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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Specimens and Reusable Fixturing for Testing Advanced Aeropropulsion Materials Under In-Plane Biaxial Loading: Results of Conceptual Design Study - Part 1

A design study was undertaken to investigate the feasibility of using simple specimen designs and reusable fixturing for in-plane biaxial tests planned for advanced aeropropulsion materials. Materials of interest in this work include: advanced metallics, polymeric matrix composites, metal and intermetallic matrix composites, and ceramic matrix composites. Early experience with advanced metallics showed that the cruciform specimen design typically used in this type of testing was impractical for these materials, primarily because of concerns regarding complexity and cost. The objective of this research was to develop specimen designs, fixturing, and procedures which would allow in-plane biaxial tests to be conducted on a wide range of aeropropulsion materials while at the same time keeping costs within acceptable limits. With this goal in mind. a conceptual design was developed centered on a specimen incorporating a relatively simple arrangement of slots and fingers for attachment and loading purposes. The ANSYS finite element code was used to demonstrate the feasibility of the approach and also to develop a number of optimized specimen designs. The same computer code was used to develop the reusable fixturing needed to position and grip the specimens in the load frame. The design adopted uses an assembly of slotted fingers which can be reconfigured as necessary to obtain optimum biaxial stress states in the specimen gage area. Most recently, prototype fixturing was manufactured and is being evaluated over a range of uniaxial and biaxial loading conditions.

Ellis, J. R.↗
NASA NTRS2017

Environmental Testbed Development to Evaluate Power Distribution Materials in Electrified Aircraft (EA)

NASA is pursuing the development of electrified propulsion (EP) technologies to improve air transportation in terms of efficiency, affordability, and sustainability. The power requirements are expected to reach 20 megawatts for large EP commercial airliners. A key challenge is transmission and distribution of the high voltage (20 kilovolts) needed for some EP systems. This is a challenge because the risk of electrical failure in aircraft at high altitude (low pressure) due to corona discharge and other forms of partial discharge increases significantly when voltages exceed 327 V. Corona discharge is a form of partial discharge in which gaseous molecules are ionized by strong electric fields. Corona discharge leads to aging in power transmission lines. Aging is a leading cause of electrical failure in electrical insulation materials. In particular, aging from electrical, vibrational, and thermal stresses decrease the performance life of insulation materials. There are currently no test standards or equipment that can effectively age materials under high altitude, voltage and frequency conditions. This poster proposes a design for a test system including an environmental chamber that can simulate the environment of future EP systems for material and component aging tests.

Materials Test chamber Design↗
NASA NTRS1994

Laminated thermoplastic composite material from recycled high density polyethylene

The design of a materials-science, educational experiment is presented. The student should understand the fundamentals of polymer processing and mechanical property testing of materials. The ability to use American Society for Testing and Materials (ASTM) standards is also necessary for designing material test specimens and testing procedures. The objectives of the experiment are (1) to understand the concept of laminated composite materials, processing, testing, and quality assurance of thermoplastic composites and (2) to observe an application example of recycled plastics.

Liu, Ping↗
NASA NTRS2023

Nasa Hytec CMC Turbine Blade Durability

The objective of the CMC turbine blade durability program is to identify critical material and design parameters that affect durability of ceramic matrix composite (CMC) turbine blades. A baseline architecture for a cooled high-pressure turbine (HPT) CMC blade and accompanying sub-component test articles were developed with the intent to demonstrate through analysis and subcomponent testing how material and design parameters impact key failure modes. As part of this program, a notional architecture for a cooled CMC blade was matured through a design review rhythm to produce a blade test article containing the necessary features required for operation in an engine like environment. Further validation of the durability of these features were achieved through coupon and sub-component testing to demonstrate the durability of cooling hole configurations and blade attachment designs. Analytical methods were also used to evaluate the acceptability of the baseline blade test article architecture against relevant design requirements and identify abatement and recommended changes to key design drivers to improve component durability for future design iterations.

CMC, Blade↗
NASA NTRS1979

Subscale solid motor nozzle tests, phase 4 and nozzle materials screening and thermal characterization, phase 5

Subscale solid motor nozzles containing a baseline material or low cost materials to be considered as potential replacements for the baseline material are designed and tested. Data are presented from tests of four identically designed 2.5 inch throat diameter nozzles and one 7 inch throat diameter nozzle. The screening of new candidate low cost materials, as well as their thermophysical and thermochemical characterization is also discussed.

