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Results for “Crack control”

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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

Surface Enhancement Improves Crack Resistance

The low plasticity burnishing (LPB) process produces a deep layer of surface compression in a quick and affordable manner to produce metal surfaces free of scratches, nicks, and gouges. The process, designed for easy inclusion in the manufacturing environment, can be performed with conventional Computer Numerical Control machine tools. This allows parts to be processed during manufacturing, rather than as a post process in a separate facility. A smooth, free-rolling spherical ball suspended in a fluid allows for single-point contact. The ball comes into mechanical contact only with the surface to be burnished, and can be moved in any direction. LPB can be applied to all types of carbon and alloy steel, stainless steel, cast iron, aluminum, titanium, and nickel- based super alloys. In addition to improving a surface's resistance to fatigue and damage, treatment stops the growth of shallow cracks. The LPB process is used on the leading edges of turbine blades to improve resistance to foreign object damage and crack growth. This means significant savings for aircraft owners, since maintenance requirements to inspect for fatigue damage, replace parts, and remove corrosion damage increase the cost of operation.

Source record↗
NASA NTRS2012

Eddy Current System and Method for Crack Detection

An eddy current system and method enables detection of sub-surface damage in a cylindrical object. The invention incorporates a dual frequency, orthogonally wound eddy current probe mounted on a stepper motor-controlled scanning system. The system is designed to inspect for outer surface damage from the interior of the cylindrical object.

Wincheski, Russell A.↗
NASA NTRS1980

Effect of W and WC on the oxidation resistance of yttria-doped silicon nitride

The effect of W and WC contamination on the oxidation and cracking in air of sintered Si3N4 - 8 w/o Y2O3 ceramics at 500, 750, and 1350 C is examined. A mixture of Si3N4 - 8Y2O3, milled with alumina balls, was divided into four portions. Three portions were doped with 2 w/o WC W, and 4 w/o W respectively, in order to simulate contamination during milling. The fourth portion was undoped and used on a control. The addition of W or WC did not affect the phase relationships in the system, as all bars with or without additions contained melilite as the major Si-Y-O-N phase after sintering. At 750 C, instability (rapid oxidation and cracking) of W-doped bars appears to have occurred as a result of oxidation of the tungsten containing melilite phase. No intermediate temperature instability was observed in bars containing 2 w/o WC or in bars with no additive. Specimens exposed at 1350 C had good oxidation resistance due to the formation of a protective siliceous oxide layer. A specimen containing 4 w/o W which was preoxidized at 1350 C had improved oxidation resistance at 750 C. The tendency towards oxidation and cracking of Si3N4 - 8 Y2O3 at 750 C is concluded to be related to tungsten content of the sintered bars.

Schuon, S.↗
DOE OSTI2025

Delamination-informed lifecycle decisions: A dielectric and machine learning framework for composite sorting and recycling

Composite materials are widely used in aerospace, marine, and automotive sectors due to their high strength-to-weight ratio and durability. However, their long-term reliability can be compromised by damage accumulation. Specifically, delamination initiation serves as a precursor to structural failure, which is often difficult to detect during damage inspection. Identifying and sorting delamination initiation in samples not only increases operational safety while providing critical information for end-of-life decisions, which influences both the service life extension value and the efficiency of fiber extraction during recycling. This research addresses two challenges: (1) developing a nondestructive, ex-situ framework to sort composite materials based on damage severity, particularly delamination, and (2) understanding how damage in composites influences resin removal during pyrolysis. Both experimental work and finite element analysis were performed to predict critical stress levels that are associated with delamination onset. Based on these results, three loading levels 50 %, 75 %, and 90 % of maximum stress, were selected for controlled experiments, generating composite samples with varying extents of damage for machine learning model training. Microscopic imaging of these samples confirmed the damage progression from matrix cracking to delamination, validating the computational predictions. We explored supervised machine learning using dielectric measurements to classify damage states. Preliminary results show an artificial neural network can identify early delamination which is a potential precursor to failure, with 94.44 % accuracy on our dataset. A parallel investigation into the effect of damage severity on pyrolysis recycling showed that heavily delaminated samples required significantly less energy for comparable matrix removal than undamaged samples.

