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NASA NTRSDate not supplied

Best Practices, Lessons Learned, and Examples on the Application of Damage Tolerance in Space Structures

Damage tolerance is an important consideration in space structures applications. The intent of damage tolerance is to demonstrate that the structure is robust to the presence of flaws over the service life of the space vehicle. Damage tolerance requirements in documents such as those in NASA, AIAA, and ISO can be challenging to implement. The intent of this paper is three-fold: (1) Provide best practices in the application of damage tolerance requirements for space applications, (2) Provide lessons learned for each of class of hardware, (3) Provide examples of challenging situations encountered in the application of damage tolerance. Examples cover additive manufacturing, composite overwrapped pressure vessels, pressurized structures, liquid rocket engines, thermal protection systems, and other classes of hardware. The philosophy and limitations of leak before burst and proof test logic are also discussed. Finally, a discussion on elastic-plastic fracture mechanics with comparisons to test data will be presented.

Best Practices↗

NASA NTRS2018

Aerospace Ceramic Materials: Thermal, Environmental Barrier Coatings and SiC/SiC Ceramic Matrix Composites for Turbine Engine Applications

Ceramic materials play increasingly important roles in aerospace applications because ceramics have unique properties, including high temperature capability, high stiffness and strengths, excellent oxidation and corrosion resistance. Ceramic materials also generally have lower densities as compared to metallic materials, making them excellent candidates for light-weight hot-section components of aircraft turbine engines, rocket exhaust nozzles, and thermal protection systems for space vehicles when they are being used for high-temperature and ultra-high temperature ceramics applications. Ceramic matrix composites (CMCs), including non-oxide and oxide CMCs, are also recently being incorporated in gas turbine engines for high pressure and high temperature section components and exhaust nozzles. However, the complexity and variability of aerospace ceramic processing methods, compositions and microstructures, the relatively low fracture toughness of the ceramic materials, still remain the challenging factors for ceramic component design, validation, life prediction, and thus broader applications. This ceramic material section paper presents an overview of aerospace ceramic materials and their characteristics. A particular emphasis has been placed on high technology level (TRL) enabling ceramic systems, that is, turbine engine thermal and environmental barrier coating systems and non-oxide type SiC/SiC CMCs. The current status and future trend of thermal and environmental barrier coatings and SiC/SiC CMC development and applications are described.

Thermal Barrier Coatings↗

NASA NTRS2013

Ceramic Adhesive and Methods for On-Orbit Repair of Re-Entry Vehicles

This adhesive is capable of repairing damaged leading edge components of reentry vehicles while in space, and is novel with regard to its ability to be applied in the vacuum of space, and in a microgravity environment. Once applied, the adhesive provides thermal and oxidation protection to the substrate (in this case, reinforced carbon/carbon composites, RCCs) during re-entry of a space vehicle. Although there may be many formulations for repair adhesives, at the time of this reporting, this is the first known adhesive capable of an on-orbit repair. The adhesive is an engineered ceramic material composed of a pre-ceramic polymer and refractory powders in the form of a paste or putty that can be applied to a scratched, cracked, or fractured composite surface, covering and protecting the damaged area. The adhesive is then "cured" with a heat cycle, thereby cross-linking the polymer into a hardened material and bonding it to the substrate. During the heat of reentry, the material is converted to a ceramic coating that provides thermal and oxidative stability to the repaired area, thus allowing the vehicle to pass safely from space into the upper atmosphere. Ceramic powders such as SiC, ZrB2 and Y2O3 are combined with allylhydridopolycarbosilane (AHPCS) resin, and are mixed to form a paste adhesive. The material is then applied to the damaged area by brush, spatula, trowel, or other means to fill cracks, gaps, and holes, or used to bond patches onto the damaged area. The material is then cured, in a vacuum, preferably at 250F (approximately equal to 121C) for two hours. The re-entry heating of the vehicle at temperatures in excess of 3,000F (approximately equal to 1,650C) then converts this material into a ceramic coating. This invention has demonstrated advantages in resistance to high temperatures, as was demonstrated in more than 100 arc-jet tests in representative environments at NASA. Extensive testing verified oxidation protection for the repaired substrate (RCC), and confirmed that the microstructure of the resulting repair leads to durability and resistance to melting or flow. Its processability and working life in a vacuum was demonstrated by NASA astronauts in glovebox processing studies, as well as on-orbit in the open space shuttle bay. All of these advantages increase the working life of NASA vehicles, as well as improve safety for any crew on a manned vehicle. The adhesive, trademarked NOAX(TM). or Non-Oxide Adhesive Experimental, flew on all space shuttle missions from Return To Flight (STS-114) until the final flight (STS- 135) as a crack repair material for the leading edges and nose cap of the vehicle. NOAX(TM) was patented under U.S. Patents 7,628,878 and 7,888,277.

