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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Shear strength of fillet welds in aluminum alloy 2219

Fillet size is discussed in terms of theoretical or design dimensions versus as-welded dimensions, drawing attention to the inherent conservatism in the design load sustaining capabilities of fillet welds. Emphasis is placed on components for the solid rocket motor, external tank, and other aerospace applications. Problems associated with inspection of fillet welds are addresses and a comparison is drawn between defect counts obtained by radiographic inspection and by visual examination of the fracture plane. Fillet weld quality is related linearly to ultimate shear strength. Correlation coefficients are obtained by simple straight line regression analysis between the variables of ultimate shear strength and accumulative discontinuity summation. Shear strength allowables are found to be equivalent to 57 percent of butt weld A allowables (F sub tu.)

Lovoy, C. V.↗
NASA NTRS1993

Generic propellant transfer unit: A project update

Currently, most satellite programs use dedicated hypergolic propellant ground servicing equipment. These 'carts' are typically program specific (non-interchangeable), costly, and non-Department of Transportation (DOT) compliant. They require safety waivers when used on government property and must be emptied before off-site transport. The emptying process usually generates large amounts of Hazardous Wastes. Fuel carts are usually loaded from multiple 208-liter (55 gallon) drums and oxidizer carts from 909-kg (2000 lb) cylinders. This further increases operating costs due to additional container samples and cart-filling transfers. NASA, Kennedy Space Center has developed reusable, generic, DOT compliant propellant delivery containers as possible replacements for the propellant-tank portion of servicing carts. Our ultimate goal is to reduce operating expenses by minimizing propellant transfers, samples, and waste generation through use of bulk propellant operations, minimizing drum or cylinder operations. This has the added benefit of increasing operating safety by decreasing overall propellant operations.

Davis, C. L.↗
NASA NTRS1974

Effects of porosity on weld-joint tensile strength of aluminum alloys

Tensile properties in defect-free weldments of aluminum alloys 2014-T6 and 2219-T87 (sheet and plate) are shown to be related to the level or concentration of induced simulated porosity. The scatter diagram shows that the ultimate tensile strength of the weldments displays the most pronounced linear relationship with the level of porosity. The relationships between yield strength or elongation and porosity are either trivial or inconsequential in the lower and intermediate levels of porosity content. In highly concentrated levels of porosity, both yield strength and elongation values decrease markedly. Correlation coefficients were obtained by simple straight line regression analysis between the variables of ultimate tensile strength and pore level. The coefficients were greater, indicating a better correlation, using a pore area accumulation concept or pore volume accumulation than the accumulation of the pore diameters. These relationships provide a useful tool for assessing the existing aerospace radiographic acceptance standards with respect to permissible porosity. In addition, these relationships, in combination with known design load requirements, will serve as an engineering guideline in determining when a weld repair is necessary based on accumulative pore level as detected by radiographic techniques.

Lovoy, C. V.↗
NASA NTRS2016

The International Space Station (ISS) Solar Alpha Rotary Joint (SARJ): Materials & Processes (M&P) Lessons Learned for a Large, Rotating Spacecraft Mechanism

The International Space Station (ISS) utilizes two large rotating mechanisms, the solar alpha rotary joints (SARJs), as part of the solar arrays' alignment system for more efficient power generation. Each SARJ is a 10.3m circumference, nitrided 15-5PH steel race ring of triangular cross-section, with 12 sets of trundle bearing assemblies transferring load across the rolling joint. The SARJ mechanism rotates continuously and slowly - once every orbit, or every 90 minutes. In 2007, the starboard SARJ suffered a lubrication failure, resulting in severe damage (spalling) to one of the race ring surfaces. Extensive effort was conducted to prevent the port SARJ from suffering the same failure, and fortunately that effort was ultimately successful in also recovering the functionality of the starboard SARJ. The M&P engineering function was key in determining the cause of failure and the means for mechanism recovery. From a M&P lessons-learned perspective, observations are made concerning the original SARJ design parameters (boundary conditions), the perceived need for nitriding the race ring, the test conditions employed during qualification, the environmental controls used for the hardware preflight, and the lubrication robustness necessary for complex kinematic mechanisms expecting high-reliability and long-life.

