SEARCH · Engineering Papers
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Composite beam connected to strain gauge and mounted on test specimen is capable of amplifying small strains by factor of 10. Tests indicate that resulting output can be 10 times greater than standard method.
An experimental evaluation of apparent thermal strains is conducted using various combinations of substrate/gauge/attachment structure and redundant high temperature extensometry. It is found that the extensometry could either confirm independent measurements of the substrate's thermal expansion, or quantify nonzero mechanical strains resulting from uncertain material behavior and boundary conditions. Apparent strain and thermal expansion behavior data can then be used to modify the raw strain measurements in order to determine either stress producing or total strains. Limitation of the correction procedure for the three selected strain gauges is noted which is due to relatively large gauge/attachment variability.
Strain gage measurement of elongation due to thermally and mechanically induced stresses
A method of determining the amount of fluid in a tank is based on measurement of strains induced in tank supports by the weight of the fluid. Unlike most prior methods, this method is nonintrusive: there is no need to insert instrumentation in the tank and, hence, no need to run wires, cables, or tubes through the tank wall. Also unlike most prior methods, this method is applicable even if the fluid in the tank is at supercritical pressure and temperature, because it does not depend on the presence of a liquid/gas interface (as in liquid-level-measuring methods). The strain gauges used in this method are of two types: foil and fiber-optic. Four foil gauges and one or more fiber-optic gauges are mounted on each of the tank-supporting legs. An additional fiber-optic gauge is mounted on an object, made of the same material as that of the tank-supporting legs, that is not subjected to any mechanical load. The reading obtained by the additional fiber-optic gauge is used to compensate for apparent strains caused by changes in temperature. The signals from the foil and fiber-optic gauges are conditioned, then digitized for input to a computer. As the tank is filled or emptied, the deformation in each leg increases or decreases, respectively. Measured deformations of all legs are added to obtain a composite deformation indicative of the change in weight of the tank plus fluid. An initial calibration is performed by recording data at two points (usually, empty and full) for which the mass or weight of fluid is known. It is assumed that the deformations are elastic, so that the line passing through the two points can be used as a calibration curve of mass (or weight) of fluid versus deformation. At the time of reporting the information for this article, a set of foil gauges had been tested on the supports of a 500-gallon (1,900-liter) tank. The gauges were found to be capable of measuring the deformations (up to 22 microstrain) that occurred during filling and emptying the tank. The fluid masses calculated from the gauge readings were found to be accurate within 4.5 percent. It has been estimated that once the fiber-optic gauges are put into operation, it should be possible to determine fluid masses with 3 percent or less. It may be possible to increase accuracy further by increasing the signal-to-noise ratio through the use of more deformable tank supporting legs.
An in-house lab was established for developing, testing, and evaluating high-temperature strain gauges and to aid in in-house applications of high-temperature strain instrumentation. The lab is automated to provide computer control of oven temperatures, imposed strain, and data sampling.
A method of determining the amount of fluid in a tank is based on measurement of strains induced in tank supports by the weight of the fluid. Unlike most prior methods, this method is nonintrusive: there is no need to insert instrumentation in the tank and, hence, no need to run wires, cables, or tubes through the tank wall. Also unlike most prior methods, this method is applicable even if the fluid in the tank is at supercritical pressure and temperature, because it does not depend on the presence of a liquid/gas interface (as in liquid-level-measuring methods). The strain gauges used in this method may be of two types: foil and fiber-optic. Four foil gauges (full bridge) are mounted on each of the tank-supporting legs. As the tank is filled or emptied, the deformation in each leg increases or decreases, respectively. Measured deformations of all legs are added to obtain a composite deformation indicative of the change in weight of the tank plus fluid. An initial calibration is performed by recording data at two points (usually, empty and full) for which the mass or weight of fluid is known. It is assumed that the deformations are elastic, so that the line passing through the two points can be used as a calibration curve of mass (or weight) of fluid versus deformation. One or more fiber-optic gauges may be used instead of the foil gauges. The resolution of the fiber-optic and foil gauges is approximately the same, but the fiber-optic gauges are immune to EMI (electromagnetic interference), are linear with respect to temperature over their entire dynamic range (as defined by the behavior of the sample), and measure thermally induced deformations as predictable signals. Conversely, long term testing has demonstrated that the foil gauges exhibit an erratic behavior whenever subjected to direct sun radiation (even if protected with a rubberized cover). Henceforth, for deployment in outdoor conditions, fiber-optic gauges are the only option if one is to rely on the system for an extended period of time when a recalibration procedure may not be acceptable. A set of foil gauges had been tested on the supports of a 500-gallon (1,900-liter) tank. The gauges were found to be capable of measuring the deformations (up to 22 micro-strain) that occurred during filling and emptying of the tank. The fluid masses calculated from the gauge readings were found to be accurate within 4.5 percent. However, the reliability of the foil gauges over a few hours was not acceptable. Therefore, the foil sensor system is acceptable for use only in controlled environments (complete shade, or indoors).