Riedell, James A.↗

NASA NTRS1982

Geoid height-age relation from Seasat altimeter profiles across the Mendocino Fracture Zone

Twenty-eight Seasat altimeter profiles crossing the Mendocino Fracture Zone are used together with seafloor ages determined from magnetic lineations to estimate the change in oceanic geoid height with age, between ages of 15 and 135 m.y. An unbiased estimate of the overall geoid offset along each profile is determined from a least-squares fit of the along-track derivative of the geoid to the geoid slope predicted from a simple two-layer gravitational edge effect model. Uncertainties based upon the statistical properties of each profile are also determined. A geoid slope-age relation is constructed by normalizing the geoid offsets and uncertainties by the age offsets. The results are in agreement with geoid slope-age relations determined from symmetrically spreading ridges (Sandwell and Schubert, 1980). However, the fracture zone estimates have smaller uncertainties and show less scatter. A comparison of these results with the geoid slope-age prediction of the boundary layer cooling model shows that the thermal structure begins to deviate from this model at an early age (20-40 m.y.). A plate cooling model with a thickness of 125 km is most compatible with the geoid slope-age estimates, although significant deviations occur; these may indicate that the lithospheric thermal structure is not entirely age dependent.

Sandwell, D. T.↗

NASA NTRSDate not supplied

Surface Temperature and the Compositional Effects of Electron Bombardment on Dione

Saturn’s icy moons are composed of mostly water ice with minor “contaminants,” such as CO2 ice, and a dark component thought to be organics, hematite and/or metallic Fe [1]. The space weathering process of electron bombardment is expected to be particularly important on the surfaces of Saturn’s inner moons (Mimas, Tethys, Dione, and Rhea), as they orbit within the extended plasma sheet of Saturn’s magnetosphere. Terrains exhibiting thermal anomalies (i.e., colder temperatures in the day and warmer temperatures at night than surrounding areas) correspond to regions of high energy electron bombardment [2; 3]. Energetic electrons impact the surfaces, fracturing ice particles into sub-micron sized grains, and this process becomes more effective for increasing particle energies [4]. In addition to alteration of ices, the dark material may also be modified or generated within icy surfaces by interaction with solar UV radiation, cosmic rays, or by particles trapped in Saturn’s magnetic field [5]. CO2 could be sourced from irradiation of dark organic material [7]. Many of these alterations should be observable in Visible and Infrared Mapping Spectrometer (VIMS) spectra [8]. We used surface temperatures derived from Cassini’s Composite Infrared Spectrometer (CIRS) to help isolate areas where space weathering due to electron bombardment is more predominant and investigated the subtle changes in VIMS spectra using machine learning techniques. We present our results here for Dione. On ocean worlds, space weathering products would be present along with any potential indications of life. We will need to understand the manifestation of space weathering in the data to separate the two processes.

