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At least 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A New Perspective of Post-Weld Baking Effect on Al-Steel Resistance Spot Weld Properties through Machine Learning and Finite Element Modeling

The root cause of post-weld baking on the mechanical performance of Al-steel dissimilar resistance spot welds (RSWs) has been determined by machine learning (ML) and finite element modeling (FEM) in this study. A deep neural network (DNN) model was constructed to associate the spot weld performance with the joint attributes, stacking materials, and other conditions, using a comprehensive experimental dataset. The DNN model positively identified that the post-weld baking reduces the joint performance, and the extent of degradation depends on the thickness of stacking materials. A three-dimensional finite element (FE) model was then used to investigate the root cause and the mechanism of the baking effect. It revealed that the formation of high thermal stresses during baking, from the mismatch of thermal expansion between steel and Al alloy, causes damage and cracking of the brittle intermetallic compound (IMC) formed at the interface of the weld nugget during welding. This in turn reduces the joint performance by promoting undesirable interfacial fracture when the welds were subjected to externally applied loads. The FEM model further revealed that increase in structural stiffness, because of increase in steel sheet thickness, reduces the thermal stresses at the interface caused by the thermal expansion mismatch and consequently lessens the detrimental effect of post-weld baking on the joint performance.

36 MATERIALS SCIENCE↗
NASA NTRS2002

Replacement of Ablators with Phase-Change Material for Thermal Protection of STS Elements

As part of the research and development program to develop new Thermal Protection System (TPS) materials for aerospace applications at NASA's Marshall Space Flight Center (MSFC), an experimental study was conducted on a new concept for a non-ablative TPS material. Potential loss of TPS material and ablation by-products from the External Tank (ET) or Solid Rocket Booster (SRB) during Shuttle flight with the related Orbiter tile damage necessitates development of a non-ablative thermal protection system. The new Thermal Management Coating (TMC) consists of phase-change material encapsulated in micro spheres and a two-part resin system to adhere the coating to the structure material. The TMC uses a phase-change material to dissipate the heat produced during supersonic flight rather than an ablative material. This new material absorbs energy as it goes through a phase change during the heating portion of the flight profile and then the energy is slowly released as the phase-change material cools and returns to its solid state inside the micro spheres. The coating was subjected to different test conditions simulating design flight environments at the NASA/MSFC Improved Hot Gas Facility (IHGF) to study its performance.

Kaul, Raj K.↗
NASA NTRS2003

Hot Views on Cold Crystals: The Application of Thermal Imaging in Cryocrystallography

We have used thermal imaging techniques to visualize the cryocooling processes of macromolecular crystals. Cryocooling is a common technique used for structural data collection to reduce radiation damage in intense X-ray beams and decrease the thermal motion of the atoms. From the thermal images it was clear that during cryocooling a cold wave progresses through a crystal starting at the face closest to the origin of the cold stream and ending at the point furthest away. As an extension to this work, we used thermal imaging to study small crystals, held in a cryo-loop, in the presence of vitrified mother liquor. The different infrared transmission and reflectance properties of the crystal in comparison to the mother liquor surrounding it are thought to be the parameter that produces the contrast that makes the crystal visible. An application of this technology may be the determination of the exact location of small crystals in a cryo-loop for automated structural genomics studies. Data from initial tests in support of application development was recorded for lysozyme crystals and for bFGF/dna complex crystals, which were cryocooled and imaged in large loops, both with visible light and with infrared radiation. The crystals were clearly distinguished from the vitrified solution in the infrared spectrum, while in the case of the bFGF/dna complex the illumination had to be carefully manipulated to make the crystal visible in the visible spectrum. These results suggest that the thermal imaging may be more sensitive than visual imaging for automated location of small crystals. However, further work on small crystals robotically mounted at SSRL did not clearly visualize those crystals. The depth of field of the camera proved to be limiting and a different cooling geometry was used, compared to the previous, successful experiments. Analysis to exploit multiple images to improve depth of field and experimental work to understand cooling geometry effects is ongoing. These results will be presented along with advantages and disadvantages of the technique and a discussion of how it might be applied.

