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At least 541 records · Page 30

Computational simulation of probabilistic lifetime strength for aerospace materials subjected to high temperature, mechanical fatigue, creep and thermal fatigue

This report presents the results of a fourth year effort of a research program, conducted for NASA-LeRC by the University of Texas at San Antonio (UTSA). The research included on-going development of methodology that provides probabilistic lifetime strength of aerospace materials via computational simulation. A probabilistic material strength degradation model, in the form of a randomized multifactor interaction equation, is postulated for strength degradation of structural components of aerospace propulsion systems subject to a number of effects or primitive variables. These primitive variables may include high temperature, fatigue or creep. In most cases, strength is reduced as a result of the action of a variable. This multifactor interaction strength degradation equation has been randomized and is included in the computer program, PROMISS. Also included in the research is the development of methodology to calibrate the above-described constitutive equation using actual experimental materials data together with regression analysis of that data, thereby predicting values for the empirical material constants for each effect or primitive variable. This regression methodology is included in the computer program, PROMISC. Actual experimental materials data were obtained from industry and the open literature for materials typically for applications in aerospace propulsion system components. Material data for Inconel 718 has been analyzed using the developed methodology.

Boyce, Lola↗

I.3.4.1.1 Overview of Advanced Characterization Within the Powertrain Materials Program (Task 4A1) (Oak Ridge National Laboratory); (Task 4A2) (Argonne National Laboratory); and (Task 4A3) (Pacific Northwest National Laboratory)

This report describes the activities performed during the third year of Thrust 4A, “Advanced Characterization,” within the DOE-EERE VTO PMCP. The goal of the PMCP, which was launched in October 2018, has been to accelerate design, development, demonstration, and deployment of new, cost-effective advanced alloy solutions via a modern ICME approach. The properties of these new materials are targeted to enable improvements in engine efficiency, lightweighting, and durability enhancement over the full range of on-road vehicle classes (e.g., Classes 1-8), including range extenders for future electric HD freight vehicles.

33 ADVANCED PROPULSION SYSTEMS↗

Multi-Functional Smart Structures for Smart Vehicles

This report summarizes the development of a new class of recyclable multi-functional composite materials for production of lightweight smart structures and surfaces. Functional high stiffness conductive composites were processed using molding methods that integrated continuous fiber and additively manufactured features. Methods for integration of sensing functionality and controls were also developed to reduce system cost while providing a new capability for structural health monitoring. This new class of composites is applicable to a broad range of vehicle interior, exterior and battery enclosure systems. By way of demonstration, a vehicle instrument panel cross car beam was developed that provided a 38% mass savings compared to steel while maintaining a cost penalty competitive to alternate lightweight material solutions. These technologies were validated for implementation by a uniquely qualified project team comprising a US automotive OEM, Tier 1 and Tier 2 supplier, with key contributions from Oak Ridge National Lab, Purdue University and Michigan State University.

33 ADVANCED PROPULSION SYSTEMS↗

Metal matrix composites for aircraft propulsion systems

A report is presented of the current status of development of five materials which might be used in the design of components for advanced aircraft propulsion systems. Boron fiber/aluminum, boron fiber/titanium, and silicon carbide fiber/titanium composites are considered for lightweight compressor fan blades. Directionally solidified eutectic superalloy and tungsten wire/superalloy composites could possibly be used in the design of turbine blades for operational temperatures as high as 1100 C.

Signorelli, R. A.↗

Erosion Resistant Coatings for Polymer Matrix Composites in Propulsion Applications

Polymer Matrix Composites (PMCs) offer lightweight and frequently low cost alternatives to other materials in many applications. High temperature PMCs are currently used in limited propulsion applications replacing metals. Yet in most cases, PMC propulsion applications are not in the direct engine flow path since particulate erosion degrades PMC component performance and therefore restricts their use in gas turbine engines. This paper compares two erosion resistant coatings (SANRES and SANPRES) on PMCs that are useful for both low and high temperature propulsion applications. Collaborating over a multi-year period, researchers at NASA Glenn Research Center, Allison Advanced Developed Company, and Rolls-Royce Corporation have optimized these coatings in terms of adhesion, surface roughness, and erosion resistance. Results are described for vigorous hot gas/particulate erosion rig and engine testing of uncoated and coated PMC fan bypass vanes from the AE 3007 regional jet gas turbine engine. Moreover, the structural durability of these coatings is described in long-term high cycle fatigue tests. Overall, both coatings performed well in all tests and will be considered for applications in both commercial and defense propulsion applications.

