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At least 469 records · Page 26

All sources NASA NTRS DOE OSTI

NASA NTRS1987

Calculation of thermomechanical fatigue life based on isothermal behavior

The isothermal and thermomechanical fatigue (TMF) crack initiation response of a hypothetical material was analyzed. Expected thermomechanical behavior was evaluated numerically based on simple, isothermal, cyclic stress-strain - time characteristics and on strainrange versus cyclic life relations that have been assigned to the material. The attempt was made to establish basic minimum requirements for the development of a physically accurate TMF life-prediction model. A worthy method must be able to deal with the simplest of conditions: that is, those for which thermal cycling, per se, introduces no damage mechanisms other than those found in isothermal behavior. Under these assumed conditions, the TMF life should be obtained uniquely from known isothermal behavior. The ramifications of making more complex assumptions will be dealt with in future studies. Although analyses are only in their early stages, considerable insight has been gained in understanding the characteristics of several existing high-temperature life-prediction methods. The present work indicates that the most viable damage parameter is based on the inelastic strainrange.

Halford, Gary R.↗

NASA NTRS1987

Calculation of thermomechanical fatigue life based on isothermal behavior

The isothermal and thermomechanical fatigue (TMF) crack initiation response of a hypothetical material was analyzed. Expected thermomechanical behavior was evaluated numerically based on simple, isothermal, cyclic stress-strain-time characteristics and on strainrange versus cyclic life relations that have been assigned to the material. The attempt was made to establish basic minimum requirements for the development of a physically accurate TMF life-prediction model. A worthy method must be able to deal with the simplest of conditions: that is, those for which thermal cycling, per se, introduces no damage mechanisms other than those found in isothermal behavior. Under these assumed conditions, the TMF life should be obtained uniquely from known isothermal behavior. The ramifications of making more complex assumptions will be dealt with in future studies. Although analyses are only in their early stages, considerable insight has been gained in understanding the characteristics of several existing high-temperature life-prediction methods. The present work indicates that the most viable damage parameter is based on the inelastic strainrange.

Halford, G. R.↗

NASA NTRS1991

High pressure water jet cutting and stripping

High pressure water cutting techniques have a wide range of applications to the American space effort. Hydroblasting techniques are commonly used during the refurbishment of the reusable solid rocket motors. The process can be controlled to strip a thermal protective ablator without incurring any damage to the painted surface underneath by using a variation of possible parameters. Hydroblasting is a technique which is easily automated. Automation removes personnel from the hostile environment of the high pressure water. Computer controlled robots can perform the same task in a fraction of the time that would be required by manual operation.

Hoppe, David T.↗

NASA NTRS1992

Preliminary results from the LDEF/UTIAS composite materials experiment

A total of 107 epoxy matrix composite samples containing carbon, boron, and aramid fiber reinforcements were flown on the Long Duration Exposure Facility (LDEF) satellite. For the first 371 days after deployment, strain and temperature data were recorded every 16 hours. Results were obtained on time to outgas, dimensional changes, coefficients of thermal expansion, atomic oxygen erosion, and damage due to micrometeoroid/debris impacts.

Tennyson, R. C.↗

NASA NTRS1992

Advanced NDE research in electromagnetic, thermal, and coherent optics

A new inspection technology called magneto-optic/eddy current imaging was investigated. The magneto-optic imager makes readily visible irregularities and inconsistencies in airframe components. Other research observed in electromagnetics included (1) disbond detection via resonant modal analysis; (2) AC magnetic field frequency dependence of magnetoacoustic emission; and (3) multi-view magneto-optic imaging. Research observed in the thermal group included (1) thermographic detection and characterization of corrosion in aircraft aluminum; (2) a multipurpose infrared imaging system for thermoelastic stress detection; (3) thermal diffusivity imaging of stress induced damage in composites; and (4) detection and measurement of ice formation on the space shuttle main fuel tank. Research observed in the optics group included advancements in optical nondestructive evaluation (NDE).

