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NASA NTRS2003

Thermo-Mechanical Processing in Friction Stir Welds

Friction stir welding is a solid-phase joining, or welding process that was invented in 1991 at The Welding Institute (TWI). The process is potentially capable of joining a wide variety of aluminum alloys that are traditionally difficult to fusion weld. The friction stir welding (FSW) process produces welds by moving a non-consumable rotating pin tool along a seam between work pieces that are firmly clamped to an anvil. At the start of the process, the rotating pin is plunged into the material to a pre-determined load. The required heat is produced by a combination of frictional and deformation heating. The shape of the tool shoulder and supporting anvil promotes a high hydrostatic pressure along the joint line as the tool shears and literally stirs the metal together. To produce a defect free weld, process variables (RPM, transverse speed, and downward force) and tool pin design must be chosen carefully. An accurate model of the material flow during the process is necessary to guide process variable selection. At MSFC a plastic slip line model of the process has been synthesized based on macroscopic images of the resulting weld material. Although this model appears to have captured the main features of the process, material specific interactions are not understood. The objective of the present research was to develop a basic understanding of the evolution of the microstructure to be able to relate it to the deformation process variables of strain, strain rate, and temperature.

Schneider, Judy↗

NASA NTRS1999

Composting on Mars or the Moon: II. Temperature feedback control with top-wise introduction of waste material and air

Whereas Earth-based composting reactors that effectively control the process are batch operations with bottom-to-top airflow, in extraterrestrial application both the fresh waste and the air need to be introduced from above. Stabilized compost and used air would exit below. This materials flow pattern permits the addition of waste whenever generated, obviating the need for multiple reactors, and the incorporation of a commode in the lid. Top loading in turn dictates top-down aeration, so that the most actively decomposing material (greatest need for heat removal and O2 replenishment) is first encountered. This novel material and aeration pattern was tested in conjunction with temperature feedback process control. Reactor characteristics were: working, volume, 0.15 m3; charge, 2 kg dry biomass per day (comparable to a 3-4 person self-sufficient bioregenerative habitat); retention time, 7 days. Judging from temperature profile, O2 level, air usage, pressure head loss, moisture, and odor, the system was effectively controlled over a 35-day period. Dry matter disappearance averaged 25% (10-42%). The compost product was substantially, though not completely, stabilized. This demonstrates the compatibility of top-wise introduction of waste and air with temperature feedback process control.

NASA Discipline Life Support Systems↗

NASA NTRS2019

Characterization of 10-ft. Diameter Aluminum Alloy 2219 Integrally Stiffened Cylinders

The integrally stiffened cylinder (ISC) process, pioneered by NASA Langley Research Center, offers significant savings for launch vehicle structures. The ISC process is a near net shape, advanced manufacturing method for fabrication of single-piece, thin-walled barrels with internal longitudinal stiffeners, eliminating the need for longitudinal welding and machining. A cost-benefit analysis of the ISC process estimated a 50 % reduction in manufacturing costs and a 10% weight savings over the current multi-piece, machined and welded construction approach for stiffened barrels. In 2017, commercial-scale manufacturing trials were pursued, leading to a successful manufacturing demonstration of 10-ft. diameter ISC barrels fabricated from Al alloy 2219. Some cracking was observed in the stiffeners during fabrication. Optical metallography was performed to evaluate the as-formed microstructures to identify potential causes of cracking, along with mechanical testing to evaluate formability. Results revealed that cracking in the stiffeners was attributed to three likely causes: 1) large Al-Cu stringer particles, 2) stick-slip friction between the mandrel and ISC due to non-optimized lubrication, and 3) differences in material flow rate between the wall and stiffener locations. Testing to gauge formability revealed a significant decrease in ductility in the longitudinal directional for the as-formed condition, attributed to reduced ductility due to the large Al-Cu stringer particles. These results provide guidance toward materials and processing modifications for future ISC forming trials.

Tayon, Wesley A.↗

NASA NTRS1980

Airbreathing propulsion component technologies

The article suggests that the 1980's will see significant improvements in virtually all gas-turbine engine components and their materials and structural design methods. These improvements will be made possible by improved theoretical models, laser Doppler measurement techniques, advances in rotor-spool technology, the evolution of engine controls, etc. It is suggested that the engine components field should expect broad and steady advances in the technologies of flow, materials, and structures in terms of scope, precision, and tools of design.