Lithium-ion battery diagnostics and prognostics rely on measurements of electrical impedance, capacity, and voltage to infer the internal state of the battery. Mechanical changes to the cell structure represent an additional measure of the battery’s state because these changes are related to the overall battery health. As lithium-ion batteries are charged and discharged, lithium ions are inserted or removed from the anode and cathode, a process called intercalation and de-intercalation. As lithium ions intercalate and de-intercalate, they can cause changes to the lattice of the electrode particles, resulting in volumetric changes. These volumetric changes cause mechanical stresses and strains on the lithium-ion battery electrodes, and subsequently, the whole cell’s thickness varies as it is charged and discharged. This paper presents a study on the use of surface-mounted strain gauges for in-situ measurement of structural changes to lithium-ion batteries, along with a characterization of the unit-to-unit differences in strain response. A neural network modeling structure is then used to predict the battery’s depth of discharge under dynamic discharge conditions.
Addition of some rare-earth oxides to prior alumina (only) coating material increases maximum service temperature of palladium/chromium-wire strain gauges. Pd/Cr wires used at temperatures up to 800 degrees C without excessive drift in electrical resistance. Oxides used: zirconia (ZrO2), yttria (Y2O3), ceria (CeO2), and hafnia (HfO2). Addition of one of these oxides to decrease oxidation of wire at high temperature. Protection against oxidation increases with concentration of rare-earth oxide. Addition of ZrO2 at 4 to 6 weight percent or Y2O3 at 1 weight percent results in smallest drift in electrical resistance.
A system is described to measure alignment between interfacing edges of mirror segments positioned to form a segmented mirror surface. It serves as a gauge having a bending beam with four piezoresistive elements coupled across the interfaces of the edges of adjacent mirror segments. The bending beam has a first position corresponding to alignment of the edges of adjacent mirror segments, and it is bendable from the first position in a direction and to a degree dependent upon the relative misalignment between the edges of adjacent mirror segments to correspondingly vary the resistance of the strain guage. A source of power and an amplifier are connected in circuit with the strain gauge whereby the output of the amplifier varies according to the misalignment of the edges of adjacent mirror segments.
Wires yield data on average strains over distances ranging from inches to many feet. Long constantan wires used to measure average strains over distances characteristic of vehicles or buildings. Connected in bridge circuit, wires measure strain accurately within 1 percent, and linearly, within 0.1 percent. Wires stretch as much as 0.15 percent and still return to zero residual strain after release.
Thermally sprayed dielectric ceramic coatings are the primary means of attaching strain and temperature gauges to hot-section rotating parts of turbine engines. As hot-section temperatures increase, lifetimes of installed gauges decrease, and seldom exceed one hour above 2,000 F (approx.1,100 C). Advanced engine components are expected to operate at temperatures approaching 2,200 F (approx.1,200 C), and the required high-temperature lifetime is 10 hours minimum. Typically, to enable a ceramic coating to adhere to the smooth surface of an engine component, a thermally sprayed NiCrAlY or NiCoCrAlY bond coat is applied to the smooth surface, thereby providing a textured surface to which the ceramic coat can adhere. The main failure mechanism of this system is decohesion and/or delamination at the interface between the ceramic top coat and the bond coat, caused by oxidation of the bond coat and stresses from the mismatch between the coefficients of thermal expansion of the ceramic top coat and the metallic bond coat. The approach taken to increase the high-temperature lifetime of a gauge attached to an engine component by the method described above involves (1) selective oxidation of the bond coat by means of a heat treatment in reduced oxygen partial pressure followed by (2) the application of a noble-metal diffusion barrier. In experiments to test this approach, heat treatments of NiCoCrAlY bond coats were carried out in a tube furnace in which, in each case, the temperature was alternately (1) increased at a rate of 3 C per minute and (2) held steady for one hour until the desired temperature was reached. The tube furnace was continuously purged with dry nitrogen gas. A final heat-treatment temperature range of 1,600 to 1,800 F (871 to 982 C) proved most beneficial.