dielectric variables↗
DOE OSTI2023

Tailoring the Toughening Effects in Two-Dimensional Nanomaterial-Reinforced Ceramic Matrix Composites

Abstract Ceramic matrix composites (CMCs) reinforced by two-dimensional (2D) nanomaterials have shown extraordinary load-carrying capacities, even in the harsh environments required by emerging applications. Their exceptional mechanical performance, especially fracture toughness, primarily arises from their heterogeneous microstructures. The deliberate dispersion of 2D reinforcements enables toughening mechanisms that are extrinsic to the matrix and thus endows the composites with substantial resistance to catastrophic failure. However, the incomplete understanding of the fracture behavior of such nanocomposites, especially the complex energy dissipation process of the matrix/reinforcement interface, limits the development of stronger and tougher CMCs. To overcome these limitations, we investigate crack deflection and energy dissipation in nanocomposites using an extended cohesive shear-lag model. This new model accounts for interfacial debonding and friction, which critically control the toughening of nanocomposites. Our analysis provides mechanistic insights for optimizing the toughening effects of CMCs.

Mechanics↗
DOE OSTI2025

Geochemical and Hydromechanical Stimulation for Reaction Acceleration (GeoHydRA) of Serpentinization for In Situ Hydrogen Production

The project team aims to develop an innovative approach to stimulate geological hydrogen generation by enhancing in-situ serpentinization of ultramafic rocks. This method can maximize hydrogen production by promoting reactive surface areas through controlled fracturing and optimizing fluid chemistry and flow rates. Key objectives include establishing optimal conditions for hydrogen generation, investigating subsurface limitations, and sustaining production via hierarchical crack systems.

08 HYDROGEN↗
NASA NTRS1986

Effects of seawater and deionized water at 0 to 80 deg C on the flexural properties of a glass/epoxy composite

The effect on the flexural properties of a glass/epoxy composite of immersion in deionized water or seawater at 0, 25, and 80 C for 451 hr was examined. The percent weight gain at 0 and 25 C was low (0.06 to 0.17 percent) and there was no significant change in the flexural properties for these environmental conditions. At 80 C there was a decrease in the flexural strength of 17 and 20 percent in seawater and deionized water, respectively. This is a comparison to control samples exposed to 80 C heat alone. These decreases were found to be nearly reversible once the samples were dried. Optical microscopy did not reveal cracking of the matrix. The flexural modulus was essentially unaffected by exposure to deionized water and seawater at 80 C.

Penn, B. G.↗
NASA NTRS1999

Changes in the Optical Properties of Materials Are Observed After 18 Months in Low Earth Orbit

Materials located on the exterior of spacecraft in low Earth orbit are subjected to a number of environmental threats, including atomic oxygen, ultraviolet radiation, thermal cycling, and micrometeroid and debris impact. Atomic oxygen attacks materials vulnerable to oxidation. Ultraviolet radiation can break chemical bonds and cause undesirable changes in optical properties. Thermal cycling can cause cracking, and micrometeroid and debris impacts can damage protective coatings. Another threat is contamination. The outgassing of volatile chemicals can contaminate nearby surfaces, changing their thermal control properties. Contaminated surfaces may undergo further change as a result of atomic oxygen and ultraviolet radiation exposure. The Passive Optical Sample Assembly (POSA) experiment was designed as a risk mitigation experiment for the International Space Station. Samples were characterized before launch, exposed for 18 months on the exterior of Mir, and characterized upon their return. Lessons learned from POSA about the durability of material properties can be applied to the space station and other long-duration missions.