Snell, Eddie↗
DOE OSTI2022

Irradiation Experiments and Thermal Analysis for Reactor System Design and Analysis at INL

Idaho National Laboratory (INL) is the nation's lead nuclear laboratory working to enhance reactor systems' safety, security, economics, and efficiency. Research and development (R&D) programs at INL support the current fleet of nuclear reactors for safer operation and newer reactors technology design, development, demonstration, and deployment. A major focus of INL's mission is the reactor system design and analysis supported by the irradiation experiments and thermal analysis of advanced and current-generation nuclear fuels and materials. The irradiation experiments and thermal analysis provide a deeper understanding of basic radiation damage processes that can determine the basis for performance improvements and verification of modeling assumptions. These experiments and analyses include experiment management: design, fabrication, characterization, irradiation, and post-irradiation examination. This research involves thermal, neutronic, and material investigation using the INL's Advanced Test Reactor (ATR) and Transient Reactor Test (TREAT) facilities. The results from these experiments and analysis are required to develop the regulatory basis for deploying new or modified fuels and materials. This seminar talk will also provide a general overview of the INL's research facilities, ongoing research programs, core capabilities, and opportunities for students and faculties.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS2009

Electrical Resistance of SiC/SiC Ceramic Matrix Composites for Damage Detection and Life-Prediction

Ceramic matrix composites (CMC) are suitable for high temperature structural applications such as turbine airfoils and hypersonic thermal protection systems due to their low density high thermal conductivity. The employment of these materials in such applications is limited by the ability to accurately monitor and predict damage evolution. Current nondestructive methods such as ultrasound, x-ray, and thermal imaging are limited in their ability to quantify small scale, transverse, in-plane, matrix cracks developed over long-time creep and fatigue conditions. CMC is a multifunctional material in which the damage is coupled with the material s electrical resistance, providing the possibility of real-time information about the damage state through monitoring of resistance. Here, resistance measurement of SiC/SiC composites under mechanical load at both room temperature monotonic and high temperature creep conditions, coupled with a modal acoustic emission technique, can relate the effects of temperature, strain, matrix cracks, fiber breaks, and oxidation to the change in electrical resistance. A multiscale model can in turn be developed for life prediction of in-service composites, based on electrical resistance methods. Results of tensile mechanical testing of SiC/SiC composites at room and high temperatures will be discussed. Data relating electrical resistivity to composite constituent content, fiber architecture, temperature, matrix crack formation, and oxidation will be explained, along with progress in modeling such properties.

Smith, Craig↗
NASA NTRS2003

Analysis of the Effects of Residual Strains and Defects on Skin/Stiffener Debonding using Decohesion Elements

Delamination is one of the predominant forms of failure in laminated composites especially when there is no reinforcement in the thickness direction. To develop composite structures that are more damage tolerant, it is necessary to understand how delamination develops and how it can affect the residual performance. A number of factors such as residual thermal strains, matrix curing shrinkage, and manufacturing defects affect how damage will grow in a composite structure. It is important to develop analysis methods that are computationally efficient that can account for all such factors. The objective of the current work is to apply a newly developed decohesion element to investigate the debond strength of skin/stiffener composite specimens. The process of initiation of delaminations and the propagation of delamination fronts is investigated. The numerical predictions are compared with published experimental results.

Davila, Carlos G.↗
DOE OSTI2020

Pool Fire Analysis Methodology for Assessing Damage to Waste Containers

This document provides guidelines, whereby the physical parameters associated with postulated flammable/combustible liquid pool fires are determined (thermal analysis) in order to estimate the number of waste containers impacted. Pool fire damage to waste containers may occur due to a container being fully engulfed (within the periphery of the pool), partially engulfed, or within the critical heat flux distance. The methodology described here for estimating the size of the pool fire is developed using spill characteristics outlined in Chapter 65 of the SFPE Handbook (Ref. 7) and testing done by Hansen (Ref. 25). For exposures, the critical flux height is determined using the detailed method of Shokri and Beyler (Ref. 8) from the flame height, calculated as described by Heskestad (Ref. 7) and the average black body emissive power, determined using the method of Shokri and Beyler (Ref. 8). Three types of liquid pool fires should be considered; unconfined crash/instantaneous spill fires, unconfined continuously flowing (also called metered leak) spill fires, and confined spill fires. All fuel sources should be considered consistent with the facility Fire Hazard Analysis (FHA). However, the most likely liquid fuel sources present in TRU waste facilities are those present on TRU waste handling vehicles (forklifts, pallet movers, transport trucks, etc.). This method can also be used for assessing damage to items other than waste containers or other methods of analysis may be used with appropriate justification.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Systems and methods for thermal barrier coatings to modify engine component thermal characteristics

An engine component comprises one or more thermal barrier coatings applied to one or more areas of the engine component. The thermal barrier coatings reduce the temperature rate of change of the areas to which the thermal barrier coating is applied. Reducing the temperature rate of change can help reduce lattice structure damage caused by different temperatures in different areas of the engine component. The thermal barrier coating can be applied as a monolithic layer on a surface of the engine component or can be applied in different areas using patterns. The patterns allow for the tuning of the performance characteristics (temperature rate of change) of the areas of the engine component and can help reduce defect propagation, such as cracks, in the thermal barrier coating from one area of the thermal barrier coating to other areas of the thermal barrier coating.

