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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Materials Safety - Not just Flammability and Toxic Offgassing

For many years, the safety community has focused on a limited subset of materials and processes requirements as key to safety: Materials flammability, Toxic offgassing, Propellant compatibility, Oxygen compatibility, and Stress-corrosion cracking. All these items are important, but the exclusive focus on these items neglects many other items that are equally important to materials safety. Examples include (but are not limited to): 1. Materials process control -- proper qualification and execution of manufacturing processes such as structural adhesive bonding, welding, and forging are crucial to materials safety. Limitation of discussions on materials process control to an arbitrary subset of processes, known as "critical processes" is a mistake, because any process where the quality of the product cannot be verified by inspection can potentially result in unsafe hardware 2 Materials structural design allowables -- development of valid design allowables when none exist in the literature requires extensive testing of multiple lots of materials and is extremely expensive. But, without valid allowables, structural analysis cannot verify structural safety 3. Corrosion control -- All forms of corrosion, not just stress corrosion, can affect structural integrity of hardware 4. Contamination control during ground processing -- contamination control is critical to manufacturing processes such as adhesive bonding and also to elimination foreign objects and debris (FOD) that are hazardous to the crew of manned spacecraft in microgravity environments. 5. Fasteners -- Fastener design, the use of verifiable secondary locking features, and proper verification of fastener torque are essential for proper structural performance This presentation discusses some of these key factors and the importance of considering them in ensuring the safety of space hardware.

Pedley, Michael D.↗
NASA NTRS1973

Preliminary weight and cost estimates for transport aircraft composite structural design concepts

Preliminary weight and cost estimates have been prepared for design concepts utilized for a transonic long range transport airframe with extensive applications of advanced composite materials. The design concepts, manufacturing approach, and anticipated details of manufacturing cost reflected in the composite airframe are substantially different from those found in conventional metal structure and offer further evidence of the advantages of advanced composite materials.

Source record↗
NASA NTRSDate not supplied

Establishing and Maintaining the Digital Thread of Additively Manufactured Materials and Applications

Additive Manufacturing (AM) and Integrated Computational Materials Engineering (ICME) are complementary enabling technologies for design and manufacturing of “fit-for-purpose” materials. Both technologies will impact rapid material design, reduction in cost- and time-to-market for new applications, and discovery and implementation of new materials. An ICME approach to design, however, requires experimentally validated material models at multiple length and time scales, an integrated framework that can connect analysis tools with one another to ensure the digital thread of an application is maintained, and the manufacturing (e.g., AM) capability to leverage processing-structure-property-performance (PSPP) relationships to achieve spatially varying material properties where desired. AM enables the implementation of the design of an optimized, spatially varying microstructure through careful selection of the processing parameters used during an additively manufactured build. In order to establish these PSPP relations, a large amount of data is necessary, and that data must be properly captured, analyzed and maintained in an information management system that can establish the required traceability between various aspects of the design process to ensure an application’s digital thread is maintained (from design to end of life). Such an information management system must be able to capture feedstock material pedigree, resulting microstructure from various build parameters, subsequent mechanical properties derived from testing, developed material models, and enable spatial variations in material assignment in an engineering application. Furthermore, the information management system should be easily integrated with traditionally engineered materials in a single, centralized platform to enable an ICME optimization tool to explore both types of manufacturing processes. At NASA GRC, a robust, 21st century materials information management system has been previously developed with a focus towards enabling ICME. In this work, GRC’s ICME schema is extended to accommodate additively manufactured materials, enabling storage of both traditionally and additively manufactured materials in the same construct. The methodology for properly capturing additively manufactured materials across the entire material lifecycle is presented, following the previously established database best practices, as a potential framework for establishing PSPP relationships for additively manufactured materials and applying them to engineering applications.