Cindy Lee Young↗

NASA NTRS1992

Lithological and textural controls on radar and diurnal thermal signatures of weathered volcanic deposits, Lunar Crater region, Nevada

Radar backscatter intensity as measured by calibrated synthetic aperture radar (SAR) systems is primarily controlled by three factors: local incidence angle, wavelength-scale roughness, and dielectric permittivity of surface materials. Radar observations may be of limited use for geological investigations of surface composition, unless the relationships between lithology and the above characteristics can be adequately understood. In arid terrains, such as the Southwest U.S., weathering signatures (e.g. soil development, fracturing, debris grain size and shape, and hill slope characteristics) are controlled to some extent by lithologic characteristics of the parent bedrock. These textural features of outcrops and their associated debris will affect radar backscatter to varying degrees, and the multiple-wavelength capability of the JPL Airborne SAR (AIRSAR) system allows sampling of textures at three distinct scales. Diurnal temperature excursions of geologic surfaces are controlled primarily by the thermal inertia of surface materials, which is a measure of the resistance of a material to a change in temperature. Other influences include albedo, surface slopes affecting insolation, local meteorological conditions and surface emissivity at the relevant thermal wavelengths. To first order, thermal inertia variations on arid terrain surfaces result from grain size distribution and porosity differences, at scales ranging from micrometers to tens of meters. Diurnal thermal emission observations, such as those made by the JPL Thermal Infrared Multispectral Scanner (TIMS) airborne instrument, are thus influenced by geometric surface characteristics at scales comparable to those controlling radar backscatter. A preliminary report on a project involving a combination of field, laboratory and remote sensing observations of weathered felsic-to basaltic volcanic rock units exposed in the southern part of the Lunar Crater Volcanic Field, in the Pancake Range of central Nevada is presented. Focus is on the relationship of radar backscatter cross sections at multiple wavelengths, apparent diurnal temperature excursions identified in multi-temporal TIMS images, surface geometries related to weathering style, and parent bedrock lithology.

Plaut, Jeffrey J.↗

NASA NTRS1990

Surface-crack growth: Models, experiments, and structures; Proceedings of the Symposium, Sparks, NV, Apr. 25, 1988

The present volume on surface-crack growth modeling, experimental methods, and structures, discusses elastoplastic behavior, the fracture analysis of three-dimensional bodies with surface cracks, optical measurements of free-surface effects on natural surfaces and through cracks, an optical and finite-element investigation of a plastically deformed surface flaw under tension, fracture behavior prediction for rapidly loaded surface-cracked specimens, and surface cracks in thick laminated fiber composite plates. Also discussed are a novel study procedure for crack initiation and growth in thermal fatigue testing, the growth of surface cracks under fatigue and monotonically increasing load, the subcritical growth of a surface flaw, surface crack propagation in notched and unnotched rods, and theoretical and experimental analyses of surface cracks in weldments.

Reuter, Walter G.↗

NASA NTRS2011

Space Shuttle Main Engine - The Relentless Pursuit of Improvement

The Space Shuttle Main Engine (SSME) is the only reusable large liquid rocket engine ever developed. The specific impulse delivered by the staged combustion cycle, substantially higher than previous rocket engines, minimized volume and weight for the integrated vehicle. The dual pre-burner configuration permitted precise mixture ratio and thrust control while the fully redundant controller and avionics provided a very high degree of system reliability and health diagnosis. The main engine controller design was the first rocket engine application to incorporate digital processing. The engine was required to operate at a high chamber pressure to minimize engine volume and weight. Power level throttling was required to minimize structural loads on the vehicle early in flight and acceleration levels on the crew late in ascent. Fatigue capability, strength, ease of assembly and disassembly, inspectability, and materials compatibility were all major considerations in achieving a fully reusable design. During the multi-decade program the design evolved substantially using a series of block upgrades. A number of materials and manufacturing challenges were encountered throughout SSME s history. Significant development was required for the final configuration of the high pressure turbopumps. Fracture control was implemented to assess life limits of critical materials and components. Survival in the hydrogen environment required assessment of hydrogen embrittlement. Instrumentation systems were a challenge due to the harsh thermal and dynamic environments within the engine. Extensive inspection procedures were developed to assess the engine components between flights. The Space Shuttle Main Engine achieved a remarkable flight performance record. All flights were successful with only one mission requiring an ascent abort condition, which still resulted in an acceptable orbit and mission. This was achieved in large part via extensive ground testing to fully characterize performance and to establish acceptable life limits. During the program over a million seconds of accumulated test and flight time was achieved. Post flight inspection and assessment was a key part of assuring proper performance of the flight hardware. By the end of the program the predicted reliability had improved by a factor of four. These unique challenges, evolution of the design, and the resulting reliability will be discussed in this paper.