Koci, Chad Palmer↗
NASA NTRS1990

Flight Set 360L006 STS-34 field joint protection system, thermal protection system, and systems tunnel components, volume 4

The performance of the thermal protection system, field joint protection system, and systems tunnel components of Flight Set 360L006, are documented, as evaluated by postflight hardware inspection. The condition of both motors was similar to previous flights. Sixteen aft edge hits were noted on the ground environment instrumentation thermal protection system. Each hit left a clean substrate, indicating that the damage was caused by nozzle severance debris and/or water impact. No National Space and Transporation System debris criteria for missing thermal protection system were violated. One 5.0 by 1.0 in. unbond was observed on the left hand center field joint K5NA closeout and was elevated to an in-flight anomaly (STS-34-M-4) by the NASA Ice/Debris team. Aft edge damage to the K5NA and an associated black streak indicate that burning debris from the nozzle severance system was the likely cause of the damage. Minor divots caused by debris were seen on previous flights, but this is the first occurrence of a K5NA unbond. Since the unbond occurred after booster separation there is no impact on flight safety and no corrective actions was taken. The right hand center field joint primary heater failed the dielectric withstanding voltage test after joint closeout. The heater was then disabled by opening the circuit breaker, and the redundant heater was used. The redundant heater performed nominally during the launch countdown. A similar condition occurred on Flight 4 when a secondary joint heater failed the dielectric withstanding voltage test.

Wilkinson, J. P.↗
NASA NTRS1997

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗
DOE OSTI2022

Electric vehicle post-crash Recovery—Stranded energy issues and mitigation strategy

In post-crash situations, passengers, bystanders, and first responders are exposed to the immediate safety risks of stranded energy in electric vehicle (EV) batteries. Stranded energy is the energy remaining inside any undamaged or damaged battery following an accident. A potentially damaged battery with an unknown state of safety might go into thermal runaway in the absence of proper monitoring, diagnostics, controls, and handling—thereby leading to potential loss of life and property damage. Therefore, it is imperative to develop standard guidelines, diagnostic methods, and tools to handle stranded energy appropriately and minimize safety risks from immediately after an EV accident to final disposal or re-entry to the road. This perspective paper identifies the challenges associated with handling stranded energy and proposes some potential solution pathways. Further, we hope to draw attention of the research and development community, original equipment manufacturers, and policymakers for motivating new insights and research needs in mitigating safety implications associated with stranded energy.

25 ENERGY STORAGE↗
NASA NTRS2011

Dual-Polarimetric Radar-Based Tornado Debris Paths Associated with EF-4 and EF-5 Tornadoes over Northern Alabama During the Historic Outbreak of 27 April 2011

An historic tornado and severe weather outbreak devastated much of the southeastern United States between 25 and 28 April 2011. On 27 April 2011, northern Alabama was particularly hard hit by a large number of tornadoes, including several that reached EF-4 and EF-5 on the Enhanced Fujita damage scale. In northern Alabama alone, there were approximately 100 fatalities and hundreds of more people who were injured or lost their homes during the havoc caused by these violent tornadic storms. Two long-track and violent (EF-4 and EF-5) tornadoes occurred within range of the University of Alabama in Huntsville (UAHuntsville) Advanced Radar for Meteorological and Operational Research (ARMOR, C-band dual-polarimetric). A unique capability of dual-polarimetric radar is the near-real time identification of lofted debris associated with ongoing tornadoes on the ground. The focus of this paper is to analyze the dual-polarimetric radar-inferred tornado debris signatures and identify the associated debris paths of the long-track EF-4 and EF-5 tornadoes near ARMOR. The relative locations of the debris and damage paths for each tornado will be ascertained by careful comparison of the ARMOR analysis with NASA MODIS (Moderate Resolution Imaging Spectroradiometer) and ASTER (Advanced Spaceborne Thermal Emission and Reflection Radiometer) satellite imagery of the tornado damage scenes and the National Weather Service tornado damage surveys. With the ongoing upgrade of the WSR-88D (Weather Surveillance Radar - 1988 Doppler) operational network to dual-polarimetry and a similar process having already taken place or ongoing for many private sector radars, dual-polarimetric radar signatures of tornado debris promise the potential to assist in the situational awareness of government and private sector forecasters and emergency managers during tornadic events. As such, a companion abstract (Schultz et al.) also submitted to this conference explores "The use of dual-polarimetric tornadic debris signatures in an operational setting."