Skinner, S. Ballou↗

NASA NTRS1993

Hollow cathode heater development for the Space Station plasma contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater design. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Three heaters have been tested to date using direct current power supplies. Performance testing was conducted to determine input current and power requirements for achieving activation and ignition temperatures, single unit operational repeatability, and unit-to-unit operational repeatability. Comparisons of performance testing data at the ignition input current level for the three heaters show the unit-to-unit repeatability of input power and tube temperature near the cathode tip to be within 3.5 W and 44 degrees C, respectively. Cyclic testing was then conducted to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Two additional heaters were subsequently fabricated and have completed 3178 cycles to date in an on-going test.

Soulas, George C.↗

NASA NTRS1994

Status of Hollow Cathode Heater Development for the Space Station Plasma Contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Heater tests included testing of the heater unit alone and plasma contactor and ion thruster testing. To date, eight heaters have been or are being processed through heater unit testing, two through plasma contactor testing and three through ion thruster testing, all using direct current power supplies. Comparisons of data from heater unit performance tests before cyclic testing, plasma contactor tests, and ion thruster tests at the ignition input current level show the average deviation of input power and tube temperature near the cathode tip to be +/-0.9 W and +/- 21 C, respectively. Heater unit testing included cyclic testing to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Four additional heaters successfully completed 6300, 6300, 700, and 700 cycles. Heater unit testing is currently ongoing for three heaters which have to date accumulated greater than 7250, greater than 5500, and greater than 5500 cycles, respectively.

Soulas, George C.↗

NASA NTRS1992

Application of fiber-reinforced bismaleimide materials to aircraft nacelle structures

Existing aircraft engine nacelle structures employ advanced composite materials to reduce weight and thereby increase overall performance. Use of advanced composite materials on existing aircraft nacelle structures includes fiber-reinforced epoxy structures and has typically been limited to regions furthest away from the hot engine core. Portions of the nacelle structure that are closer to the engine require materials with a higher temperature capability. In these portions, existing nacelle structures employ aluminum sandwich construction and skin/stringer construction. The aluminum structure is composed of many detail parts and assemblies and is usually protected by some form of ablative, insulator, or metallic thermal shield. A one-piece composite inner cowl for a new-generation engine nacelle structure has been designed using fiber-reinforced bismaleimide (BMI) materials and honeycomb core in a sandwich construction. The new composite design has many advantages over the existing aluminum structure. Multiple details were integrated into the one-piece composite design, thereby significantly reducing the number of detail parts and fasteners. The use of lightweight materials and the reduction of the number of joints result in a significant weight reduction over the aluminum design; manufacturing labor and the overall number of tools required have also been reduced. Several significant technical issues were addressed in the development of a BMI composite design. Technical evaluation of the available BMI systems led to the selection of a toughened BMI material which was resistant to microcracking under thermal cyclic loading and enhanced the damage tolerance of the structure. Technical evaluation of the degradation of BMI materials in contact with aluminum and other metals validated methods for isolation of the various materials. Graphite-reinforced BMI in contact with aluminum and some steels was found to degrade in salt spray testing. Isolation techniques such as those used for graphite-reinforced epoxy structures were shown to provide adequate protection. The springback and producibility of large BMI structures were evaluated by manufacturing prototype hardware which had the full-scale cross section of the one-piece composite structure.

Peros, Vasilios↗

NASA NTRS1995

Power MOSFETs Formed In Silicon Carbide

High-performance power metal/oxide/semiconductor field-effect transistors (MOSFETs) fabricated in silicon carbide. Devices offer potential advantages over silicon-based MOSFETs, including lower "on" - state resistances at same rated voltages, ability to operate at higher temperatures, and higher thermal conductivity. Also more resistant to damage by ionizing radiation, an advantage for switching appications in nuclear facilities.