Jaworske, Donald A.↗
DOE OSTI2021

Multiscale Understanding of Surface Structural Effects on High-Temperature Operational Resiliency of Layered Oxide Cathodes

The worldwide energy demand in electric vehicles and the increasing global temperature have called for development of high-energy and long-life lithium-ion batteries (LIBs) with improved high temperature operational resiliency. However, current attention has been mostly focused on cycling aging at elevated temperature, leaving considerable gaps of knowledge in the failure mechanism and practical control of abusive calendar aging and thermal runaway that are highly related to the eventual operational lifetime and safety performance of LIBs. Herein, using a combination of various in situ synchrotron X-ray and electron microscopy techniques, we report a multiscale understanding of surface structure effects involved in regulating the high temperature operational tolerance of polycrystalline Ni-rich layered cathodes. Our results collectively show that an ultraconformal poly (3,4-ethylenedioxythiophene) coating can effectively prevent LiNi 0.8 Co 0.1 Mn 0.1 O 2 cathode from undesired phase transformation and transition metal dissolution on the surface, atomic displacement and dislocations within primary particles, intergranular cracking along the grain boundaries within secondary particles, and intensive bulk oxygen release during high state-of-charge and high temperature aging. As a result, the present work highlights the essential role of surface structure controls in overcoming the multiscale degradation pathways of high-energy battery materials at extreme temperature.

25 ENERGY STORAGE↗
DOE OSTI2021

In situ synchrotron investigation of degenerate graphite nodule evolution in ductile cast iron

Ductile cast irons (DCIs) are of increasing importance in the renewable energy and transportation sectors. The distribution and morphology of the graphite nodules, in particular the formation of degenerate features during solidification, dictate the mechanical performance of DCIs. In situ high-speed synchrotron X-ray tomography was used to capture the evolution of graphite nodules during solidification of DCI, including degenerate features and the effect of the carbon concentration field. The degeneration of nodules is observed to increase with re-melting cycles, which is attributed to Mg-loss. The dendritic primary austenite and carbon concentration gradients in the surrounding liquid phase were found to control nodule morphology by locally restricting and promoting growth. A coupled diffusion-mechanical model was developed, confirming the experimentally informed hypothesis that protrusions form through liquation cracking of the austenite shell and subsequent localised growth. In conclusion, these results provide valuable insights into the solidification kinetics of cast irons, supporting the design of advanced alloys.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Single-Cycle Versus Multicycle Proof Testing

Report compares single-cycle with multiple-cycle mechanical-stress tests of parts under mechanical stresses. Objective of proof testing: to screen out gross manufacturing or material deficiencies and provide additional assurance of quality. Report concludes that changes in distribution of crack sizes during multicycle proof testing depend on initial distribution, number of cycles, relationship between resistance of material and elastic/plastic fracture-mechanics parameter, relationship between load control and displacement control, and magnitude of applied load or displacement. Whether single-cycle or multicycle testing used depends on shape, material, and technique of fabrication of components tested.

Hudak, S. J., Jr.↗
NASA NTRS1994

An Analytical Tool for Fracture Control

The structural integrity of critical NASA space flight hardware is ensured through a damage tolerance program which is dictated in the fracture control requirements. The goal of a fracture control program is to ensure proper material selection and control, control of working stress levels, use of fracture resistant design concepts, manufacturing process control, and the use of qualified inspection procedures. The damage tolerance philosophy assumes that all components contain initial defects and the damage accumulation process is thus entirely crack propagation. The service capability of fracture critical components is determined by analysis and/or test. A large percentage of NASA fracture critical hardware is certified by analysis only and it is therefore imperative that the analysis code utilized contain the latest state of the art technology. Not all space contractors and vendors are able to develop and maintain an analysis code which meets this requirement. A response to this need has been fulfilled by the development of the NASA/FLAGRO (NASGRO) fracture mechanics code here at the Johnson Space Center. The NASGRO code is based primarily in Linear Elastic Fracture Mechanics (LEFM) and is continually updated to meet to needs of the user community. Development assistance comes from other NASA centers as well as the European Space Agency (ESA). The code currently has a vast materials data file (over 350 different entries) which defines the material strength, fracture toughness, crack growth rate, and crack growth threshold. The code also allows for user defined inputs of data from other sources. The code also provides a large library of stress intensity factor solutions for numerous geometries and loading conditions.