Golden, Johnny L.↗
DOE OSTI2025

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1992

Design and analysis of seals for extended service life

Space Station Freedom is being developed for a service life of up to thirty years. As a consequence, the design requirements for the seals to be used are unprecedented. Full scale testing to assure the selected seals can satisfy the design requirements are not feasible. As an alternative, a sub-scale test program has been developed by MSFC to calibrate the analysis tools to be used to certify the proposed design. This research has been conducted in support of the MSFC Integrated Seal Test Program. The ultimate objective of this research is to correlate analysis and test results to qualify the analytical tools, which in turn, are to be used to qualify the flight hardware. This research is totally focused on O-rings that are compressed by perpendicular clamping forces. In this type of seal the O-ring is clamped between the sealing surfaces by loads perpendicular to the circular cross section.

Bower, Mark V.↗
DOE OSTI2021

Tailored Fiber Placement for Complex Preforms

Tailored Fiber Placement (TFP) offers a novel approach to optimize fiber architecture for the fabrication of complex, structural parts not traditionally suitable for advanced composites. This technology not only offers new routes for weight reduction via metal substitution, it also offers cost reduction through minimization of material scrap and reduced labor. This reduction in component weight leads to increased fuel efficiency, and reduced production energy consumption, thereby, helping to achieve the stated IACMI technical goals. This technology leverages centuries of manufacturing development in support of the textile and embroidery industry. One major drawback to this technology is the lack of commercial or non- proprietary structural performance data and robust analytical tools used to optimize fiber architecture and predict performance. This project was structured to utilize common sub-element features to validate analytical performance tools, generate performance data, and gather cost and performance data on components of interest. This project was designed to give industry sponsors the confidence and ability to take full advantage of TFP to fabricate primary, highly loaded structure and integrate features such as metallic fasteners. The project focused principally on the use of high strength carbon fiber, such as T700, and the use of aerospace epoxy resin matrix to primarily support development of new composite applications in vehicle, aerospace, and industrial markets. This project applied previously developed analytical tools to predict the performance of TFP produced parts. This work focused on developing the pipeline to characterize material in order to accurately predict component performance when modifying the TFP print paths and stitch density. This focused on experimental characterization via standardized ASTM testing, alongside experimental testing of more representative service components by testing curved beam strength, beam shear performance, a large scale TFP lug, and ultimately designing a fully TFP clip bracket that reduced weight and cost compared to a traditional metallic component. The new knowledge gained from this program included: 1) development and demonstration of novel analytical tools applied to analysis of TFP preforms; 2) development and demonstration of a building block approach using coupons and sub-elements to optimize the design of a more complex component; 3) demonstration that optimized fiber orientation using TFP can exceed performance of conventional textile composite materials and can open new applications currently limited to metallic components; 4) Demonstration of performance and cost benefits of the TFP process as compared to metallic and conventional textile composites. Recommendations for follow-on work include development of design allowables to assess the impact of high temperature/moisture exposure or saturation during loading, tracking the impact of stitching needle wear on the performance of parts and ability to stitch thicker preforms, using TFP preforms as local reinforcement at areas of bearing or complex loading, and topology optimization of components by tow steering. The expertise developed during the course of this project can be leveraged to provide commercial engineering design and fabrication services using TFP. UDRI is in the process of formalizing their partnership with Spintech, who will serve as the commercialization partner for this technology and provide molding services and deliver finished components to the end user. UDRI will continue to produce the preforms until the economics allow Spintech to procure its own TFP equipment or lease UDRI equipment, at which point UDRI will step away from manufacture and serve as the engineering and design lead on product development.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Interactions between fullerene derivatives and biological systems

Attention towards nanoparticles from the pharmaceutical and biomedical fields has significantly increased due to their attractive surface modification, high drug-loading, and improved pharmacokinetics. Fullerenes, an allotrope of carbon, stand out for their molecularly precise structure, potent radical-scavenging activity, photoactivatable reactive-oxygen species generation, and ability to definitively confine metal atoms and clusters. Accordingly, fullerene systems have been applied in various biological contexts, including increased and controlled drug delivery, antioxidative, anti-inflammatory, and photodynamic therapy, and magnetic resonance imaging. Ultimately, the pleiotropic activity of fullerenes, coupled with its precise structure and functionalization, can realize precise and tailorable medicines. Here, different from some excellent reviews focusing on the structure and chemistry of fullerene derivatives and their biomedical applications, this review highlights the interaction of fullerene materials with biological systems, with insights into their structural influence on their interactions with the cellular environment.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Fatigue characterization of advanced carbon-carbon composites