Palmour, John W.↗

NASA NTRS2001

Paper-Thin Coating Offers Maximum Protection

Wessex Incorporated has recently taken a technology that was originally developed for NASA as a protective coating for ceramic materials used in heatshields for space vehicles, and modified it for use in applications such as building materials, machinery, and transportation. The technology, developed at NASA Ames Research Center as a protective coating for flexible ceramic composites (PCC), is environmentally safe, water-based, and contains no solvents. Many other flame-retardant materials contain petroleum-based components, which can produce toxic smoke under flame. Wessex versions of PCC can be used to shield ceramics, wood, plasterboard, steel, plastics, fiberglass, and other materials from catastrophic fires. They are extraordinarily tough and exhibit excellent resistance to thermal shock, vibration, abrasion, and mechanical damage. One thin layer of coating provides necessary protection and allows for flexibility while avoiding excessive weight disadvantages. The coating essentially reduces the likelihood of the underlying material becoming so hot that it combusts and thus inhibits the "flashover" phenomenon from occurring.

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NASA NTRS1996

Silicon Carbide Epitaxial Films Studied by Atomic Force Microscopy

Silicon carbide (SiC) holds great potential as an electronic material because of its wide band gap energy, high breakdown electric field, thermal stability, and resistance to radiation damage. Possible aerospace applications of high-temperature, high-power, or high-radiation SiC electronic devices include sensors, control electronics, and power electronics that can operate at temperatures up to 600 C and beyond. Commercially available SiC devices now include blue light-emitting diodes (LED's) and high-voltage diodes for operation up to 350 C, with other devices under development. At present, morphological defects in epitaxially grown SiC films limit their use in device applications. Research geared toward reducing the number of structural inhomogeneities can benefit from an understanding of the type and nature of problems that cause defects. The Atomic Force Microscope (AFM) has proven to be a useful tool in characterizing defects present on the surface of SiC epitaxial films. The in-house High-Temperature Integrated Electronics and Sensors (HTIES) Program at the NASA Lewis Research Center not only extended the dopant concentration range achievable in epitaxial SiC films, but it reduced the concentration of some types of defects. Advanced structural characterization using the AFM was warranted to identify the type and structure of the remaining film defects and morphological inhomogeneities. The AFM can give quantitative information on surface topography down to molecular scales. Acquired, in part, in support of the Advanced High Temperature Engine Materials Technology Program (HITEMP), the AFM had been used previously to detect partial fiber debonding in composite material cross sections. Atomic force microscopy examination of epitaxial SiC film surfaces revealed molecular-scale details of some unwanted surface features. Growth pits propagating from defects in the substrate, and hillocks due, presumably, to existing screw dislocations in the substrates, were imaged. Away from local defects, step bunching was observed to yield step heights of hundreds of angstroms, with possible implications for the uniformity of dopants incorporated in SiC devices during fabrication. The quantitative topographic data from the AFM allow the relevant defect information to be extracted, such as the size and distribution of step bunching and the Burgers vector of screw dislocations. These atomic force microscopy results have furthered the understanding of the dynamic epitaxial SiC growth process. A model describing the observed hillock step bunching has been proposed. This cooperation between researchers involved in crystal growth, electronic device fabrication, and surface structural characterization is likely to continue as atomic force microscopy is used to improve SiC films for high-temperature electronic devices for NASA's advanced turbine engines and space power devices, as well as for future applications in the automotive industry.