Rosen, C.↗

NASA NTRS2013

Elastic-Plastic J-Integral Solutions or Surface Cracks in Tension Using an Interpolation Methodology

No closed form solutions exist for the elastic-plastic J-integral for surface cracks due to the nonlinear, three-dimensional nature of the problem. Traditionally, each surface crack must be analyzed with a unique and time-consuming nonlinear finite element analysis. To overcome this shortcoming, the authors have developed and analyzed an array of 600 3D nonlinear finite element models for surface cracks in flat plates under tension loading. The solution space covers a wide range of crack shapes and depths (shape: 0.2 less than or equal to a/c less than or equal to 1, depth: 0.2 less than or equal to a/B less than or equal to 0.8) and material flow properties (elastic modulus-to-yield ratio: 100 less than or equal to E/ys less than or equal to 1,000, and hardening: 3 less than or equal to n less than or equal to 20). The authors have developed a methodology for interpolating between the goemetric and material property variables that allows the user to reliably evaluate the full elastic-plastic J-integral and force versus crack mouth opening displacement solution; thus, a solution can be obtained very rapidly by users without elastic-plastic fracture mechanics modeling experience. Complete solutions for the 600 models and 25 additional benchmark models are provided in tabular format.

Allen, P. A.↗

NASA NTRS2013

Elastic-Plastic J-Integral Solutions or Surface Cracks in Tension Using an Interpolation Methodology. Appendix C -- Finite Element Models Solution Database File, Appendix D -- Benchmark Finite Element Models Solution Database File

Allen, Phillip A.↗

NASA NTRSDate not supplied

Multiscale Modeling of Woven Ablative Thermal Protection System Materials

The NASA Entry Systems Modeling project maintains a portfolio of computational model and tool development activities focused on reducing performance uncertainties in ablative Thermal Protection System (TPS) materials for NASA missions. The development activities span material scale and strive to allow microstructural characterization of material structure and properties, mesoscale analyses of damage, and macroscale evaluation of heatshield performance and recession in a given aerothermodynamic environment. This talk will detail the application of developed capabilities at all three scales to the woven TPS material that the Agency has selected as the heatshield for the Mars Sample Return Earth Entry System (MSR-EES) mission – 3D Mid-Density Carbon Phenolic (3MDCP). Each of the applications focuses on driving down uncertainties in material performance and thus risk for MSR-EES and other future missions that may leverage woven TPS. At the microscale, machine learning techniques are used to characterize images from destructive microscopy and inform structural variability. At the mesoscale, Lagrangian techniques are used to simulate ballistic impact and interpret damage modes noted in experiments. At the macroscale, coupled flow-material response techniques are validated by Arc Jet testing to enable heatshield design for missions with massive ablation.

Justin B Haskins↗

NASA NTRS1979

Mass flow in loop type coronal transients

Coronal transients having characteristics of a well-defined loop structure are examined, particularly with respect to temporal changes in the density and mass per unit length along the loop over periods of several days after the initial eruption. Measurements of mass distributions as a function of time are presented for eight transients, and one particular transient with a fairly simple configuration is investigated in more detail. Theoretical calculations are combined with the masses and densities derived from the observations to obtain estimates of the material flow in the transients; this flow is modeled on the assumption that magnetic forces drive and confine the loop. The flow field is found to be diverging everywhere, indicating that the density decreases in time. It is inferred that the transient legs are approximately in hydrostatic equilibrium and that most of the mass of the transient is lost from the sun during the initial phase.

Anzer, U.↗

NASA NTRS1999

Initial Study of Friction Pull Plug Welding

Pull plug friction welding is a new process being developed to conveniently eliminate defects from welded plate tank structures. The general idea is to drill a hole of precise, optimized dimensions and weld a plug into it, filling the hole perfectly. A conically-shaped plug is rotated at high angular velocity as it is brought into contact with the plate material in the hole. As the plug is pulled into the hole, friction rapidly raises the temperature to the point at which the plate material flows plastically. After a brief heating phase, the plug rotation is terminated. The plug is then pulled upon with a forging force, solidly welding the plug into the hole in the plate. Three aspects of this process were addressed in this study. The transient temperature distribution was analyzed based on slightly idealized boundary conditions for different plug geometries. Variations in hole geometry and ram speed were considered, and a program was created to calculate volumes of displaced material and empty space, as well as many other relevant dimensions. The relation between the axially applied forging force and the actual forging pressure between the plate and plug surfaces was determined for various configurations.