Carey, Lawrence D.↗
NASA NTRS2012

Dual-Polarimetric Radar-Based Tornado Debris Paths Associated with EF-4 and EF-5 Tornadoes over Northern Alabama During the Historic Outbreak of 27 April 2011

An historic tornado and severe weather outbreak devastated much of the southeastern United States between 25 and 28 April 2011. On 27 April 2011, northern Alabama was particularly hard hit by a large number of tornadoes, including several that reached EF-4 and EF-5 on the Enhanced Fujita damage scale. In northern Alabama alone, there were approximately 100 fatalities and hundreds of more people who were injured or lost their homes during the havoc caused by these violent tornadic storms. Two long-track and violent (EF-4 and EF-5) tornadoes occurred within range of the University of Alabama in Huntsville (UAHuntsville) Advanced Radar for Meteorological and Operational Research (ARMOR, C-band dual-polarimetric). A unique capability of dual-polarimetric radar is the near-real time identification of lofted debris associated with ongoing tornadoes on the ground. The focus of this paper is to analyze the dual-polarimetric radar-inferred tornado debris signatures and identify the associated debris paths of the long-track EF-4 and EF-5 tornadoes near ARMOR. The relative locations of the debris and damage paths for each tornado will be ascertained by careful comparison of the ARMOR analysis with NASA MODIS (Moderate Resolution Imaging Spectroradiometer) and ASTER (Advanced Spaceborne Thermal Emission and Reflection Radiometer) satellite imagery of the tornado damage scenes and the National Weather Service tornado damage surveys. With the ongoing upgrade of the WSR-88D (Weather Surveillance Radar 1988 Doppler) operational network to dual-polarimetry and a similar process having already taken place or ongoing for many private sector radars, dual-polarimetric radar signatures of tornado debris promise the potential to assist in the situational awareness of government and private sector forecasters and emergency managers during tornadic events. As such, a companion abstract (Schultz et al.) also submitted to this conference explores The use of dual-polarimetric tornadic debris signatures in an operational setting.

Carey, Lawrence D.↗
NASA NTRS2009

Handbook for Designing MMOD Protection

Spacecraft are subject to micro-meteoroid and orbital debris (MMOD) impact damage which have the potential to degrade performance, shorten the mission, or result in catastrophic loss of the vehicle. Specific MMOD protection requirements are established by NASA for each spacecraft early in the program/project life, to ensure the spacecraft meets desired safety and mission success goals. Both the design and operations influences spacecraft survivability in the MMOD environment, and NASA considers both in meeting MMOD protection requirements. The purpose of this handbook is to provide spacecraft designers and operations personnel with knowledge gained by NASA in implementing effective MMOD protection for the International Space Station, Space Shuttle, and various science spacecraft. It has been drawn from a number of previous publications [10-14], as well as new work. This handbook documents design and operational methods to reduce MMOD risk. In addition, this handbook describes tools and equations needed to design proper MMOD protection. It is a living report, in that it will be updated and re-released periodically in future with additional information. Providing effective and efficient MMOD protection is essential for ensuring safe and successful operations of spacecraft and satellites. A variety of shields protect crew modules, external pressurized vessels and critical equipment from MMOD on the International Space Station (ISS). Certain Space Shuttle Orbiter vehicle systems are hardened from MMOD impact, and operational rules are established to reduce the risk from MMOD (i.e., flight attitudes are selected and late inspection of sensitive thermal protection surfaces are conducted to reduce MMOD impacts). Science spacecraft include specific provisions to meet MMOD protection requirements in their design (for example, Stardust & GLAST). Commercial satellites such as Iridium and Bigelow Aerospace Genesis spacecraft incorporate MMOD protection. The development of low-weight, effective MMOD protection has enabled these spacecraft missions to be performed successfully. This handbook describes these shielding techniques. For future exploration activities to the Moon and Mars, implementing high-performance MMOD shielding will be necessary to meet protection requirements with minimum mass penalty. A current area of technology development in MMOD shielding is the incorporation of sensors to detect and locate MMOD impact damage. Depending on the type of sensor the signals from the sensor can be processed to infer the location of the impact and the extent of damage. The objective of the sensors is to locate critical damage that would endanger the spacecraft or crew immediately or during reentry (such as an air leak from crew module or critical damage to thermal protection system of reentry vehicles). The information from the sensors can then be used with repair kits, patch kits, hatch closure or other appropriate remedial techniques to reduce MMOD risk.