Sutter, James K.↗

The Use of Immersion Rigs for High Temperature Hydrogen Exposure Testing Within the Nuclear Thermal Rocket Element Environmental Simulator (NTREES): NTREES-5 Hydrogen Heat Exchanger (N5HHX-01)

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility at NASA’s Marshall Space Flight Center (MSFC) subjects materials and components typically found on nuclear thermal propulsion (NTP) systems to non-nuclear simulations of prototypic NTP reactor thermohydraulic environments. With 1.2 MW of inductive power available, the currently employed methods to simulate nuclear heating in NTREES consist of 1) inductively heating a test specimen, which typically cannot be performed on ceramic materials, or 2) heating gas that envelops the test specimen. The latter of these has provided a basis for developing so-called “immersion rigs” to be used in NTREES. Furthermore, immersion rigs are especially useful in the case of smaller, technically challenging test specimens. One such device, the “NTREES-5 Hydrogen Heat Exchanger” (N5HHX-01), designed and deployed to test small material coupons to ~0.5 g/s of 2800 K, 500 psi Hydrogen, is discussed herein. To achieve this desired delivery temperature level, the most suitable material for the N5HHX’s construction was pure tungsten, which imposed budgetary and manufacturing challenges. Also discussed in this paper is the design of the N5HHX rig’s sample container, which became the first iteration of improving NTREES small material coupon test operations by permitting rapid changeout of different material samples.

Reactor Testing↗

Characterization, Operation and Analysis of Test Motors Containing Aluminized Hybrid Fuels

NASA Marshall Space Flight Center's Materials and Processes Department, with support from the Propulsion Systems Department, has renewed the development and maintenance of a hybrid test bed for exposing ablative thermal protection materials to an environment similar to that seen in solid rocket motors (SRM). The Solid Fuel Torch (SFT), operated during the Space Shuttle program, utilized gaseous oxygen for oxidizer and an aluminized hydroxyl-terminated polybutadiene (HTPB) fuel grain to expose a converging section of phenolic material to a 400 psi, 2-phase flow combustion environment. The configuration allows for up to a 2 foot long, 5 inch diameter fuel grain cartridge. Wanting to now test rubber insulation materials with a turn-back feature to mimic the geometry of an aft dome being impinged by alumina particles, the throat area has now been increased by several times to afford flow similarity. Combined with the desire to maintain a higher operating pressure, the oxidizer flow rate is being increased by a factor of 10. Out of these changes has arisen the need to characterize the fuel/oxidizer combination in a higher mass flux condition than has been previously tested at MSFC, and at which the literature has little to no reporting as well. Testing for fuel regression rate comprised a two-level, full factorial design available over Aluminum loading level, mass flow rate, pressure, and diameter. The data taken significantly surpasses the previous available data on regression rate of aluminized HTPB fuel burning with gaseous oxygen. It encompasses higher mass fluxes, and appears to generate more consistent data. The good test article and facility design and testing work of the Penn State HPCL combined with careful analysis of the data and good planning has made this possible. This should be able to assist with developing rate laws that are useful both for research planning and for developing flight system sizing relationships that can help optimize hybrid rocket concepts for trade studies. The successful approach of this DOE and test setup is applicable to other propellant combinations as well.