Rich, Brian S.↗

NASA NTRS1985

Geomorphology and Geology of the Southwestern Margaritifer Sinus and Argyre Regions of Mars. Part 4: Flow Ejecta Crater Distribution

Flow ejecta craters - craters surrounded by lobate ejecta blankets - are found throughout the study area. The ratio of the crater's diameter to that of the flow ejecta in this region is approximately 40 to 45%. Flow ejecta craters are dominantly sharply defined craters, with slightly degraded craters being somewhat less common. This is probably indicative of the ejecta's relatively low resistence to weathering and susceptibility to burial. Flow ejecta craters here seem to occur within a narrow range of crater sizes - the smallest being about 4km in diameter and the largest being about 27km in diameter. Ejecta blankets of craters at 4km are easily seen and those of smaller craters are simply not seen even in images with better than average resolution for the region. This may be due to the depth of excavation of small impacting bodies being insufficient to reach volatile-rich material. Flow ejecta craters above 24km are rare, and those craters above 27km do not display flow ejecta blankets. This may be a result of an excavation depth so great that the volatile content of the ejecta is insufficient to form a fluid ejecta blanket. The geomorphic/geologic unit appears also to play an important role in the formation of flow ejecta craters. Given the typical size range for the occurrence of flow ejecta craters for most units, it can be seen that the percentage of flow ejecta craters to the total number of craters within this size range varies significantly from one unit to the next. The wide variance in flow ejecta crater density over this relatively small geographical area argues strongly for a lithologic control of their distribution.

Parker, T. J.↗

NASA NTRS1998

Phase Inversion: Inferring Solar Subphotospheric Flow and Other Asphericity from the Distortion of Acoustic Waves

A method is proposed for analyzing an almost monochromatic train of waves propagating in a single direction in an inhomogeneous medium that is not otherwise changing in time. An effective phase is defined in terms of the Hilbert transform of the wave function, which is related, via the JWKB approximation, to the spatial variation of the background state against which the wave is propagating. The contaminating effect of interference between the truly monochromatic components of the train is eliminated using its propagation properties. Measurement errors, provided they are uncorrelated, are manifest as rapidly varying noise; although that noise can dominate the raw phase-processed signal, it can largely be removed by low-pass filtering. The intended purpose of the analysis is to determine the distortion of solar oscillations induced by horizontal structural variation and material flow. It should be possible to apply the method directly to sectoral modes. The horizontal phase distortion provides a measure of longitudinally averaged properties of the Sun in the vicinity of the equator, averaged also in radius down to the depth to which the modes penetrate. By combining such averages from different modes, the two-dimensional variation can be inferred by standard inversion techniques. After taking due account of horizontal refraction, it should be possible to apply the technique also to locally sectoral modes that propagate obliquely to the equator and thereby build a network of lateral averages at each radius, from which the full three-dimensional structure of the Sun can, in principle, be determined as an inverse Radon transform.

Gough, Douglas↗

NASA NTRS1991

Characterizing He II flow through porous materials using counterflow data

An empirical extension of the two-fluid model is used to characterize He II flow through porous materials. It is shown that four empirical parameters are necessary to describe the pressure and temperature differences induced by He II flow through a porous sample. The three parameters required to determine pressure differences are measured in counterflow and found to compare favorably with those for isothermal flow. The fourth parameter, the Gorter-Mellink constant, differs substantially from smooth tube values. It is concluded that parameter values determined from counterflow can be used to predict pressure and temperature differences in a variety of flows to an accuracy of about +/- 20 percent.

Maddocks, J. R.↗

NASA NTRS1972

Fast response densitometer for measuring liquid density

Densitometer was developed which produces linear voltage proportional to changes in density of flowing liquid hydrogen. Unit has fast response time and good system stability, statistical variation, and thermal equilibrium. System accuracy is 2 percent of total density span. Basic design may be altered to include measurement of other flowing materials.