Arnold, J.↗
NASA NTRSDate not supplied

Expanding the Capability of A Legacy Combustion Flametube to Test High Temperature Engine Materials in Relevant Environments

New materials and component designs are needed to advance gas turbine engine technology and provide the performance and efficiency needs for future applications. In order to advance these materials, testing in combustion environments is a critical step prior to engine testing. In this work, we detail the design and the fabrication of a materials test sector in a flametube combustor facility. The facility simulates a combustion environment similar to that experienced by components in gas turbine engines. The flow regime is characterized by a combination of high-temperature, high-velocity, high-heat flux, and high-velocity that components experience in gas turbine engines. Exposure of components in this facility allows for the study of combined environmental effects and the impact on both coating and substrate durability. The test facility may operate across a wide range of pressures from 275-400 psig (1,896-2,758 kPa) and an air flow rate of 5 lb/s (2.27 kg/s). While combustion gas temperature is expected in excess of 3,000°F (1,649°C), 900°F (482°C) cooling air may be supplied to the backside of components or test articles. The flametube combustor was previously used to evaluate fuel injectors and combustion products, and the new test configuration will also allow for materials exposure to complex, engine-like conditions. The interior of the Test Section was additively manufactured from GRCop-84 and cryogenically fit and brazed to a stainless steel 304 housing. The use of a copper liner minimizes welds and with active cooling, is expected to provide better durability over traditional hardware using stainless steel or Inconel with a ceramic liner. The Test Section has two opposing removable windows approximately 230 mm x 80 mm that can accommodate articles up to 85 mm tall. This modular design allows for custom platforms to hold coupons, panels, or airfoil shapes to be tested with minimal re-engineering or fabrication. The bolted joint and sealing remains consistent, so any new testing only needs to work within the existing design footprint. This paper will provide an overview of the facility capabilities, design considerations, as well as thermal and structural analysis of the hardware. Future testing of ceramic matrix composite (CMC) airfoils and advanced environmental barrier coatings (EBCs) will also be discussed.

Combustion↗
NASA NTRS2015

Design and Preliminary Testing of the International Docking Adapter's Peripheral Docking Target

The International Docking Adapter's Peripheral Docking Target (PDT) was designed to allow a docking spacecraft to judge its alignment relative to the docking system. The PDT was designed to be compatible with relative sensors using visible cameras, thermal imagers, or Light Detection and Ranging (LIDAR) technologies. The conceptual design team tested prototype designs and materials to determine the contrast requirements for the features. This paper will discuss the design of the PDT, the methodology and results of the tests, and the conclusions pertaining to PDT design that were drawn from testing.

Foster, Christopher W.↗
NASA NTRS2017

Europa Propulsion Valve Seat Material Testing

The Europa mission and spacecraft design presented unique challenges for selection of valve seat materials that met the fluid compatibility requirements, and combined fluid compatibility and high radiation exposure level requirements. The Europa spacecraft pressurization system valves will be exposed to fully saturated propellant vapor for the duration of the mission. The effects of Nitrogen Tetroxide (NTO) and Monomethylhydrazine (MMH) propellant vapors on heritage valve seat materials, such as Vespel SP-1 and Polychlorotrifluoroethylene (PCTFE), were evaluated to determine if an alternate material is required. In liquid system applications, Teflon is the only available compatible valve seat material. Radiation exposure data for Teflon in an air or vacuum environment has been previously documented. Radiation exposure data for Teflon in an oxidizer environment such as NTO, was not available, and it was unknown whether the effects would be similar to those on air-exposed samples. Material testing was conducted by Marshall Space Flight Center (MSFC) and White Sands Test Facility (WSTF) to determine the effects of propellant vapor on heritage seat materials for pressurization valve applications, and the effects of combined radiation and NTO propellant exposure on Teflon. The results indicated that changes in heritage pressurization valve seat materials' properties rendered them unsuitable for the Europa application. The combined radiation and NTO exposure testing of Teflon produced results equivalent to combined radiation and air exposure results.

Addona, Brad M.↗
NASA NTRS1981

Design allowables for T300/5208 graphite/epoxy composite materials

Material coupon tests were conducted to formulate design allowables for T300/5208 graphite/epoxy unidirectional tape and bidirectional fabric composites. This paper gives a description of the tests conducted, representative ply level and laminate test data, and results of the statistical analysis. The design allowables for tension and compression strength are given and include the effect of notches, impact damage, temperature extremes and moisture absorption.

Ekvall, J. C.↗
NASA NTRS2014

Composite Overview and Composite Aerocover Overview

Materials Science Division within the Engineering Directorate tasked by the Ares Launch Vehicle Division (LX-V) and the Fluids Testing and Technology Development Branch (NE-F6) to design, fabricate and test an aerodynamic composite shield for potential Heavy Lift Launch Vehicle infusion and a composite strut that will serve as a pathfinder in evaluating calorimeter data for the CRYOSTAT (cryogenic on orbit storage and transfer) Project. ATP project is to carry the design and development of the aerodynamic composite cover or "bracket" from cradle to grave including materials research, purchasing, design, fabrication, testing, analysis and presentation of the final product. Effort consisted of support from the Materials Testing & Corrosion Control Branch (NE-L2) for mechanical testing, the Prototype Development Branch (NE-L3) for CAD drawing, design/analysis, and fabrication, Materials & Processes Engineering Branch (NE-L4) for project management and materials selection; the Applied Physics Branch (NE-LS) for NDE/NDI support; and the Chemical Analysis Branch (NE-L6) for developmental systems evaluation. Funded by the Ares Launch Vehicle Division and the Fluids Testing and Technology Development Branch will provide ODC