Data management↗
NASA NTRS2010

Turbopump Seal Testing at Marshall Space Flight Center

The new ARES space flight program has presented many challenges to aerospace engineers and designers. One of the areas for consideration are the seals in the turbopumps that supply cryogenic propellants to the combustion chamber in the upper stage. Heritage face seals that worked in the past might not be sufficient in the newer turbopumps with increased speeds, pressures across the seals, and loads. New seal materials, engineering designs, and analysis techniques have been developed since the early use of these heritage seals, however, rub conditions and surface degradation at the sliding contact cannot be reliably predicted. Testing is required to determine the safe operating limits and verify seal wear life over the operating range. Rocketdyne in Canoga Park California entered into a task agreement with MSFC to design, fabricate, build, test, disassemble, and inspect hardware after tests of carbon materials and wear resistant coatings. The purpose of testing would be to determine the safe operating limits, empirically iterate the design, and select the best combination of materials for face seals and mating rings. This paper summarizes the many hours and efforts of individuals and teams to get the program operating successfully and presents the test results that were obtained.

Gibson, Howard G.↗
NASA NTRS1984

Hot stage and sample cell design for the solidification of transparent materials with and without forced convection

A temperature gradient stage design for optical microscopy is described. Exceptional thermal stability is the major feature. The stage is used to study crystal growth phenomena occurring at the solid-liquid interface. The apparatus is designed to use transparent organic solutions as models for the study of metal-like solidification. The stage provides a controlled thermal environment for unidirectional solidification of low melting temperature materials. Freezing rate is regulated by mechanically sliding in the stage a thin glass cell containing the materials being studied. Two cell assemblies are described. One type is used for convection-free and the other for controlled forced convection studies of the solidification interface.

Kaukler, W. F.↗
NASA NTRSDate not supplied

Predicting Fiber Failure of Plain Weave Fabric with Recursive Multiscale Micromechanics

Recent advances in the development of machine learning (ML) algorithms have enabled the creation of predictive models that can improve decision making, decrease computational cost, and improve efficiency in a variety of fields. As an organization begins to develop and implement such models, the data used in the training, validation, and testing of machine learning models, the model parameters, and the use cases or limitations of the models must be properly stored to ensure models are both fully traceable and used correctly. In the context of predicting material behavior, advances in computationally intense, physics-based, modeling of material behavior at various length scales, and the emergence of Integrated Computational Materials Engineering (ICME) have driven the need for developing data-driven surrogate models of the physics-based simulation tools using machine learning (ML) techniques. Surrogate model development allows for accurate material behavior prediction at a fraction of the cost of its physics-based counterpart, allowing for multiscale simulations of real-world applications, further enabling the ability to design fit-for-purpose materials for a reasonable computational investment. However, training such models requires extensive data, and thus effective data management is necessary to reach the full potential that ML can offer to material design and ICME. This paper proposes a generalized, robust schema that allows organizations to store both real (experimental) and virtual (simulation) data used to train machine learning models and the defining model parameters and architectures. The developed schema allows for various types of data inputs and outputs, including single point values, time-series data, and images that can be used in for various types of machine learning models while following outlined best practices for effective data management. An effective schema for machine learning data and models can help prevent the recreation of virtual/real training data and surrogate models, can help reduce the time to create new models similar to existing ones by offering a starting point in the hyperparameter determination stages, minimize resources devoted to verification and validation (V&V) and certification of models, and ensure that data and surrogate models are not misused due to full traceability of both the data and ML model. It also allows organizations access to models that have already been developed, such that they can be used in the design of new materials, enabling the overall goals of ICME.

Failure↗
NASA NTRS1964

Spacecraft structural concepts.

Thermal strains, deformations, stresses and fluctuating and static pressures on spacecraft in terms of structural design and material selection

STRUCTURAL STRAIN↗
NASA NTRS1972

Status of reusable surface insulation thermal protection system technology programs

The development of three low-density rigidized insulation materials for the shuttle TPS application is reported. These materials consist of one high purity silica system and two systems based on mullite, an aluminum silicate. Both systems consist of fibers joined together with appropriate binders to obtain a rigidized insulation composite. Both material systems require the application of a glassy coating to provide a wear resistant, high emittance surface and to prevent the absorption of water by the fiber matrix. The technology program has addressed the development of water impervious coatings, methods of assembling the materials in design concepts while minimizing the thermal stress in the insulation, achieving compatibility between the RSI material and the structural system, and test evaluations to demonstrate the feasibility of the surface insulation concept.

Greenshields, D. H.↗
NASA NTRS1992

Designing, engineering, and testing wood structures

The objective of this paper is to introduce basic structural engineering concepts in a clear, simple manner while actively involving students. This project emphasizes the fact that a good design uses materials efficiently. The test structure in this experiment can easily be built and has various design options. Even when the structure is loaded to collapsing, only one or two pieces usually break, leaving the remaining pieces intact and reusable.