Response of quasi-isotropic laminates of SiC coated Carbon-Carbon (C/C) composites under flexural fatigue are investigated at room temperature. Virgin as well as mission cycled specimens are tested to study the effects of thermal and pressure cycling on the fatigue performance of C/C. Tests were conducted in three point bending with a stress ratio of 0.2 and frequency of 1 Hz. Fatigue strength of C/C has been found to be considerably high - approximately above 85 percent of the ultimate flexural strength. The fatigue strength appears to be decreasing with the increase in the number of mission cycling of the specimens. This lower strength with the mission cycled specimens is attributed to the loss of interfacial bond strength due to thermal and pressure cycling of the material. C/C is also found to be highly sensitive to the applied stress level during cyclic loading, and this sensitivity is observed to increase with the mission cycling. Weibull characterization on the fatigue data has been performed, and the wide scatter in the Weibull distribution is discussed. Fractured as well as untested specimens were C-scanned, and the progressive damage growth during fatigue is presented.

Mahfuz, Hassan↗
DOE OSTI2022

Technology Integration to Gain Commercial Efficiency for the Urban Goods Delivery System, Meet Future Demand for City Passenger and Delivery Load/Unload Spaces, and Reduce Energy Consumption

This three-year project supported by the U.S. Department of Energy Vehicle Technologies Office has the potential to radically improve the urban freight system in ways that help both the public and private sectors. Working from 2018-2021, project researchers at the University of Washington’s Urban Freight Lab and collaborators at the Pacific Northwest National Laboratory have produced key data, tested technologies in complex urban settings, developed a prototype parking availability app, and helped close major knowledge gaps. All the fruits of this project can be harnessed to help cities better understand, support and actively manage truck load/unload operations and their urban freight transport infrastructure. Project learnings and tools can be used to help make goods delivery firms more efficient by reducing miles traveled and the time it takes to complete deliveries, benefitting businesses and residents who rely on the urban freight system for supplies of goods. And, ultimately, these project learnings and tools can be used to make cities more livable by minimizing wasted travel, which, in turn, contributes to reductions in fuel consumption and emissions. Cities today are challenged to effectively and efficiently manage their infrastructure to absorb the impacts of ever-increasing e-commerce-fueled delivery demand. All delivery trucks need to park somewhere to unload and load. Yet today’s delivery drivers have no visibility on available parking until they arrive at a site, which may be full. That means they can wind up cruising for parking, which wastes time and fuel and contributes to congestion. Once drivers do find parking, the faster they can unload at the spot, the faster they free up space for other drivers, helping others avoid circling for parking. This makes the parking space—and thus the greater load/unload network—more productive. To this end, the research team successfully met the project’s three goals, developing and piloting strategies and technologies to: 1. Reduce parking-seeking behavior in the study area by 20%; 2. Reduce parcel truck dwell time (the time a truck spends in a spot to load/unload) in the study area by 30%; 3. Increase curb space, alley space and private loading bay occupancy rates in the study area. The research team met these goals by creating and piloting on Seattle streets OpenPark, a first-of-its-kind real-time and forecasting curb parking app customized for commercial delivery drivers—giving drivers the “missing link” in their commonly used routing tools that tell them how best to get to delivery locations, but not what parking is available to use when they get there. Installing in-ground sensors on commercial vehicle load zones (CVLZs) and passenger load zones (PLZs) in the 10-block study area in Seattle’s downtown neighbourhood of Belltown let researchers glean real-time curb parking data. The research team also met project goals by piloting three parcel lockers in public and private spaces open to any delivery carrier, creating a consolidated delivery hub that lets drivers complete deliveries faster and spend less time parked. Researchers collected and analysed data to produce the first empirical, robust, statistically significant results as to the impact of the lockers, and app, on on-the-ground operations. In addition to collecting and analyzing sensor and other real-time and historical data, researchers rode along with delivery drivers to confirm real-world routing and parking behavior. Researchers also surveyed building managers on their private loading bay operations to understand how to boost usage.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1996

Crash-Energy Absorbing Composite Structure and Method of Fabrication

A stand-alone, crash-energy absorbing structure and fabrication method are provided. A plurality of adjoining rigid cells are each constructed of resin-cured fiber reinforcement and are arranged in a geometric configuration. The fiber reinforcement can be in the form of a fabric or braided fibers wrapped about a core that is either left in place or removed from the ultimate cured structure. The geometric configuration of cells is held together with more fiber reinforcement (in the form of fabric or braided fibers) in order to integrate the cells in the geometric configuration. The additional fiber reinforcement is resin-cured to the cells. Curing of the cells and ultimate structure can occur in a single step. In applications where post-crash integrity is necessary, ductile fibers can be used to integrate the cells in the geometric configuration. The novelty of the present invention is that simple fabrication techniques are used to create structures that can be formed in a variety of net stable shapes without additional reinforcement and can withstand combined loading while crushing in a desired direction.