Patin, Raymond M.↗
NASA NTRS1971

Crack Growth of D6 Steel in Air and High Pressure Oxygen

Fracture and subcritical flaw growth characteristics were experimentally deter­mined for electroless nickel plated D6 steel in dry air and high pressure oxygen environments as applicable to the Lunar Module/Environmental Control System (LM/ECS) descent gaseous oxygen (GOX) tank. The material tested included forgings, plate, and actual LM/ECS descent GOX tank material. Parent metal and TIG (tungsten inert gas) welds were tested. Tests indicate that proof testing the tanks at 4000 pounds per square inch or higher will insure safe operation at 3060 pounds per square inch. Although significant flaw growth can occur during proofing, subsequent growth of flaws during normal tank operation is negligible.

Bixler, W. D.↗
NASA NTRS1974

Characteristics and performance of several mass spectrometer residual gas analyzers

The operation and properties of various mass-spectrometer residual gas analyzers for use in vacuum measurements were analyzed in terms of efficiencies of ion extraction, ion separation and transmission, and ion collection. Types of instruments studied were magnetic sector, omegatron, quadrupole, and monopole. Experimental results presented include absolute sensitivity to argon, relative sensitivity to 10 gases, and cracking patterns for these gases. It is shown that the properties are strongly dependent on instrument range, resolution, and the particular voltages, currents, or field intensities used to control the instrument.

Hultzman, W. W.↗
NASA NTRS1993

Fluorescence measurements of the thermal control experiments coatings on LDEF S0069 and A0114

Fluorescence measurements were made on the thermal control coatings from the Long Duration Experiment Facility (LDEF) S0069, Thermal Control Surfaces Experiment (TCSE); and the A0114, Interaction of Atomic Oxygen with Material Surfaces in Low Earth orbit. Fluorescence was observed in two types of thermal control coatings and is attributed to pigments or binders. In addition, fluorescence measurement on the silver Teflon from the front cover of TCSE led to confirmation of damage (cracking) to the metal layers during application.

Zwiener, J. M.↗
NASA NTRS1999

Ultrasonic Nondestructive Characterization of Adhesive Bonds

Adhesives and adhesive joints are widely used in various industrial applications to reduce weight and costs, and to increase reliability. For example, advances in aerospace technology have been made possible, in part, through the use of lightweight materials and weight-saving structural designs. Joints, in particular, have been and continue to be areas in which weight can be trimmed from an airframe through the use of novel attachment techniques. In order to save weight over traditional riveted designs, to avoid the introduction of stress concentrations associated with rivet holes, and to take full advantage of advanced composite materials, engineers and designers have been specifying an ever-increasing number of adhesively bonded joints for use on airframes. Nondestructive characterization for quality control and remaining life prediction has been a key enabling technology for the effective use of adhesive joints. Conventional linear ultrasonic techniques generally can only detect flaws (delamination, cracks, voids, etc) in the joint assembly. However, more important to structural reliability is the bond strength. Although strength, in principle, cannot be measured nondestructively, a slight change in material nonlinearity may indicate the onset of failure. Furthermore, microstructural variations due to aging or under-curing may also cause changes in the third order elastic constants, which are related to the ultrasonic nonlinear parameter of the polymer adhesive. It is therefore reasonable to anticipate a correlation between changes in the ultrasonic nonlinear acoustic parameter and the remaining bond strength. It has been observed that higher harmonics of the fundamental frequency are generated when an ultrasonic wave passes through a nonlinear material. It seems that such nonlinearity can be effectively used to characterize bond strength. Several theories have been developed to model this nonlinear effect. Based on a microscopic description of the nonlinear interface binding force, a quantitative method was presented. Recently, a comparison between the experimental and simulated results based on a similar theoretical model was presented. A through-transmission setup for water immersion mode-converted shear waves was used to analyze the ultrasonic nonlinear parameter of an adhesive bond. In addition, ultrasonic guided waves have been used to analyze adhesive or diffusion bonded joints. In this paper, the ultrasonic nonlinear parameter is used to characterize the curing state of a polymer/aluminum adhesive joint. Ultrasonic through-transmission tests were conducted on samples cured under various conditions. The magnitude of the second order harmonic was measured and the corresponding ultrasonic nonlinear parameter was evaluated. A fairly good correlation between the curing condition and the nonlinear parameter is observed. The results show that the nonlinear parameter might be used as a good indicator of the cure state for adhesive joints.