Kibbey, Timothy P.↗

Characterization, Operation and Analysis of Test Motors Containing Aluminized Hybrid Fuels

NASA Marshall Space Flight Center's Materials and Processes Department, with support from the Propulsion Systems Department, has renewed the development and maintenance of a hybrid test bed for exposing ablative thermal protection materials to an environment similar to that seen in solid rocket motors (SRM). The Solid Fuel Torch (SFT), operated during the Space Shuttle program, utilized gaseous oxygen for oxidizer and an aluminized hydroxyl-terminated polybutadiene (HTPB) fuel grain to expose a converging section of phenolic material to a 400 psi, 2-phase flow combustion environment. The configuration allows for up to a 2 foot long, 5 inch diameter fuel grain cartridge. Wanting to now test rubber insulation materials with a turn-back feature to mimic the geometry of an aft dome being impinged by alumina particles, the throat area has now been increased by several times to afford flow similarity. Combined with the desire to maintain a higher operating pressure, the oxidizer flow rate is being increased by a factor of 10. Out of these changes has arisen the need to characterize the fuel/oxidizer combination in a higher mass flux condition than has been previously tested at MSFC, and at which the literature has little to no reporting as well. Testing for fuel regression rate comprised a two-level, full factorial design available over Aluminum loading level, mass flow rate, pressure, and diameter. The data taken significantly surpasses the previous available data on regression rate of aluminized HTPB fuel burning with gaseous oxygen. It encompasses higher mass fluxes, and appears to generate more consistent data. The good test article and facility design and testing work of the Penn State HPCL combined with careful analysis of the data and good planning has made this possible. This should be able to assist with developing rate laws that are useful both for research planning and for developing flight system sizing relationships that can help optimize hybrid rocket concepts for trade studies. The successful approach of this DOE and test setup is applicable to other propellant combinations as well.

Kibbey, Timothy P.↗

Characterization and Detailed Analysis of Regression Behavior for HTPB Solid Fuels Containing High Aluminum Loadings

NASA Marshall Space Flight Center's Materials and Processes Department, with support from the Propulsion Systems Department, has renewed the development and maintenance of a hybrid test bed for exposing ablative thermal protection materials to an environment similar to that seen in solid rocket motors (SRM). The Solid Fuel Torch (SFT), operated during the Space Shuttle program, utilized gaseous oxygen for oxidizer and an aluminized hydroxyl-terminated polybutadiene (HTPB) fuel grain to expose a converging section of phenolic material to a 400 psi, 2-phase flow combustion environment. The configuration allows for up to a 2 foot long, 5 inch diameter fuel grain cartridge. Wanting to now test rubber insulation materials with a turn-back feature to mimic the geometry of an aft dome being impinged by alumina particles, the throat area has now been increased by several times to afford flow similarity. Combined with the desire to maintain a higher operating pressure, the oxidizer flow rate is being increased by a factor of 10. Out of these changes has arisen the need to characterize the fuel/oxidizer combination in a higher mass flux condition than has been previously tested at MSFC, and at which the literature has little to no reporting as well. For (especially) metalized fuels, hybrid references have pointed out possible dependence of fuel regression rate on a number of variables: mass flux, G - oxidizer only (G0), or - total mass flux (Gtot), Length, L, Pressure, P, and Diameter, D.

Kibbey, Timothy P.↗

NASA CERCER Development TDM Presentation

In NASA's Space Nuclear Propulsion program there is a development effort of for a composite fuel containing zirconium carbide (ZrC) and uranium mononitride (UN), this fuel form is referred to as a CERCER (ceramic-ceramic). These series of slides were put together to showcase the primary achievements in our research over the past year to our program sponsors. This is a yearly meeting to evaluate progress.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Mechanisms of transport enhancement for self-propelled nanoswimmers in a porous matrix

Significance As with living microorganisms, many real-world applications of synthetic micro/nanoswimmers are likely to rely on transport in complex environments, a phenomenon that remains poorly understood. Here, we report anomalously rapid transport of self-propelled particles in a porous medium, where nanoswimmers escaped from cavities more than an order of magnitude faster than expected compared to corresponding Brownian particles. This phenomenon was determined to be due to nuanced effects associated with self-propulsion, including enhanced mobility in confinement, efficient surface-mediated searching for holes, and the abolition of barriers at cavity exits. These mechanisms are broadly generalizable, and the previously unknown transport efficiency of nanoswimmers in complex porous environments suggests tremendous opportunities in forward-looking applications, including drug delivery and environmental remediation.