Arnold, Jim↗
DOE OSTI2025

R&D Program for HEP High-Power Targets at Fermilab

A high-power target system is a key beam element to complete future High Energy Physics (HEP) experiments. In the recent past, major accelerator facilities have been limited in beam power not by their accelerators, but by the beam intercepting device survivability. The target must then endure high power pulsed beam, leading to high cycle thermal stresses/pressures and thermal shocks. The increased beam power will also create significant challenges such as corrosion and radiation damage that can cause harmful effects on the material and degrade their mechanical and thermal properties during irradiation. This can eventually lead to the failure of the material and drastically reduce the lifetime of targets and beam intercepting devices. In order to operate reliable beam-intercepting devices in the framework of energy and intensity increase projects of the future, it is essential to develop a strong R&D program and have synergy with various expertise. After presenting the high power targetry challenges facing next generation multi-MW accelerators, we will give an overview of Fermilab’s R&D program in support of High Power Targetry development. The RaDIATE collaboration (Radiation Damage In Accelerator Target Environment), managed by Fermilab, also draws on existing expertise in related fields to execute a coordinated strategy for high power targetry R&D between the 14 international member institutions.

Pellemoine, Frederique [Fermilab]↗
NASA NTRS1998

HST Multi Layer Insulation Failure Review Board Findings

The mechanical and optical properties of the thermal control materials on the Hubble Space Telescope (HST) have degraded over the nearly seven years the telescope has been in orbit. Astronaut observations and photographs from the Second Servicing Mission (SM2) revealed large cracks in the metallized Teflon fluorinated ethylene propylene (FEP), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. Also, the absorptance of the bonded metallized Teflon FEP radiator surfaces of the telescope has increased over time. A Failure Review Board was established to determine the damage mechanism and to identify a replacement material. Samples of the top layer of the MLI and radiator material were retrieved during SM2, and a thorough investigation into the degradation followed in order to determine the primary cause of the damage. Mapping of the cracks on HST and the ground testing showed that thermal cycling with deep-layer damage from electron and proton radiation are necessary to cause the observed embrittlement. Further, strong evidence was found indicating that chain scission (reduced molecular weight) is the dominant form of damage to the metallized Teflon FEP. Given the damage to the outer layer of the multi-layer insulation (MLI) that was apparent during the second servicing mission (SM2), the decision was made to replace the outer layer during subsequent servicing missions. The replacement material had to meet the stringent thermal requirements of the spacecraft and maintain structural integrity for at least ten years. Ten candidate materials were exposed to simulated orbital environments and a replacement material was selected. This presentation will summarize the FRB results, in particular, the analysis of the retrieved specimens, the results of the simulated environmental exposures, and the selection of the replacement material. The NASA Space Environments and Effects community needs to hear these results because they reveal that Teflon (FEP) films should not be used in LEO as routinely as they are today.

Townsend, Jacqueline↗
NASA NTRS1988

Development and properties of aluminum-clad graphite/epoxy tubes for space structures

This paper presents the development and properties of seamless aluminum-clad P75/Epoxy tubes and the unique manufacturing method used in their production. Thermo-mechanical properties of the tubes were determined analytically and verified by tests. These properties were shown to be suitable for space structures that require high stiffness, low weight and thermal expansion, and dimensional stability during operational life. A special feature of the tubes is the ability to tune the tube for thermal expansion after fabrication by a chemical milling process. The tubes are also resistant to atomic oxygen and handling damage. The toughness of the tubes was demonstrated by impact testing. Cyclic thermal testing showed no adverse effects on the expansion and stiffness behavior of the tubes. The paper also includes a discussion of a joining method that uses aluminum end fittings and an efficient scarf joint configuration. Additional studies considered various adhesives and fitting materials. Joint allowables were higher for titanium and B4C particulate magnesium fittings. The effect of different adhesives under static loading conditions favored the high-strength adhesives.

Johnson, R. R.↗