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NASA NTRS2005

Discrete Event Supervisory Control Applied to Propulsion Systems

The theory of discrete event supervisory (DES) control was applied to the optimal control of a twin-engine aircraft propulsion system and demonstrated in a simulation. The supervisory control, which is implemented as a finite-state automaton, oversees the behavior of a system and manages it in such a way that it maximizes a performance criterion, similar to a traditional optimal control problem. DES controllers can be nested such that a high-level controller supervises multiple lower level controllers. This structure can be expanded to control huge, complex systems, providing optimal performance and increasing autonomy with each additional level. The DES control strategy for propulsion systems was validated using a distributed testbed consisting of multiple computers--each representing a module of the overall propulsion system--to simulate real-time hardware-in-the-loop testing. In the first experiment, DES control was applied to the operation of a nonlinear simulation of a turbofan engine (running in closed loop using its own feedback controller) to minimize engine structural damage caused by a combination of thermal and structural loads. This enables increased on-wing time for the engine through better management of the engine-component life usage. Thus, the engine-level DES acts as a life-extending controller through its interaction with and manipulation of the engine s operation.

Litt, Jonathan S.↗

NASA NTRS2008

Operability of an Ejector Enhanced Pulse Combustor in a Gas Turbine Environment

A pressure-gain combustor comprised of a mechanically valved, liquid fueled pulsejet, an ejector, and an enclosing shroud, was coupled to a small automotive turbocharger to form a self-aspirating, thrust producing gas turbine engine. The system was constructed in order to investigate issues associated with the interaction of pulsed combustion devices and turbomachinery. Installed instrumentation allowed for sensing of distributed low frequency pressure and temperature, high frequency pressure in the shroud, fuel flow rate, rotational speed, thrust, and laboratory noise. The engine ran successfully and reliably, achieving a sustained thrust of 5 to 6 lbf, and maintaining a rotor speed of approximately 90,000 rpm, with a combustor pressure gain of approximately 4 percent. Numerical simulations of the system without pressure-gain combustion indicated that the turbocharger would not operate. Thus, the new combustor represented a substantial improvement in system performance. Acoustic measurements in the shroud and laboratory indicated turbine stage sound pressure level attenuation of 20 dB. This is consistent with published results from detonative combustion experiments. As expected, the mechanical reed valves suffered considerable damage under the higher pressure and thermal loading characteristics of this system. This result underscores the need for development of more robust valve systems for this application. The efficiency of the turbomachinery components did not appear to be significantly affected by unsteadiness associated with pulsed combustion, though the steady component efficiencies were already low, and thus not expected to be particularly sensitive.

Paxson, Daniel E.↗

NASA NTRS2013

Polymers Advance Heat Management Materials for Vehicles

For 6 years prior to the retirement of the Space Shuttle Program, the shuttles carried an onboard repair kit with a tool for emergency use: two tubes of NOAX, or "good goo," as some people called it. NOAX flew on all 22 flights following the Columbia accident, and was designed to repair damage that occurred on the exterior of the shuttle. Bill McMahon, a structural materials engineer at Marshall Space Flight Center says NASA needed a solution for the widest range of possible damage to the shuttle s exterior thermal protection system. "NASA looked at several options in early 2004 and decided on a sealant. Ultimately, NOAX performed the best and was selected," he says. To prove NOAX would work effectively required hundreds of samples manufactured at Marshall and Johnson, and a concerted effort from various NASA field centers. Johnson Space Center provided programmatic leadership, testing, tools, and crew training; Glenn Research Center provided materials analysis; Langley Research Center provided test support and led an effort to perform large patch repairs; Ames Research Center provided additional testing; and Marshall provided further testing and the site of NOAX manufacturing. Although the sealant never had to be used in an emergency situation, it was tested by astronauts on samples of reinforced carbon-carbon (RCC) during two shuttle missions. (RCC is the thermal material on areas of the shuttle that experience the most heat, such as the nose cone and wing leading edges.) The material handled well on orbit, and tests showed the NOAX patch held up well on RCC.

