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DOE OSTI2024

Determining reference standard strength for neutron-irradiated reduced activation ferritic/martensitic steel F82H by Bayesian method

The deterministic approach widely adopted in the design of structural components relies on systematically defined design limits using empirically determined safety factors. However, this approach is not always appropriate because structures are subjected to a variety of loads in the practical environment, which may result in excessively conservative design limits. In recent years, a more rigorous probabilistic approach that incorporates material strength distributions has become an important solution. In the probabilistic approach, the probability density functions of material strength properties underpin the design criteria. Here, the objective of this study is to identify the density distribution functions that best describe tensile properties of irradiated F82H to define a reference strength for DEMO design. Due to the limited number of existing data, this study specifically employs a Bayesian prediction method based on Monte Carlo simulations to determine a material reference value with statistical reliability and to investigate its effectiveness. For example, the dependence of tensile properties of 300 °C irradiated materials on irradiation damage and the range predicted by 95% Bayesian estimation was evaluated. As a statistical model for the dose dependence of statistical parameters, the normal distribution exhibited a better fit for 0.2% proof strength and tensile strength, whereas the distribution of total elongation data gave comparable reference values for both the normal and Weibull distribution models. Both models gave comparable criteria for the distribution of total elongation data. The Weibull model also gave better results for uniform elongation. The function best describing the model was a logarithmic law for both 0.2% proof strength and tensile strength, while a power law for both total and uniform elongation, which allowed for more comprehensive data prediction of irradiation data with statistical accuracy for DEMO reactor design.

36 MATERIALS SCIENCE↗

DOE OSTI2023

An Assessment of Machine Learning Applied to Ultrasonic Nondestructive Evaluation

In the United States, the nuclear industry performs inservice inspection (ISI) through nondestructive examination (NDE) methods in accordance with guidelines specified in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components. Ultrasonic nondestructive testing and evaluation (NDT&E) is one of the more commonly used techniques for inspecting Class 1 structural components in nuclear power systems. As the number of qualified NDE inspectors declines, the nuclear industry is looking to take advantage of advances in automation to enhance inspection capabilities. Advances in computational power, cloud-based computing, and machine learning algorithms make automated data analysis possible. Machine learning (ML) has shown huge potential in automated data analyses for ultrasonic NDE in the context of weld inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1974

Fracture control methods for space vehicles. Volume 1: Fracture control design methods

A systematic approach for applying methods for fracture control in the structural components of space vehicles consists of four major steps. The first step is to define the primary load-carrying structural elements and the type of load, environment, and design stress levels acting upon them. The second step is to identify the potential fracture-critical parts by means of a selection logic flow diagram. The third step is to evaluate the safe-life and fail-safe capabilities of the specified part. The last step in the sequence is to apply the control procedures that will prevent damage to the fracture-critical parts. The fracture control methods discussed include fatigue design and analysis methods, methods for preventing crack-like defects, fracture mechanics analysis methods, and nondestructive evaluation methods. An example problem is presented for evaluation of the safe-crack-growth capability of the space shuttle crew compartment skin structure.

Liu, A. F.↗

NASA NTRS2003

Hydrogen Permeability of a Polymer Based Composite Tank Material Under Tetra-Axial Strain

In order to increase the performance of future expendable and reusable launch vehicles and reduce per-pound payload launch costs, weight reductions have been sought in vehicle components. Historically, the cryogenic propellant tanks for launch vehicles have been constructed from metal. These are some of the largest structural components in the vehicle and contribute significantly to the vehicles total dry weight. A successful replacement material will be conformable, have a high strength to weight ratio, and have a low gas-permeability to the cryogens being stored, i.e., oxygen and hydrogen. Polymer-based composites are likely candidates to fill this role. Polymer and polymer-based composites in general are known to have acceptable gas permeation properties in their as-cured state.1 The use of polymer-based composites for this application has been proposed for some time.2 Some successes have been reported with oxygen3, but other than the DC-XA experience, those with hydrogen have been limited. The primary reason for this has been the small molecular diameter of hydrogen, the lower temperatures of the liquid, and that the composite materials examined to date have all been susceptible to microcrack formation in response to the thermal-mechanical cycles experienced in the use-environment. There have been numerous accounts of composite materials with reported acceptable resistance to the formation of microcracks when exposed to various mechanical and/or thermal cycles. However, virtually all of these studies have employed uniaxial loads and there has been no discussion or empirical evidence pertaining to how these loads relate to the biaxial state of stress in the material in its use environment. Furthermore, many of these studies have suffered from a lack of instrument sensitivity in detecting hydrogen permeability, no standards, insufficient documentation of test conditions, testing of cycled materials in their unload state, and/or false assumptions about the nature of the microcracks in the material. This paper documents the results of hydrogen permeability testing on a Bismaleimide (BMI) based graphite fiber composite material under a variety of tetra-axial strain states.