59 BASIC BIOLOGICAL SCIENCES↗

Overview of Advanced Space Propulsion Activities in the Space Environmental Effects Team at MSFC

Exploration of our solar system, and beyond, requires spacecraft velocities beyond our current technological level. Technologies addressing this limitation are numerous. The Space Environmental Effects (SEE) Team at the Marshall Space Flight Center (MSFC) is focused on three discipline areas of advanced propulsion; Tethers, Beamed Energy, and Plasma. This presentation will give an overview of advanced propulsion related activities in the Space Environmental Effects Team at MSFC. Advancements in the application of tethers for spacecraft propulsion were made while developing the Propulsive Small Expendable Deployer System (ProSEDS). New tether materials were developed to meet the specifications of the ProSEDS mission and new techniques had to be developed to test and characterize these tethers. Plasma contactors were developed, tested and modified to meet new requirements. Follow-on activities in tether propulsion include the Air-SEDS activity. Beamed energy activities initiated with an experimental investigation to quantify the momentum transfer subsequent to high power, 5J, ablative laser interaction with materials. The next step with this experimental investigation is to quantify non-ablative photon momentum transfer. This step was started last year and will be used to characterize the efficiency of solar sail materials before and after exposure to Space Environmental Effects (SEE). Our focus with plasma, for propulsion, concentrates on optimizing energy deposition into a magnetically confined plasma and integration of measurement techniques for determining plasma parameters. Plasma confinement is accomplished with the Marshall Magnetic Mirror (M3) device. Initial energy coupling experiments will consist of injecting a 50 amp electron beam into a target plasma. Measurements of plasma temperature and density will be used to determine the effect of changes in magnetic field structure, beam current, and gas species. Experimental observations will be compared to predictions from computer modeling.

Edwards, David↗

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗

Bringing the Future Within Reach: Celebrating 75 Years of the NASA John H. Glenn Research Center

The National Aeronautics and Space Administration (NASA) Glenn Research Center in Cleveland, Ohio, has been making the future for 75 years. The center's work with aircraft engines, high-energy fuels, communications technology, electric propulsion, energy conversion and storage, and materials and structures has been, and continues to be, crucial to both the Agency and the region. Glenn has partnered with industry, universities, and other agencies to continually advance technologies that are propelling the nation's aerospace community into the future. Nonetheless these continued accomplishments would not be possible without the legacy of our first three decades of research, which led to over one hundred R&D 100 Awards, three Robert J. Collier Trophies, and an Emmy. Glenn, which is located in Cleveland, Ohio, is 1 of 10 NASA field centers, and 1 of only 3 that stem from an earlier research organization-the National Advisory Committee for Aeronautics (NACA). Glenn began operation in 1942 as the NACA Aircraft Engine Research Laboratory (AERL). In 1947 the NACA renamed the lab the Flight Propulsion Laboratory to reflect the expansion of the research. In September 1948, following the death of the NACA's Director of Aeronautics, George Lewis, the NACA rededicated the lab as the Lewis Flight Propulsion Laboratory. On 1 October 1958, the lab was incorporated into the new NASA space agency and was renamed the NASA Lewis Research Center. Following John Glenn's return to space on the space shuttle, on 1 March 1999 the center name was changed once again, becoming the NASA John H. Glenn Research Center.

Arrighi, Robert S.↗

Lightweight Damage Tolerant, High-Temperature Radiators for Nuclear Power and Propulsion