Source record↗

NASA NTRS1976

The pressure and energy balance of the cool corona over sunspots

The 22 largest sunspots observed with the Skylab SO55 spectrometer are studied for a relation between their EUV radiation and their umbral size or magnetic classification. The ultimate goal is to determine why the coronal plasma is so cool over a sunspot and how this cool plasma manages to support itself against gravity. Based on the time behavior of the EUV emission, a steady-state model is developed for the pressure and energy balance of the cool coronal-plasma loops over the spots. Analysis of the temperature structure in a typical loop indicates that the loop is exceedingly well insulated from the outside corona, that its energy balance is determined purely by internal heating and cooling processes, and that a heat input of about 0.0001 erg/cu cm per sec is required along the full length of the loop. It is proposed that: (1) coronal material flows steadily across the field lines at the tops of the loops and falls downward along both sides under gravity; (2) the corona is heated by mechanical-energy transport across the very thin transition region immediately over network-cell interiors; and (3) strong magnetic fields tend to inhibit mechanical-energy dissipation in the corona.

Foukal, P. V.↗

NASA NTRS1977

Comparison of volcanic features of Elysium /Mars/ and Tibesti /Earth/

The summit caldera and flank morphologies of Elysium Mons on Mars and Emi Koussi in the Tibesti region in northern Chad are similar in many ways. In both cases the large central caldera is about 12 km in diameter and from 500 to 1000 m deep; both calderas contain numerous craters and large irregular pits. Crater size/frequency analysis of Elysium Mons is thought to indicate that most of the craters are of endergonic origin. The flanks, characterized by subdued hummocky terrain, differ from those of the younger Tharsis Ridge and show little if any sign of recent material flow. Evidence against pluvial episodes within 100,000 or 1,000,000 years is provided by the lack of aqueous erosional forms. It is suggested that the source of the Elysium volcanics has been chemically evolved and probably involves silicic magma. The data are consistent with the view that the martian crust has been stable and essentially motionless for an extended period of martian geologic time.

Malin, M. C.↗

NASA NTRS1979

Nonterrestrial material processing and manufacturing of large space systems

Nonterrestrial processing of materials and manufacturing of large space system components from preprocessed lunar materials at a manufacturing site in space is described. Lunar materials mined and preprocessed at the lunar resource complex will be flown to the space manufacturing facility (SMF), where together with supplementary terrestrial materials, they will be final processed and fabricated into space communication systems, solar cell blankets, radio frequency generators, and electrical equipment. Satellite Power System (SPS) material requirements and lunar material availability and utilization are detailed, and the SMF processing, refining, fabricating facilities, material flow and manpower requirements are described.

Von Tiesenhausen, G.↗

NASA NTRS1979

Accelerated stress testing of terrestrial solar cells

A program to investigate the reliability characteristics of unencapsulated low-cost terrestrial solar cells using accelerated stress testing is described. Reliability (or parametric degradation) factors appropriate to the cell technologies and use conditions were studied and a series of accelerated stress tests was synthesized. An electrical measurement procedure and a data analysis and management system was derived, and stress test fixturing and material flow procedures were set up after consideration was given to the number of cells to be stress tested and measured and the nature of the information to be obtained from the process. Selected results and conclusions are presented.

Prince, J. L.↗

NASA NTRS1981

Z-model analysis of impact cratering - An overview

The Maxwell Z-Model has been applied to two continuum mechanics computer calculations: (1) a laboratory-scale impact of an aluminum projectile into plasticene clay, and (2) a planetary-scale impact of an iron meteor into gabbroic anorthosite. The material flow in the cratering flow field may be well approximated by incompressible flow for most of the excavation stage of crater growth. The center of the flow field is located beneath, not at, the surface. Soon after energy partitioning is complete, Z can assume values less than 2.0 associated with the initial directedness of the projectile's momentum. The Z-Model parameters are time dependent during a significant portion of the crater growth time, and Z increases steadily with time from about 2.0 or slightly less at the beginning of the excavation stage to level off at values in the neighborhood of about 3.0 before the excavation stage is half-over.

Austin, M. G.↗