Stokes, Eric H.↗

NASA NTRS2008

Crew Launch Vehicle Mobile Launcher Solid Rocket Motor Plume Induced Environment

The plume-induced environment created by the Ares 1 first stage, five-segment reusable solid rocket motor (RSRMV) will impose high heating rates and impact pressures on Launch Complex 39. The extremes of these environments pose a potential threat to weaken or even cause structural components to fail if insufficiently designed. Therefore the ability to accurately predict these environments is critical to assist in specifying structural design requirements to insure overall structural integrity and flight safety. This paper presents the predicted thermal and pressure environments induced by the launch of the Crew Launch Vehicle (CLV) from Launch Complex (LC) 39. Once the environments are predicted, a follow-on thermal analysis is required to determine the surface temperature response and the degradation rate of the materials. An example of structures responding to the plume-induced environment will be provided.

Vu, Bruce T.↗

NASA NTRS1999

Vacuum Plasma Spray (VPS) Forming of Solar Thermal Propulsion Components Using Refractory Metals

The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorber cavity for a fully-functioning, ground test unit of a solar then-nal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (greater than 25000 C [greater than 4530 F]) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.

Zimmerman, Frank R.↗

NASA NTRS1998

Vacuum Plasma Spray (VPS) Forming of Solar Thermal Propulsion Components Using Refractory Metals

The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorption cavity for a fully-functioning, ground test unit of a solar thermal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (less than 2500 C) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.

Zimmerman, Frank↗

NASA NTRS2000

A Primer In Advanced Fatigue Life Prediction Methods

Metal fatigue has plagued structural components for centuries, and it remains a critical durability issue in today's aerospace hardware. This is true despite vastly improved and advanced materials, increased mechanistic understanding, and development of accurate structural analysis and advanced fatigue life prediction tools. Each advance is quickly taken advantage of to produce safer, more reliable more cost effective, and better performing products. In other words, as the envelop is expanded, components are then designed to operate just as close to the newly expanded envelop as they were to the initial one. The problem is perennial. The economic importance of addressing structural durability issues early in the design process is emphasized. Tradeoffs with performance, cost, and legislated restrictions are pointed out. Several aspects of structural durability of advanced systems, advanced materials and advanced fatigue life prediction methods are presented. Specific items include the basic elements of durability analysis, conventional designs, barriers to be overcome for advanced systems, high-temperature life prediction for both creep-fatigue and thermomechanical fatigue, mean stress effects, multiaxial stress-strain states, and cumulative fatigue damage accumulation assessment.

Halford, Gary R.↗

NASA NTRS2002

NASA GRC Fatigue Crack Initiation Life Prediction Models

Metal fatigue has plagued structural components for centuries, and it remains a critical durability issue in today's aerospace hardware. This is true despite vastly improved and advanced materials, increased mechanistic understanding, and development of accurate structural analysis and advanced fatigue life prediction tools. Each advance is quickly taken advantage of to produce safer, more reliable, more cost effective, and better performing products. In other words, as the envelope is expanded, components are then designed to operate just as close to the newly expanded envelope as they were to the initial one. The problem is perennial. The economic importance of addressing structural durability issues early in the design process is emphasized. Tradeoffs with performance, cost, and legislated restrictions are pointed out. Several aspects of structural durability of advanced systems, advanced materials and advanced fatigue life prediction methods are presented. Specific items include the basic elements of durability analysis, conventional designs, barriers to be overcome for advanced systems, high-temperature life prediction for both creep-fatigue and thermomechanical fatigue, mean stress effects, multiaxial stress-strain states, and cumulative fatigue damage accumulation assessment.

Arya, Vinod K.↗

NASA NTRS1972

Program for establishing long-time flight service performance of composite materials in the center wing structure of C-130 aircraft. Phase 1: Advanced development

Areas where selective reinforcement of conventional metallic structure can improve static strength/fatigue endurance at lower weight than would be possible if metal reinforcement were used are discussed. These advantages are now being demonstrated by design, fabrication, and tests of three boron-epoxy reinforced C-130E center wing boxes. This structural component was previously redesigned using an aluminum build-up to meet increased severity of fatigue loadings. Direct comparisons of relative structural weights, manufacturing costs, and producibility can therefore be obtained, and the long-time flight service performance of the composite reinforced structure can be evaluated against the wide background of metal reinforced structure.

