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NASA NTRS2003

Impedance-Based Structural Health Monitoring for Composite Laminates at Cryogenic Environments

One of the important ways of increasing the payload in a reusable launch vehicle (RLV) is to replace heavy metallic materials by lightweight composite laminates. Among various parts and systems of the RLV, this project focuses on tanks containing cryogenic fuel. Historically, aluminum alloys have been used as the materials to construct fuel tanks for launch vehicles. To replace aluminum alloys with composite laminates or honeycomb materials, engineers have to make sure that the composites are free of defects before, during, and after launch. In addition to robust design and manufacturing procedures, the performance of the composite structures needs to be monitored constantly.In recent years, the impedance-based health monitoring technique has shown its promise in many applications. This technique makes use of the special properties of smart piezoelectric materials to identify the change of material properties due to the nucleation and progression of damage. The piezoceramic patch serves as a sensor and an actuator simultaneously. The piezoelectric patch is bonded onto an existing structure or embedded into a new structure and electrically excited at high frequencies. The signature (impedance or admittance) is extracted as a function of the exciting frequency and is compared with the baseline signature of the healthy state. The damage is quantified using root mean square deviation (RMSD) in the impedance signatures with respect to the baseline signature. A major advantage of this technique is that the procedure is nondestructive in nature and does not perturb the properties and performance of the materials and structures. This project aims at applying the impedance-based nondestructive testing technique to the damage identification of composite laminates at cryogenic temperature.

Tseng, Kevin↗

NASA NTRS2003

Development of Oxidation Protection Coatings for Gamma Titanium Aluminide Alloys

Metallic material systems play a key role in meeting the stringent weight and durability requirements for reusable launch vehicle (RLV) airframe hot structures. Gamma titanium aluminides (gamma-TiAl) have been identified as high-payoff materials for high-temperature applications. The low density and good elevated temperature mechanical properties of gamma-TiAl alloys make them attractive candidates for durable lightweight hot structure and thermal protection systems at temperatures as high as 871 C. However, oxidation significantly degrades gamma-TiAl alloys under the high-temperature service conditions associated with the RLV operating environment. This paper discusses ongoing efforts at NASA Langley Research Center to develop durable ultrathin coatings for protecting gamma-TiAl alloys from high-temperature oxidation environments. In addition to offering oxidation protection, these multifunctional coatings are being engineered to provide thermal control features to help minimize heat input into the hot structures. This paper describes the coating development effort and discusses the effects of long-term high-temperature exposures on the microstructure of coated and uncoated gamma-TiAl alloys. The alloy of primary consideration was the Plansee alloy gamma-Met, but limited studies of the newer alloy gamma-Met-PX were also included. The oxidation behavior of the uncoated materials was evaluated over the temperature range of 704 C to 871 C. Sol-gel-based coatings were applied to the gamma-TiAl samples by dipping and spraying, and the performance evaluated at 871 C. Results showed that the coatings improve the oxidation resistance, but that further development is necessary.

Wallace, T. A.↗

NASA NTRS1998

The Mars oxidant experiment (MOx) for Mars '96

The MOx instrument was developed to characterize the reactive nature of the martian soil. The objectives of MOx were: (1) to measure the rate of degradation of organics in the martian environment; (2) to determine if the reactions seen by the Viking biology experiments were caused by a soil oxidant and measure the reactivity of the soil and atmosphere: (3) to monitor the degradation, when exposed to the martian environment, of materials of potential use in future missions; and, finally, (4) to develop technologies and approaches that can be part of future soil analysis instrumentation. The basic approach taken in the MOx instrument was to place a variety of materials composed as thin films in contact with the soil and monitor the physical and chemical changes that result. The optical reflectance of the thin films was the primary sensing-mode. Thin films of organic materials, metals, and semiconductors were prepared. Laboratory simulations demonstrated the response of thin films to active oxidants.

Flight Experiment↗

NASA NTRS2004

Characterization of Individual Aerosol Particles Associated with Clouds (CRYSTAL-FACE)

The aim of our research was to obtain data on the chemical and physical properties of individual aerosol particles from near the bottoms and tops of the deep convective systems that lead to the generation of tropical cirrus clouds and to provide insights into the particles that serve as CCN or IN. We used analytical transmission electron microscopy (ATEM), including energy-dispersive X-ray spectrometry (EDS) and electron energy-loss spectroscopy (EELS), and field-emission electron microscopy (FESEM) to compare the compositions, concentrations, size distributions, shapes, surface coatings, and degrees of aggregation of individual particles from cloud bases and the anvils near the tropopause. Aggregates of sea salt and mineral dust, ammonium sulfate, and soot particles are abundant in in-cloud samples. Cirrus samples contain many H2SO4 droplets, but acidic sulfate particles are rare at the cloud bases. H2SO4 probably formed at higher altitudes through oxidation of SO2 in cloud droplets. The relatively high extent of ammoniation in the upper troposphere in-cloud samples appears to have resulted from vertical transport by strong convection. The morphology of H2SO4 droplets indicates that they had been at least yartiy ammoniated at the time of collection. They are internally mixed with organic materials, metal sulfates, and solid particles of various compositions. Ammoniation and internal mixing of result in freezing at higher temperature than in pure H2SO4 aerosols. K- and S-bearing organic particles and Si-Al-rich particles are common throughout. Sea salt and mineral dust were incorporated into the convective systems from the cloud bases and worked as ice nuclei while being vertically transported. The nonsulfate particles originated from the lower troposphere and were transported to the upper troposphere and lower stratosphere.

