wt%, because of the better dispersion of the silicate in the polymer matrix.

Campbell, Sandi G.↗
NASA NTRS2006

Verification of Numerical Solutions for the Deployment of the Highly Nonlinear MARSIS Antenna Boom Lenticular Joints

The MARSIS antenna booms are constructed using lenticular hinges between straight boom segments in a novel design which allows the booms to be extremely lightweight while retaining a high stiffness and well defined structural properties once they are deployed. Lenticular hinges are elegant in form but are complicated to model as they deploy dynamically and require highly specialized nonlinear techniques founded on carefully measured mechanical properties. Results from component level testing were incorporated into a highly specialized ADAMS model which employed an automated damping algorithm to account for the discontinuous boom lengths formed during the deployment. Additional models with more limited capabilities were also developed in both DADS and ABAQUS to verify the ADAMS model computations and to help better define the numerical behavior of the models at the component and system levels. A careful comparison is made between the ADAMS and DADS models in a series of progressive steps in order to verify their numerical results. Different trade studies considered in the model development are outlined to demonstrate a suitable level of model fidelity. Some model sensitivities to various parameters are explored using subscale and full system models. Finally, some full system DADS models are exercised to illustrate the limitations of traditional modeling techniques for variable geometry systems which were overcome in the ADAMS model.

Mars↗
NASA NTRS2008

Effect of Weld Tool Geometry on Friction Stir Welded AA2219-T87 Properties

In this study, flat panels of AA2219-T87 were friction stir welded (FSWed) using weld tools with tapered pins The three pin geometries of the weld tools included: 0 (straight cylinder), 30 , and 60 angles on the frustum. For each weld tool geometry, the FSW process parameters were optimized to eliminate defects. A constant heat input was maintained while varying the process parameters of spindle rpm and travel speed. This provided a constant heat input for each FSW weld panel while altering the hot working conditions imparted to the workpiece. The resulting mechanical properties were evaluated from tensile test results of the FSW joint.

Querin, Joseph A.↗