Kellas, Sotiris↗
NASA NTRS2009

Damage Tolerance Testing of a NASA TransHab Derivative Woven Inflatable Module

Current options for Lunar habitat architecture include inflatable habitats and airlocks. Inflatable structures can have mass and volume advantages over conventional structures. However, inflatable structures carry different inherent risks and are at a lower Technical Readiness Level (TRL) than more conventional metallic structures. One of the risks associated with inflatable structures is in understanding the tolerance to induced damage. The Damage Tolerance Test (DTT) is designed to study the structural integrity of an expandable structure. TransHab (Figure 1) was an experimental inflatable module developed at the NASA/Johnson Space Center in the 1990 s. The TransHab design was originally envisioned for use in Mars Transits but was also studied as a potential habitat for the International Space Station (ISS). The design of the TransHab module was based on a woven design using an Aramid fabric. Testing of this design demonstrated a high level of predictability and repeatability with analytical predictions of stresses and deflections. Based on JSC s experience with the design and analysis of woven inflatable structures, the Damage Tolerance Test article was designed and fabricated using a woven design. The DTT article was inflated to 45 psig, representing 25% of the ultimate burst pressure, and one of the one-inch wide longitudinal structural members was severed by initiating a Linear Shaped Charge (LSC). Strain gage measurements, at the interface between the expandable elements (straps) and the nonexpandable metallic elements for pre-selected longitudinal straps, were taken throughout pressurization of the module and strap separation. Strain gage measurements show no change in longitudinal strap loading at the bulkhead interface after strap separation indicating loads in the restraint layer were re-distributed local to the damaged area due to the effects of friction under high internal pressure loading. The test completed all primary objectives with better than expected results. This paper will discuss space inflatable structures, damage tolerance analysis, test results, and applicability to the Lunar architecture.

Edgecombe, John↗
NASA NTRS2019

Combined Qualification Vibration Testing and Fixed Base Modal Testing Utilizing a Fixed Based Correction Method

Vibration testing spaceflight hardware is a vital, but time consuming and expensive endeavor. Traditionally modal tests are performed at the component, subassembly, or system level, preferably free-free with mass loaded interfaces or fixed base on a seismic mass to identify the fundamental structural dynamic (modal) characteristics. Vibration tests are then traditionally performed on single-axis slip tables at qualification levels that envelope the maximum predicted flight environment and workmanship in order to verify the spaceflight hardware can survive its flight environment. These two tests currently require two significantly different test setups, facilities, and ultimately reconfiguration of the spaceflight hardware. The vision of this research is to show how traditional fixed-base modal testing can be accomplished using vibration qualification testing facilities, which not only streamlines testing and reduces test costs, but also opens up the possibility of performing modal testing to untraditionally high excitation levels that provide for test-correlated finite element models to be more representative of the spaceflight hardware's response in a flight environment. This paper documents the first steps towards this vision, which is the comparison of modal parameters identified from a traditional fixed-based modal test performed on a modal floor and those obtained by utilizing a fixed based correction method with a large single-axis electrodynamic shaker driving a slip table supplemented with additional small portable shakers driving on the slip table and test article. To show robustness of this approach, the test article chosen is a simple linear weldment, whose mass, size, and modal parameters couple well with the dynamics of the shaker/slip table. This paper will show that all dynamics due to the shaker/slip table were successfully removed resulting in true fixed-base modal parameters, including modal damping, being successfully extracted from a traditional style base-shake vibration test setup.

Base-Shake↗
NASA NTRS1994

Test plan. GCPS task 7, subtask 7.1: IHM development

The overall objective of Task 7 is to identify cost-effective life cycle integrated health management (IHM) approaches for a reusable launch vehicle's primary structure. Acceptable IHM approaches must: eliminate and accommodate faults through robust designs, identify optimum inspection/maintenance periods, automate ground and on-board test and check-out, and accommodate and detect structural faults by providing wide and localized area sensor and test coverage as required. These requirements are elements of our targeted primary structure low cost operations approach using airline-like maintenance by exception philosophies. This development plan will follow an evolutionary path paving the way to the ultimate development of flight-quality production, operations, and vehicle systems. This effort will be focused on maturing the recommended sensor technologies required for localized and wide area health monitoring to a technology readiness level (TRL) of 6 and to establish flight ready system design requirements. The following is a brief list of IHM program objectives: design out faults by analyzing material properties, structural geometry, and load and environment variables and identify failure modes and damage tolerance requirements; design in system robustness while meeting performance objectives (weight limitations) of the reusable launch vehicle primary structure; establish structural integrity margins to preclude the need for test and checkout and predict optimum inspection/maintenance periods through life prediction analysis; identify optimum fault protection system concept definitions combining system robustness and integrity margins established above with cost effective health monitoring technologies; and use coupons, panels, and integrated full scale primary structure test articles to identify, evaluate, and characterize the preferred NDE/NDI/IHM sensor technologies that will be a part of the fault protection system.