Gorman, Thomas M.↗
NASA NTRS2008

Full-field Strain Methods for Investigating Failure Mechanisms in Triaxial Braided Composites

Composite materials made with triaxial braid architecture and large tow size carbon fibers are beginning to be used in many applications, including composite aircraft and engine structures. Recent advancements in braiding technology have led to commercially viable manufacturing approaches for making large structures with complex shape. Although the large unit cell size of these materials is an advantage for manufacturing efficiency, the fiber architecture presents some challenges for materials characterization, design, and analysis. In some cases, the static load capability of structures made using these materials has been higher than expected based on material strength properties measured using standard coupon tests. A potential problem with using standard tests methods for these materials is that the unit cell size can be an unacceptably large fraction of the specimen dimensions. More detailed investigation of deformation and failure processes in large unit cell size triaxial braid composites is needed to evaluate the applicability of standard test methods for these materials and to develop alternative testing approaches. In recent years, commercial equipment has become available that enables digital image correlation to be used on a more routine basis for investigation of full field 3D deformation in materials and structures. In this paper, some new techniques that have been developed to investigate local deformation and failure using digital image correlation techniques are presented. The methods were used to measure both local and global strains during standard straight-sided coupon tensile tests on composite materials made with 12 and 24 k yarns and a 0/+60/-60 triaxial braid architecture. Local deformation and failure within fiber bundles was observed, and this local failure had a significant effect on global stiffness and strength. The matrix material had a large effect on local damage initiation for the two matrix materials used in this investigation. Premature failure in regions of the unit cell near the edge of the straight-sided specimens was observed for transverse tensile tests in which the braid axial fibers were perpendicular to the specimen axis and the bias fibers terminated on the cut edges in the specimen gage section. This edge effect is one factor that could contribute to a measured strength that is lower than the actual material strength in a structure without edge effects.

Littell, Justin D.↗
NASA NTRSDate not supplied

Mars Space Suit Materials Testing Using SHERLOC Calibration Target Data: The Max-CF Project

The Mars 2020/“Perseverance” rover carries a suite of space suit materials as part of the SHERLOC* calibration target [1]. The materials are periodically analyzed by SHERLOC as part of a regular calibration routine and are generating a rich data set regarding their degradation in the martian surface environment. The Maximization of Calibration Fabrics (Max-CF) project will effectively turn SHERLOC data into a measure of space suit material service lifetimes by exposing a second set of materials in a Mars chamber, replicating SHERLOC measurements using the analogous ACRONM** instrument at JSC, and then performing materials testing to include tensile testing. These data can be used to inform space suit design and/or materials development, improving crew safety for future Mars missions. This will partially address NASA’s Strategic Knowledge Gap 8 (Mars Surface Technology) which identifies a need to develop technologies to “sustain humans on the surface of Mars [and] enable human mobility and exploration” [2]. This abstract describes the overall Max-CF project and progress on the laboratory-based study to date.

M Fries↗
NASA NTRS1992

Evaluation of an innovative high temperature ceramic wafer seal for hypersonic engine applications

A critical mechanical system in advanced hypersonic engines is the panel-edge seal system that seals gaps between the articulating engine panels and the adjacent engine splitter walls. Significant advancements in seal technology are required to meet the extreme demands placed on the seals, including the simultaneous requirements of low leakage, conformable, high temperature, high pressure, sliding operation. In this investigation, the design, development, analytical and experimental evaluation of a new ceramic wafer seal that shows promise of meeting these demands will be addressed. A high temperature seal test fixture was designed and fabricated to measure static seal leakage performance under engine simulated conditions. Ceramic wafer seal leakage rates are presented for engine-simulated air pressure differentials (up to 100 psi), and temperature (up to 1350 F), sealing both flat and distorted wall conditions, where distortions can be as large as 0.15 inches in only an 18 inch span. Seal leakage rates are low, meeting an industry-established tentative leakage limit for all combinations of temperature, pressure and wall conditions considered. A seal leakage model developed from externally-pressurized gas film bearing theory is also presented. Predicted leakage rates agree favorably with the measured data for nearly all conditions of temperature and pressure. Discrepancies noted at high engine pressure and temperature are attributed to thermally-induced, non-uniform changes in the size and shape of the leakage gap condition. The challenging thermal environment the seal must operate in places considerable demands on the seal concept and material selection. Of the many high temperature materials considered in the design, ceramics were the only materials that met the many challenging seal material design requirements. Of the aluminum oxide, silicon carbide, and silicon nitride ceramics considered in the material ranking scheme developed herein, the silicon nitride class of ceramics ranked the highest because of their high temperature strength; resistance to the intense heating rates; resistance to hydrogen damage; and good structural properties. Baseline seal feasibility has been established through the research conducted in this investigation. Recommendations for future work are also discussed.