Caraccio, Anne↗
NASA NTRS1975

Evaluation of materials and design modifications for aircraft brakes

A test program is described which was carried out to evaluate several proposed design modifications and several high-temperature friction materials for use in aircraft disk brakes. The evaluation program was carried out on a specially built test apparatus utilizing a disk brake and wheel half from a small het aircraft. The apparatus enabled control of brake pressure, velocity, and braking time. Tests were run under both constant and variable velocity conditions and covered a kinetic energy range similar to that encountered in aircraft brake service. The results of the design evaluation program showed that some improvement in brake performance can be realized by making design changes in the components of the brake containing friction material. The materials evaluation showed that two friction materials show potential for use in aircraft disk brakes. One of the materials is a nickel-based sintered composite, while the other is a molybdenum-based material. Both materials show much lower wear rates than conventional copper-based materials and are better able to withstand the high temperatures encountered during braking. Additional materials improvement is necessary since both materials show a significant negative slope of the friction-velocity curve at low velocities.

Ho, T. L.↗
NASA NTRS1974

Analysis of three-point-bend test for materials with unequal tension and compression properties

An analysis capability is described for the three-point-bend test applicable to materials of linear but unequal tensile and compressive stress-strain relations. The capability consists of numerous equations of simple form and their graphical representation. Procedures are described to examine the local stress concentrations and failure modes initiation. Examples are given to illustrate the usefulness and ease of application of the capability. Comparisons are made with materials which have equal tensile and compressive properties. The results indicate possible underestimates for flexural modulus or strength ranging from 25 to 50 percent greater than values predicted when accounting for unequal properties. The capability can also be used to reduce test data from three-point-bending tests, extract material properties useful in design from these test data, select test specimen dimensions, and size structural members.

Chamis, C. C.↗
NASA NTRS2010

Ares V: Progress Toward Unprecedented Heavy Lift

Ares V represents the vehicle that will again make possible human exploration beyond low Earth orbit. The Ares V is part of NASA s Constellation Program architecture developed to support the International Space Station (ISS), establish a permanent human presence on the Moon, and explore it to an extent far greater than was possible with the Apollo Program. Ares V will carry the lunar lander to orbit where it will join the Orion crew spacecraft, launched by the smaller Ares I launch vehicle. Then the Ares V upper stage will send the Orion and lander to the Moon. Ares V is also intended to launch automated cargo landers to the Moon. The Ares vehicles are designed to employ the proven technologies and experience from the Space Shuttle, Delta IV, and earlier U.S. programs, as well as sharing common components where feasible. The Ares V is in an early stage of concept development. However, commonality allows it to benefit from development work already under way on the Ares I, including the first stage booster, and upper stage, J-2X upper stage engine. This paper will discuss progress to date on the Ares V and its potential for freeing payload designers from current mass and volume constraints. Progress includes development progress on Ares I elements that will be shared by the two launch vehicles. The Ares I first stage recently completed a successful test firing of Development Motor 1 (DM-1). The J-2X engine is proceeding with manufacturing of components for the first development engines that will be used for testing. Several component-level tests have been completed or are under way that will help verify designs and confirm solutions to design challenges. The Ares V Earth departure stage will benefit from the Ares I upper stage development, including design, manufacturing, and materials testing. NASA is also working with government and industry to collect data on flights and testing of the operational RS-68 engine and potential upgrades. The Ares V team continues to evaluate technical options, vehicle configurations, and operations concepts for the Ares V. The team recently completed a Fall Face-to-Face meeting that served as a stepping-stone to the Systems Requirements Review (SRR). This four-day meeting served as an information exchange for the various teams at several NASA field centers and supporting contractors.

Sumrall, Phil↗
NASA NTRS1985

Guidelines for structural verification and fracture control of Shuttle payloads

The procedures followed by the NASA Office of the Chief Engineer in developing the guidelines concerning the structures, materials, and fracture control of the Space Shuttle payloads are described. Factors controlling the payload launch safety, such as crew and passenger safety, reusability, and mixes of payloads in a single launch are emphasized. Special consideration is given to the STS design and testing approaches, materials considerations, safety criticality review processes, nondestructive evaluation inspection for STS payload fracture control, fracture mechanics screening procedures, and components of special concern (e.g., pressurized vessels, fasteners, and composite structures).

Lifer, C. E.↗
NASA NTRS2009

Design and Testing of Braided Composite Fan Case Materials and Components

Triaxial braid composite materials are beginning to be used in fan cases for commercial gas turbine engines. The primary benefit for the use of composite materials is reduced weight and the associated reduction in fuel consumption. However, there are also cost benefits in some applications. This paper presents a description of the braided composite materials and discusses aspects of the braiding process that can be utilized for efficient fabrication of composite cases. The paper also presents an approach that was developed for evaluating the braided composite materials and composite fan cases in a ballistic impact laboratory. Impact of composite panels with a soft projectile is used for materials evaluation. Impact of composite fan cases with fan blades or blade-like projectiles is used to evaluate containment capability. A post-impact structural load test is used to evaluate the capability of the impacted fan case to survive dynamic loads during engine spool down. Validation of these new test methods is demonstrated by comparison with results of engine blade-out tests.

Roberts, Gary D.↗