Greenberg, H. S.↗
DOE OSTI2024

Strengthening mechanisms for microstructures containing unimodal and bimodal γ' precipitates in ATI 718Plus

Here, the influence of γ' precipitate size distribution on the deformation mechanisms under tensile loading in ATI 718Plus was studied. A set of aging treatments within the temperature range of 720 °C–900 °C was performed on solution-treated samples to obtain various γ' precipitate size distributions. Unimodal and bimodal γ' precipitate size distributions were achieved through single-step and two-step aging sequences, respectively, and such microstructures were tensile tested to failure to assess their yield strength, ultimate tensile strength, and elongation-to-failure. Some of the tensile samples were interrupted after achieving 3–4 % plastic strain, and the deformed microstructures were examined using transmission electron microscopy to investigate the γ' precipitate-dislocation interactions. For the unimodal γ' precipitate size distribution samples with the smaller γ' precipitates (radius ~ 7 nm), dislocations sheared through the precipitates. Both dislocation loops and paired dislocations were observed for the microstructures containing larger γ' precipitates (radius ~ 24 nm). The microstructure containing a bimodal γ' precipitate size distribution, which included average γ' precipitate radii of ~6 nm and ~28 nm, exhibited shearing as the dominant deformation mechanism, and this microstructure exhibited the highest strength values. The experimental observations were rationalized based on the theoretically-calculated critical resolved shear stress values for shearing and looping and a modified model for predicting the yield strength for bimodal microstructures was introduced.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Uniaxial and biaxial tensioning effects on thin membrane materials

Thin laminated membranes are being considered for various surface applications on future large space structural systems. Some of the thin membranes would be stretched across or between structural members with the requirement that the membrane be maintained within specified limits of smoothness which would be dictated by the particular applications such as antenna reflector requirements. The multiaxial tensile force required to maintain the smoothness in the membrane needs to be determined for use in the structure design. Therefore, several types of thicknesses of thin membrane materials have been subjected to varied levels of uniaxial and biaxial tensile loads. During the biaxial tests, deviations of the material surface smoothness were measured by a noncontacting capacitance probe. Basic materials consisted of composites of vacuum deposited aluminum on Mylar and Kapton ranging in thickness from 0.00025 in (0.000635 cm) to 0.002 in (0.00508 cm). Some of the material was reinforced with Kevlar and Nomex scrim. The uniaxial tests determined the material elongation and tensile forces up to ultimate conditions. Biaxial tests indicated that a relatively smooth material surface could be achieved with tensile force of approximately 1 to 15 Newtons per centimeter, depending upon the material thickness and/or reinforcement.

Hinson, W. F.↗
DOE OSTI2020

Novel PBX formulations containing thermally-expandable microspheres for on-demand control of explosive behavior

In this work, we present the formulation and analysis of inert Plastic-Bonded eXplosive (PBX)-surrogates loaded with thermally expandable microspheres (TEMs). TEMs consist of a thermoplastic acrylonitrile shell (10-50 µm diameter) encapsulating an inert low boiling hydrocarbon. Upon heating, the TEMs expand as the shell softens while the hydrocarbon gasifies, increasing the internal pressure and expanding the particle by as much as 120 vol%. We hypothesize that TEM expansion within a PBX will introduce tunable changes in local density and porosity, and ultimately the shock sensitivity. This paper focuses on microstructural analysis of surrogate PBX-TEM formulations, both before and after thermally- induced TEM expansion. The formulations were analyzed by scanning electron microscopy (SEM), ultra-small angle neutron scattering (USANS), and X-ray Computed Tomography (x-ray CT) under various thermal conditions. Evidence suggests that TEM expansion within a PBX is a viable method to impart microstructural changes that are predicted to have a measurable, on-demand effect on the initiation sensitivity. Future work includes development of PBX-TEM formulations with HMX and shock initiation experiments.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