NASA is increasingly emphasizing exploration to bodies beyond near-Earth orbit. New propulsion systems and new spacecraft are being built for these missions. As the target bodies get further out from Earth, high energy density systems, e.g., nuclear fusion, for propulsion and power will be advantageous. The mass and size of these systems, including supporting systems such as the heat exchange system, including thermal radiators, will need to be as small as possible. Conventional heat exchange systems are a significant portion of the total thermal management mass and size. Nuclear electric propulsion (NEP) is a promising option for high-speed, in-space travel due to the high energy density of nuclear fission power sources and efficient electric thrusters. Heat from the reactor is converted to power for use in propulsion or for system power. The heat not used in the power conversion is then radiated to space as shown in figure 1. Advanced power conversion technologies will require high operating temperatures and would benefit from lightweight radiator materials. Radiator performance dictates power output for nuclear electric propulsion systems. Pitch-based carbon fiber materials have the potential to offer significant improvements in operating temperature, thermal conductivity, and mass. These properties combine to allow significant decreases in the total mass of the radiators and significant increases in the operating temperature of the fins. A Center-funded project at NASA Marshall Space Flight Center has shown that high thermal conductivity, woven carbon fiber fins with no matrix material, can be used to dissipate waste heat from NEP systems and because of high specific power (kW/kg), will require less mass and possibly less total area than standard metal and composite radiator fins for radiating the same amount of heat. This project uses an innovative approach to reduce the mass and size required for the thermal radiators to the point that in-space NEP and power is enabled. High thermal conductivity carbon fibers are lightweight, damage tolerant, and can be heated to high temperature. Areal densities in the NASA set target range of 2 to 4 kg/m2 (for enabling NEP) are achieved and with specific powers (kW/kg) a factor of about 7 greater than conventional metal fins and about 1.5 greater than carbon composite fins. Figure 2 shows one fin under test. All tests were done under vacuum conditions.

Craven, Paul D.↗

Summary of Expansions and Updates in GREET ® 2021

The GREET® (Greenhouse gases, Regulated Emissions, and Energy use in Technologies) model has been developed by Argonne National Laboratory (Argonne) with the support of the U.S. Department of Energy (DOE). GREET is a life-cycle analysis (LCA) tool, structured to systematically examine the energy and environmental effects of a wide variety of transportation fuels and vehicle technologies in major transportation sectors (i.e., road, air, marine, and rail) and other end-use sectors, and energy systems. Within the transportation sector, GREET covers road, air, water, and rail transportation sub-sectors. Recently, GREET was expanded to cover the building sector. Historically, GREET includes LCA of various materials such as steel, aluminum, cement, and different plastic types. Argonne has expanded and updated the model in various sectors in GREET 2021, and this report provides a summary of the release.

09 BIOMASS FUELS↗

Computational simulation of coupled material degradation processes for probabilistic lifetime strength of aerospace materials

The research included ongoing development of methodology that provides probabilistic lifetime strength of aerospace materials via computational simulation. A probabilistic material strength degradation model, in the form of a randomized multifactor interaction equation, is postulated for strength degradation of structural components of aerospace propulsion systems subjected to a number of effects or primative variables. These primative variable may include high temperature, fatigue or creep. In most cases, strength is reduced as a result of the action of a variable. This multifactor interaction strength degradation equation has been randomized and is included in the computer program, PROMISS. Also included in the research is the development of methodology to calibrate the above described constitutive equation using actual experimental materials data together with linear regression of that data, thereby predicting values for the empirical material constraints for each effect or primative variable. This regression methodology is included in the computer program, PROMISC. Actual experimental materials data were obtained from the open literature for materials typically of interest to those studying aerospace propulsion system components. Material data for Inconel 718 was analyzed using the developed methodology.

Boyce, Lola↗

Microstructural evolutions, phase transformations and hard magnetic properties in polycrystalline Ce–Co–Fe–Cu alloys

This work focuses on systematic studies of Ce–Co based 1:5 permanent magnet alloys of CeCo 4.4-x Fe x Cu 0.6 and CeCo 3.9-x Fe x Cu 1.2 (x = 0, 0.3, 0.6, 0.9, 1.2, 1.8) by varying Co:Fe. The overarching aim of this manuscript is to elucidate the hard-magnetic properties through a better understanding of phase formation by the structural, microstructural, and magnetic properties in these materials. Improved mutual solubility of Fe in the 1:5 phase has been observed with an extended homogeneity range by Cu substitution. For both composition series, Fe contents of x ≤ 0.6 show a homogeneous microstructure with a single 1:5 phase and good magnetic properties. The composition region 0.6 < x ≤ 0.9 appears to be near the boundary of solubility and evolution of other phases. At x = 1.8, it is found that the homogeneous 1:5 phase and magnetic hardness deteriorated due to the evolution of secondary phases such as 2:17, 2:7, and Fe–Co. Furthermore, the addition of Fe improved both the magnetization and Curie temperature via increased effective exchange interactions, while an increase in Cu content enhanced coercivity.

33 ADVANCED PROPULSION SYSTEMS↗