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NASA NTRS2007

Kennedy Space Center (KSC) Launch Pad Avian Abatement Efforts Including Related KSC Road Kill Reduction Effort

While birds might seem harmless, there's a good reason for the concern. During the July 2005 launch of Discovery on mission STS-1 14, a vulture soaring around the launch pad impacted the shuttle's external tank just after liftoff. With a vulture's average weight ranging from 3 to 5 pounds. a strike at a critical point on the Shuttle -- like the nose or wing leading thermal protection panels -- could cause catastrophic damage to the vehicle. The foam chunk that fatefully struck Columbia's wing in 2003 weighed only 1.7 pounds. (Cheryl L. Mansfield "Bye Bye Birdies" 2006) To address this issue, NASA formed an "Avian Abatement Team". The team goal is to have safer Shuttle missions by reducing the vulture population at KSC near the pad area thereby reducing the probability of another vulture strike during a Shuttle launch.

Schlierf, Roland↗

NASA NTRS2017

Thermal Protection for Mars Sample Return Earth Entry Vehicle: A Grand Challenge for Design Methodology and Reliability Verification

Mars Sample Return is our Grand Challenge for the coming decade. TPS (Thermal Protection System) nominal performance is not the key challenge. The main difficulty for designers is the need to verify unprecedented reliability for the entry system: current guidelines for prevention of backward contamination require that the probability of spores larger than 1 micron diameter escaping into the Earth environment be lower than 1 million for the entire system, and the allocation to TPS would be more stringent than that. For reference, the reliability allocation for Orion TPS is closer to 11000, and the demonstrated reliability for previous human Earth return systems was closer to 1100. Improving reliability by more than 3 orders of magnitude is a grand challenge indeed. The TPS community must embrace the possibility of new architectures that are focused on reliability above thermal performance and mass efficiency. MSR (Mars Sample Return) EEV (Earth Entry Vehicle) will be hit with MMOD (Micrometeoroid and Orbital Debris) prior to reentry. A chute-less aero-shell design which allows for self-righting shape was baselined in prior MSR studies, with the assumption that a passive system will maximize EEV robustness. Hence the aero-shell along with the TPS has to take ground impact and not break apart. System verification will require testing to establish ablative performance and thermal failure but also testing of damage from MMOD, and structural performance at ground impact. Mission requirements will demand analysis, testing and verification that are focused on establishing reliability of the design. In this proposed talk, we will focus on the grand challenge of MSR EEV TPS and the need for innovative approaches to address challenges in modeling, testing, manufacturing and verification.

Design and Verification for Reliability↗

NASA NTRS2018

Radiation Transport and Shielding Challenges at NASA Marshall Space Flight Center

Several unique radiation transport and shielding challenges for various spacecraft and ground test facilities have recently been explored at NASA Marshall Space Flight Center (MSFC). Many radiation transport methods and code packages have been utilized during this effort, and some additional analytical tools have been developed to support this work. This includes the development of a nuclear thermal propulsion stage, in which radiation damage to hardware, radiation heating, and crew dose must be assessed for a large spacecraft. Radiation shielding for such a stage must be optimized to minimize weight, and additional dose consequences are expected from cosmic sources. Development of a nuclear engine requires ground test facilities, which themselves require significant development effort that includes deep-penetration shielding analysis for facility design and site selection. Additional radiation transport analysis has been performed in support of a notional lander mission to Europa, the icy moon of Jupiter. The radiation burden to spacecraft has been analyzed, and charged particle radiation transport methods have been utilized to apply correct doses to material samples in ground test facilities.

Caffrey, Jarvis A.↗

NASA NTRS2019

Thermally-Induced Healing of Electrically-Insulating Ethylene-Octene Copolymers

We report on electrical insulating materials that not only have sufficient mechanical toughness to survive use conditions, but also possess the ability to undergo thermally induced self-repair when damaged. By controlling the cross-link density, a modified ethylene-octene copolymer (EOC) is able to retain its self-healing abilities while also being used at temperatures greater than the original, unmodified polymer. Specifically, an EOC cross-linked with 0.25 wt% dicumyl peroxide affords a material ability to recover 61% of its critical fracture energy — a value similar to thermoplastic EOC. Furthermore, as shown by dielectric spectroscopy, the cross-linked EOC retains good electrically-insulating properties.

Self-healing↗