VanHooser, Katherine P.↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Woven↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials

Discrete Element Method↗

NASA NTRS1985

The effects of grain size on the flow and fracture of long-range ordered alloys

The effects of grain size on the mechanical properties of long-range ordered alloys are examined with reference to the short-term behavior of aluminide intermetallics. It is shown that in those L1(2) alloys which exhibit anomalous thermal strengthening, the grain size affects the magnitude of the strengthening. In some cases it also affects ductility, whereby the tensile elongation and the tensile strength increase as the grain size decreases below a critical point. It is also believed that grain size may affect the partitioning of microalloying elements, such as boron, in Ni3Al.

Schulson, E. M.↗

NASA NTRS1972

Gaseous hydrogen-induced cracking of Ti-5Al-2.5Sn.

Study of the kinetics of hydrogen-induced cracking in the Ti-5Al-2.5Sn titanium alloy, which has a structure of acicular alpha platelets in a beta matrix. The crack-growth rate at low stress-intensity levels was found to be exponentially dependent on stress intensity but essentially independent of temperature. The crack-growth rate at intermediate stress-intensity levels was found to be independent of stress intensity but dependent on temperature in such a way that crack-growth rate was controlled by a thermally activated mechanism having an activation energy of 5500 cal/mole and varied as the square root of the hydrogen pressure. The crack-growth rate at stress-intensity levels very near the fracture toughness is presumed to be independent of environment. The results are interpreted to suggest that crack growth at high stress intensities is controlled by normal, bulk failure mechanisms such as void coalescence and the like. At intermediate stress-intensity levels the transport of hydrogen to some interaction site along the alpha-beta boundary is the rate-controlling mechanism. The crack-growth behavior at low stress intensities suggests that the hydrogen interacts at this site to produce a strain-induced hydride which, in turn, induces crack growth by restricting plastic flow at the crack tip.

Williams, D. P.↗

NASA NTRS1984

Strain analysis of the Leoville chondrite and conditions in asteroidal interiors

Deformed chondrules in the Leoville carbonaceous chondrite define a preferred orientation, also recognized previously in other CV3 chondrites. Identifying the strain mechanism is necessary for understanding the conditions which caused this compressional shortening. Luckly, the major mineralogical constituent of CV3 meteorites is olivine, for which experimental data on strain mechanisms exist. The conditions that caused strain in the olivine were obviously applicable to the whole meteorite. Possible mechanisms of olivine deformation are cataclasis, low temperature plasticity, power low creep, and diffusional flow, each of which occurs under different combinations of temperature and deviatoric stress. Cataclasis can be ruled out on the basis of its high deviatoric stress requirements; some fractures occur in chondrule olivines, but these may have formed during excavation or impact. Low temperature plasticity and power low creep occur by means of various types of lattice dislocations. However, methods of thermal decoration and chemical etching of dislocations failed to indicate evidence for either mechanism. Thus, the inference is that diffusional flow, characteristic of low to moderately high temperatures and low deviatoric stress, was the major deformation mechanism.

Cain, P. M.↗

NASA NTRS1987

Effect of heat treatment on the fracture behaviour of directionally solidified (gamma/gamma-prime)-alpha alloy

An investigation is conducted into the influence of various heat treatments on the work of fracture and its relation to microstructure for a directionally solidified Ni-33Mo-5.7Al (wt pct) (gamma/gamma-prime)-alpha alloy. The jagged crack propagation observed is due to delamination of the ligaments and associated plastic deformation. Fracture behavior is examined with respect to alloy microstructures and load-deflection curves. The four heat-treatment conditions considered are: (1) as-directionally solidified, (2) solutionized, (3) directionally solidified and thermally cycled, and (4) solutionized and thermally cycled.