Wireless strain sensors with minimal power needs are essential for long-term monitoring in energy-limited environments. We present a soft tunneling barrier-integrated gold thin film for negative strain sensing with near-zero energy consumption. The device features a strain-induced transition from an insulating to a metallic state, increasing conductivity by 9 orders of magnitude under a controlled strain. It consists of Au-PDMS-Au nanofilm layers, where the Au structures are near the percolation threshold and the PDMS layer acts as a tunneling barrier. Under strain, thinning due to the Poisson effect lowers the barrier’s potential height, enabling electron tunneling and forming an electrical path. Further, with a standby power consumption of ~10 –5 mW over 10 6 times lower than conventional sensors (~12.5 mW), this device is ideal for real-time, long-term stationary structural monitoring in multiple locations.
Strain gage apparent strain (thermal output) is one of the largest sources of error associated with the measurement of strain when temperatures and mechanical loads are varied. In this paper, experimentally determined apparent strains of WK-type strain gages, installed on both metallic and composite-laminate materials of various lay-ups and resin systems for temperatures ranging from -450 F to 230 F are presented. For the composite materials apparent strain in both the 0 ply orientation angle and the 90 ply orientation angle were measured. Metal specimens tested included: aluminum-lithium alloy (Al-LI 2195-T87), aluminum alloy (Al 2219-T87), and titanium alloy. Composite materials tested include: graphite-toughened-epoxy (IM7/997- 2), graphite-bismaleimide (IM7/5260), and graphite-K3 (IM7/K3B). The experimentally determined apparent strain data are curve fit with a fourth-order polynomial for each of the materials studied. The apparent strain data and the polynomials that are fit to the data are compared with those produced by the strain gage manufacturer, and the results and comparisons are presented. Unacceptably high errors between the manufacture's data and the experimentally determined data were observed (especially at temperatures below - 270-F).
Gauges fabricated from specially developed Fe-Cr-Al-V-Ti-Y alloy wire in the Republic of China were evaluated for use in static strain measurement of hot gas turbine engines. Gauge factor variation with temperature, apparent strain, and drift were included. Results of gauge factor versus temperature tests show gauge factor decreasing with increasing temperature. The average slope is -3-1/2 percent/100 K, with an uncertainty band of + or - 8 percent. Values of room temperature gauge factor for the Chinese and Kanthal A-1 gauges averaged 2.73 and 2.12, respectively. The room temperature gauge factor of the Chinese gauges was specified to be 2.62. The apparent strain data for both the Chinese alloy and Kanthal A-1 showed large cycle to cycle nonrepeatability. All apparent strain curves had a similar S-shape, first going negative and then rising to positive value with increasing temperatures. The mean curve for the Chinese gauges between room temperature and 100 K had a total apparent strain of 1500 microstrain. The equivalent value for Kanthal A-1 was about 9000 microstrain. Drift tests at 950 K for 50 hr show an average drift rate of about -9 microstrain/hr. Short-term (1 hr) rates are higher, averaging about -40 microstrain for the first hour. In the temperature range 700 to 870 K, however, short-term drift rates can be as high as 1700 microstrain for the first hour. Therefore, static strain measurements in this temperature range should be avoided.
A novel optical method of measuring 2-D surface strain is proposed. Two linear strains along orthogonal axes and the shear strain between those axes is determined by a variation of Yamaguchi's laser-speckle strain gage technique. It offers the advantages of shorter data acquisition times, less stringent alignment requirements, and reduced decorrelation effects when compared to a previously implemented optical strain rosette technique. The method automatically cancels the translational and rotational components of rigid body motion while simplifying the optical system and improving the speed of response.
A novel optical method of measuring 2-D surface strain is proposed. Two linear strains along orthogonal axes and the shear strain between those axes is determined by a variation of Yamaguchi's laser-speckle strain gage technique. It offers the advantages of shorter data acquisition times, less stringent alignment requirements, and reduced decorrelation effects when compared to a previously implemented optical strain rosette technique. The method automatically cancels the translational and rotational components of rigid body motion while simplifying the optical system and improving the speed of response.
Temperature effects on electrical resistivity of metallic strain gage materials