Harvill, W. E.↗

NASA NTRS1994

Fabricating Structural Stiffeners By Superplastic Forming

Superplastic forming (SPF) of aluminum alloys effective technique for making strong, lightweight structural components conforming to close dimensional tolerances. Technique applied in experimental fabrication of prototypes of stiffening ribs for cylindrical tanks. When making structural panel, stiffening ribs spot-welded to metal skin. Use of discrete eliminates machining waste, and use of SPF. Cost of fabrication reduced.

Bales, Thomas T.↗

NASA NTRS2018

EDEN Mars Transit Habitat Concept of Operations

Jackson Behre↗

NASA NTRS2018

Food Sanitation Device for Use in Microgravity

EDEN is a transportation/orbital habitat that carries large amounts of crew members, food, and supplies from Earth to Mars and back, but can also act as a permanent, simulated-1g-environment space station in Martian orbit. The focus of the project is to create a temporary, but long-term living environment that focuses on human health and food production. The project is composed of four major habitable parts (in addition to other major components). Moving from the center out, the first is a central core that acts as a hub that connects to the structural spokes, the main propulsion rockets and serves as a place for other spacecraft to dock onto, in addition to housing some of the basic station control, navigation and automated computer systems. The second set of parts are the spokes that connect the ring to the central core; these are the primary structural components with elevators in the middle carrying people from the ring to the core. The ‘lower’ portions, near the ring and it’s 1g environment, also act as storage centers. The third part is the 2-story outer ring This project served as an engineering senior design project at Temple University, and as part of NASA’s eXploration and Habitation (X-Hab) 2018 Academic Innovation Challenge. The goal of the project was to design, construct, and test a device which would be used in microgravity to sanitize produce. This is part of a NASA’s effort to grow and sanitize fresh produce on the International Space Station (ISS), in order to provide more nutritious meal options to the astronauts. Our team designed a 3-D printed spherical device with UV-C LEDs lining the interior. The designed device consists of an 8” spherical chamber, 10 UV-C LEDs, and a touchscreen user interface to control the device. Our design meets the project requirements by offering several features: a simple user interface, minimal crew time to operate, no waste produced, and the ability to sanitize multiple types of produce. The main reductions in Salmonella bacteria and Aspergillus Flavus mold were not verified. However, the aerobic plate count requirement was greatly exceeded and validated. Testing of the device resulted in visual results confirming significant decrease in E. coli activity with increased UV-C exposure, as well as quantitative results confirming significant reduction in CFU/g for the aerobic plate count. These reductions achieved from 1.464 x 10 7 to 2 x 10 4 CFU/g (2.86 log reduction) after 5 minutes, were significantly more than the requirements given by NASA ( of the craft, which holds all of the food production along with medical bays, a control center and a few parks. This ring also integrates the rigid keystone modules, which are the interface between the spokes, the expandable-construction portions of the ring and the habitation pods. The keystone modules also incorporate redundant, distributed ECLSS systems, medical storage, airlocks, and other integral station functions. The last parts are the habitation pods; these hold the sleeping quarters along with the bathrooms, showers, kitchen space and lounge areas. These expandable modules latch onto the keystone modules of the ring, which serves as a circulatory link between the different habitation pods.

Damien Gordon↗

DOE OSTI2024

Development of Graphite Thermal and Mechanical Modeling Capabilities in Grizzly

Nuclear-grade graphites are used extensively in the core designs of multiple types of advanced nuclear reactors. In the reactor environment, graphite is exposed over long durations to extreme conditions, including high temperatures, radiation and potentially molten salt and oxygen. Exposure to these conditions can cause several degradation mechanisms in graphite, including nonuniform volumetric strains induced by irradiation and thermal expansion, which lead to stresses that can compromise the performance of graphite components. Evaluating component integrity, predicting component performance over the reactor lifetime, and developing design standards all require robust tools for predicting fracture initiation and propagation in graphite structural components in nuclear reactors. This report documents progress in an ongoing effort to develop modeling and simulation tools in the Grizzly code for predicting the performance of graphite exposed to reactor conditions. Recent developments include a set of thermal and mechanical models that now include the IG-110, NBG-18, and H-451 graphite grades. Improvements have also been made to a nonlinear damaged plasticity model applicable to predicting damage under tension and compression to quasibrittle materials, including graphite. In addition, enhancements have been made to the extended finite element method implementation targeted at simulating graphite fracture. These include new capabilities for crack nucleation in the interior of a solid body, improved treatment of crack nucleation on free surfaces, and more robust modeling approaches for crack growth approaching free surfaces or other cracks.