Sriramamurthy, A. M.↗

NASA NTRS1987

Super-Zip separation joint performance investigation

Following functional failures of two of five Lockheed Super-Zip spacecraft separation joints in a development test series to quantify thermal effects, an investigation program was initiated on this and related systems to assist in preventing recurrence. The Super-Zip joint, applied in a ring configuration, utilizes an explosively expanded tube to fracture surrounding prenotched aluminum plates to achieve planar separation. A unique test method was developed and more than 300 individual test firings were conducted to provide an understanding of severance mechanisms, the functional performance effects of system variables, and the most likely cause of system failure. An approach for defining functional margin was developed, as well as specific recommendations for improving existing and future systems.

Bement, Laurence J.↗

NASA NTRS2006

Metallurgical Mechanisms Controlling Mechanical Properties of Aluminum Alloy 2219 Produced by Electron Beam Freeform Fabrication

The electron beam freeform fabrication (EBF3) layer-additive manufacturing process has been developed to directly fabricate complex geometry components. EBF3 introduces metal wire into a molten pool created on the surface of a substrate by a focused electron beam. Part geometry is achieved by translating the substrate with respect to the beam to build the part one layer at a time. Tensile properties demonstrated for electron beam deposited aluminum and titanium alloys are comparable to wrought products, although the microstructures of the deposits exhibit cast features. Understanding the metallurgical mechanisms controlling mechanical properties is essential to maximizing application of the EBF3 process. Tensile mechanical properties and microstructures were examined for aluminum alloy 2219 fabricated over a range of EBF3 process variables. Unique microstructures were observed within the deposited layers and at interlayer boundaries, which varied within the deposit height due to microstructural evolution associated with the complex thermal history experienced during subsequent layer deposition. Microstructures exhibited irregularly shaped grains with interior dendritic structures, described based on overall grain size, morphology, distribution, and dendrite spacing, and were correlated with deposition parameters. Fracture features were compared with microstructural elements to define fracture paths and aid in definition of basic processing-microstructure-property correlations.

Domack, Marcia S.↗

NASA NTRS2013

Micromechanics Fatigue Damage Analysis Modeling for Fabric Reinforced Ceramic Matrix Composites

A micromechanics analysis modeling method was developed to analyze the damage progression and fatigue failure of fabric reinforced composite structures, especially for the brittle ceramic matrix material composites. A repeating unit cell concept of fabric reinforced composites was used to represent the global composite structure. The thermal and mechanical properties of the repeating unit cell were considered as the same as those of the global composite structure. The three-phase micromechanics, the shear-lag, and the continuum fracture mechanics models were integrated with a statistical model in the repeating unit cell to predict the progressive damages and fatigue life of the composite structures. The global structure failure was defined as the loss of loading capability of the repeating unit cell, which depends on the stiffness reduction due to material slice failures and nonlinear material properties in the repeating unit cell. The present methodology is demonstrated with the analysis results evaluated through the experimental test performed with carbon fiber reinforced silicon carbide matrix plain weave composite specimens.

Min, J. B.↗

NASA NTRS1977

The design of an Fe-12Mn-O.2Ti alloy steel for low temperature use

An investigation was made to improve the low temperature mechanical properties of Fe-8 approximately 12% Mn-O 2Ti alloy steels. A two-phase(alpha + gamma) tempering in combination with cold working or hot working was identified as an effective treatment. A potential application as a Ni-free cryogenic steel was shown for this alloy. It was also shown that an Fe-8Mn steel could be grain-refined by a purely thermal treatment because of its dislocated martensitic structure and absence of epsilon phase. A significant reduction of the ductile-brittle transition temperature was obtained in this alloy. The nature and origin of brittle fracture in Fe-Mn alloys were also investigated. Two embrittling regions were found in a cooling curve of an Fe-12Mn-O 2Ti steel which was shown to be responsible for intergranular fracture. Auger electron spectroscopy identified no segregation during solution-annealing treatment. Avoiding the embrittling zones by controlled cooling led to a high cryogenic toughness in a solution-annealed condition.

Hwang, S. K.↗