Qu, Jianmin↗
DOE OSTI2022

Characterization of Acoustic Emissions From Analogue Rocks Using Sparse Regression‐DMDc

Abstract Moisture loss in rock is known to generate acoustic emissions (AE). Phenomena that result in AE during drying are related to the movement of fluids through the pores and induced‐cracks that arise from differential mineral shrinkage, especially in clay‐bearing rock. AE from the movement of fluids occurs from the reconfiguration of fluid interfaces during drying, while AE from mineral shrinkage involves the debonding within or between minerals. Here, analogue rock samples were used to examine the differences in the AE signatures when one or both AE source‐types are present. An unsupervised sparse regression model, Dynamic Mode Decomposition with control, that extends Dynamic Mode Decomposition is used to characterize the AE signals recorded during the drying of porous analogue rock samples fabricated with ordinary Portland cement, with and without clay. This method can effectively and accurately reconstruct acoustic signals emitted from samples that only experience moisture loss without cracking. However, the method struggles to reconstruct signals from samples with intricate crack networks that formed during drying because AE generating mechanisms can emit contemporaneously, and the resulting waves propagate through drying‐induced cracks that can lead to multiple internal reflections. Thus, the differential reconstruction accuracy of time series generated by different underlying physical processes provides a robust filter for reducing large data catalogs. In general, both dynamics and sparse initiating events are learned directly from data and this method exposes a data hierarchy based on the complexity of the intrinsic dynamics.

58 GEOSCIENCES↗
DOE OSTI2022

High-Energy Solid-State Lithium Batteries with Organic Cathode Materials (Final Report)

Organic materials made from abundant elements via low-energy processes are emerging as sustainable and low-cost alternatives to transition metal oxides as the electrode materials for high- energy batteries in the wake of supply chain and environmental issues associated with critical materials during the transition to clean energy. Organic insertion materials (OIMs) offer material- level energy comparable to transition metal oxides, but they have durability difficulties owing to dissolving in common liquid electrolytes. Combining ceramic-based solid electrolytes with organic electrode materials is one intriguing solution. The goal of this project is to design and synthesize high-energy OIMs, to understand the chemical dynamics and mechanical properties at the OIM-sulfide interface during electrochemical cycling, and to develop methods for constructing the optimum cathode microstructure, which will lead to improved electrochemical performance. The project team has accomplished the following over the last four years: (a) demonstrating that the mechanical softness of organic electrode materials is uniquely beneficial in suppressing crack formation at the electrode-electrolyte interface during cell operation; (b) understanding the interaction between cathode microstructure and the mechanical properties of individual components; and (c) establishing predictive control of cathode microstructure by tuning the mechanical properties of solid electrolytes and OIMs; (d) determining the chemical combability of sulfide electrolyte with high-energy OIMs and finally (f) laying out a road map toward a specific energy of 500 Wh kg -1 for solid-state lithium batteries. 14 publications resulted from this project.

25 ENERGY STORAGE↗