36 MATERIALS SCIENCE↗

NASA NTRS1978

Practical experience in analysis of aerospace shell structures

A review of the experience in analyzing structural components of several NASA space vehicles is given. Improvements to shell analysis capability which had a direct impact on accurately predicting the structural behavior of complex shell structures are identified. The status of current capability for shell analysis is reviewed and the areas still needing improvement are indicated.

Anderson, M. S.↗

NASA NTRS2003

Hypergravity Stimulates Osteoblast Proliferation Via Matrix-Integrin-Signaling Pathways

Extensive characterizations of the physiologic consequences of microgravity and gravity indicate that lack of weight-bearing may cause tissue atrophy through cellular and subcellular level mechanisms. We hypothesize that gravity is needed for the efficient transduction of cell growth and survival signals from the extra-cellular matrix (ECM) in mechanosensitive tissues. Recent work from our laboratory and from others shows that an increase of gravity increases bone cell growth and survival. We found that 50-g hypergravity stimulation increased osteoblast proliferation for cells grown on Collagen Type I and Fibronectin, but not on Laminin or uncoated plastic. This may be a tissue-specific response, because 50-g hypergravity stimulation caused no increase in proliferation for primary rat fibroblasts. These results combined with RT-PCR for all possible integrins indicate that beta1 integrin subunit may be involved. The osteoblast proliferation response on Collagen Type I was greater at 25-g than at 10-g or 50-g; 24-h duration of hypergravity was necessary to see an increase in proliferation. Survival was enhanced during hypergravity stimulation by the presence of matrix. Flow cytometry analysis indicated that cell cycle may be altered; BrdU incorporation in proliferating cells showed an increase in the number of actively dividing cells from about 60% at 1-g to over 90% at 25-g. To further investigate the molecular components involved, we applied fluorescence labeling of cytoskeletal and signaling molecules to cells after 2 to 30 minutes of hypergravity stimulation. While structural components did not appear to be altered, phosphorylation increased, indicating that signaling pathways may be activated. These data indicate that gravity mechanostimulation of osteoblast proliferation involves specific matrix-integrin signaling pathways which are sensitive to duration and g-level.

Vercoutere, W.↗

NASA NTRS2005

Structural Anomaly Detection Using Fiber Optic Sensors and Inverse Finite Element Method

NASA Langley Research Center is investigating a variety of techniques for mitigating aircraft accidents due to structural component failure. One technique under consideration combines distributed fiber optic strain sensing with an inverse finite element method for detecting and characterizing structural anomalies anomalies that may provide early indication of airframe structure degradation. The technique identifies structural anomalies that result in observable changes in localized strain but do not impact the overall surface shape. Surface shape information is provided by an Inverse Finite Element Method that computes full-field displacements and internal loads using strain data from in-situ fiberoptic sensors. This paper describes a prototype of such a system and reports results from a series of laboratory tests conducted on a test coupon subjected to increasing levels of damage.

Quach, Cuong C.↗

NASA NTRS2019

Development of Composite Sandwich Bonded Longitudinal Joints for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composite technologies with a focus on composite bonded joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA’s expertise and capabilities. The project has goals of advancing composite technologies and providing lightweight structures to support future NASA exploration missions. In particular, the CTE project will demonstrate weight-saving, performance-enhancing composite bonded joint technology for Space Launch System (SLS)-scale composite hardware. Advancements from the CTE project may be incorporated as future block upgrades for SLS structural components. This paper discusses the details of the development of a composite sandwich bonded longitudinal joint for a generic space launch vehicle structure called the CTE Point Design. The paper includes details of the design, analysis, materials, manufacturing, and testing of sub-element joint test articles to test the capability of the joint design. The test results show that the composite longitudinal bonded joint design significantly exceeds the design loads with a 2.0 factor of safety. Analysis pre-test failure predictions for all sub-element bonded joint test coupons were all within 10% of the average test coupon failure load. This testing and analysis provides confidence in the potential use of composite bonded joints for future launch vehicle structures.

Segal, Kenneth N.↗