Steinetz, Bruce M.↗
NASA NTRS1996

Cost Models for MMC Manufacturing Processes

The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.

Elzey, Dana M.↗
NASA NTRS2000

Materials for Low-Energy Neutron Radiation Shielding

Various candidate aircraft and spacecraft materials were analyzed and compared in a low-energy neutron environment using the Monte Carlo N-Particle (MCNP) transport code with an energy range up to 20 MeV. Some candidate materials have been tested in particle beams, and others seemed reasonable to analyze in this manner before deciding to test them. The two metal alloys analyzed are actual materials being designed into or used in aircraft and spacecraft today. This analysis shows that hydrogen-bearing materials have the best shielding characteristics over the metal alloys. It also shows that neutrons above 1 MeV are reflected out of the face of the slab better by larger quantities of carbon in the material. If a low-energy absorber is added to the material, fewer neutrons are transmitted through the material. Future analyses should focus on combinations of scatterers and absorbers to optimize these reaction channels and on the higher energy neutron component (above 50 MeV).

Singleterry, Robert C., Jr.↗
NASA NTRS2001

Novel High Efficient Organic Photovoltaic Materials

In man's mission to the outer space or a remote site, the most abundant, renewable, nonpolluting, and unlimited external energy source is light. Photovoltaic (PV) materials can convert light into electrical power. In order to generate appreciable electrical power in space or on the Earth, it is necessary to collect sunlight from large areas due to the low density of sunlight, and this would be very costly using current commercially available inorganic solar cells. Future organic or polymer based solar cells seemed very attractive due to several reasons. These include lightweight, flexible shape, ultra-fast optoelectronic response time (this also makes organic PV materials attractive for developing ultra-fast photo detectors), tunability of energy band-gaps via molecular design, versatile materials synthesis and device fabrication schemes, and much lower cost on large-scale industrial production. It has been predicted that nano-phase separated block copolymer systems containing electron rich donor blocks and electron deficient acceptor blocks will facilitate the charge separation and migration due to improved electronic ultrastructure and morphology in comparison to current polymer composite photovoltaic system. This presentation will describe our recent progress in the design, synthesis and characterization of a novel donor-bridge-acceptor block copolymer system for potential high-efficient organic optoelectronic applications. Specifically, the donor block contains an electron donating alkyloxy derivatized polyphenylenevinylene, the acceptor block contains an electron withdrawing alkyl-sulfone derivatized polyphenylenevinylene, and the bridge block contains an electronically neutral non-conjugated aliphatic hydrocarbon chain. The key synthetic strategy includes the synthesis of each individual block first, then couple the blocks together. While the donor block stabilizes the holes, the acceptor block stabilizes the electrons. The bridge block is designed to hinder the electron-hole recombination. Thus, improved charge separation is expected. In addition, charge migration will also be facilitated due to the expected nano-phase separated and highly ordered block copolymer ultrastructural. The combination of all these factors will result in significant overall enhancement of photovoltaic power conversion efficiency.

Sun, Sam↗
NASA NTRS1977

Design, fabrication, and test of a composite material wind turbine rotor blade

The aerodynamic design, structural design, fabrication, and structural testing is described for a 60 foot long filament wound, fiberglass/epoxy resin matrix wind turbine rotor blade for a 125 foot diameter, 100 kW wind energy conversion system. One blade was fabricated which met all aerodynamic shape requirements and was structurally capable of operating under all specified design conditions. The feasibility of filament winding large rotor blades was demonstrated.

Griffee, D. G., Jr.↗