Buseck, Peter R.↗

NASA NTRS2005

Impact of Lunar Dust on the Exploration Initiative

From the Apollo era it is known that dust on the Moon can cause serious problems for exploration activities. Such problems include adhering to clothing and equipment, reducing external visibility on landings, and causing difficulty to breathing and vision within the spacecraft. An important step in dealing with dust-related problems is to understand how dust grains behave in the lunar environment. All astronauts who walked on the Moon reported difficulties with lunar dust. Eugene Cernan, commander of Apollo 17, stated that one of the most aggravating, restricting facets of lunar surface exploration is the dust and its adherence to everything no matter what kind of material, whether it be skin, suit material, metal, no matter what it be and it's restrictive friction-like action to everything it gets on. Dust has also been highlighted as a priority by the Mars Exploration Program Assessment Group (MEPAG): 1A. Characterize both aeolian dust and particulates that would be kicked up from the martian regolith by surface operations of a human mission with fidelity sufficient to establish credible engineering simulation labs and/or software codes on Earth. We shall briefly describe the properties of lunar dust and its impact on the Apollo astronauts, and then summarize three main problems areas for understanding its behavior: Dust Adhesion and Abrasion, Surface Electric Fields and Dust Transport. These issues are all inter-related and must be well understood in order to minimize the impact of dust on lunar surface exploration.

Stubbs, T. J.↗

NASA NTRS2005

Formaldehyde Concentration Dynamics of the International Space Station Cabin Atmosphere

Formaldehyde presents a significant challenge to maintaining cabin air quality on board crewed spacecraft. Generation sources include offgassing from a variety of non-metallic materials as well as human metabolism. Because generation sources are pervasive and human health can be affected by continual exposure to low concentrations, toxicology and air quality control engineering experts jointly identified formaldehyde as a key compound to be monitored as part the International Space Station's (ISS) environmental health monitoring and maintenance program. Data acquired from in-flight air quality monitoring methods are the basis for assessing the cabin environment's suitability for long-term habitation and monitoring the performance of passive and active controls that are in place to minimize crew exposure. Formaldehyde concentration trends and dynamics served in the ISS cabin atmosphere are reviewed implications to present and future flight operations discussed.

Perry, J. L.↗

NASA NTRS2005

The Role of Toxicity Testing in NASA's Future Missions

NASA has deemed it necessary to perform the Toxicity Test (offgassing of toxic products) on all non-metallic materials proposed for use in habitable environments onboard the Shuttle and International Space Station flS,!J. This requirement stems from the desire to maintain a healthy, breathable atmosphere for the astronauts. As Shuttle missions have lengthened and with the habitation of the International Space Station, the need for understanding and controlling the contaminants in breathable atmospheres has increased. The increased duration of humans in space present two concerns to the astronauts with regard to their breathing air: 1. Breathing the on-board air. 2. Improved cleaning/filtering of existing air. Trends using existing toxicity data for materials and an understanding of the air cleaning/filtering capabilities in relation to Spacecraft Maximum Allowable Concentrations (SMAC) of offgassed components are explored. Recommendations are made for materials selection practices that should be followed to ensure a safe and healthy breathing environment for astronauts aboard these long term projects. The importance and relevance of Toxicity testing and materials selection in conjunction with the new NASA missions of creating a human presence on the Moon and traveling to Mars are described.

Whitfield, Steve↗

NASA NTRS2007

Current Challenges for HTCMC Aero-Propulsion Components

In comparison to the best metallic materials, HTCMC aero-propulsion engine components offer the opportunity of reduced weight and higher temperature operation, with corresponding improvements in engine cooling requirements, emissions, thrust, and specific fuel consumption. Although much progress has been made in the development of advanced HTCMC constituent materials and processes, major challenges still remain for their implementation into these components. The objectives of this presentation are to briefly review (1) potential HTCMC aero-propulsion components and their generic material performance requirements, (2) recent progress at NASA and elsewhere concerning advanced constituents and processes for meeting these requirements, (3) key HTCMC component implementation challenges that are currently being encountered, and (4) on-going activities within the new NASA Fundamental Aeronautics Program that are addressing these challenges.

DiCarlo, James A.↗

NASA NTRS2007

Ceramic Integration Technologies for Aerospace and Energy Systems: Technical Challenges and Opportunities

Ceramic integration technology has been recognized as an enabling technology for the implementation of advanced ceramic systems in a number of high-temperature applications in aerospace, power generation, nuclear, chemical, and electronic industries. Various ceramic integration technologies (joining, brazing, attachments, repair, etc.) play a role in fabrication and manufacturing of large and complex shaped parts of various functionalities. However, the development of robust and reliable integrated systems with optimum performance requires the understanding of many thermochemical and thermomechanical factors, particularly for high temperature applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Experimental results for bonding and integration of SiC based LDI fuel injector, high conductivity C/C composite based heat rejection system, solid oxide fuel cells system, ultra high temperature ceramics for leading edges, and ceramic composites for thermostructural applications will be presented. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be discussed.

Singh, Mrityunjay↗

NASA NTRS1999

Semiconductor etching by hyperthermal neutral beams

An at-least dual chamber apparatus and method in which high flux beams of fast moving neutral reactive species are created, collimated and used to etch semiconductor or metal materials from the surface of a workpiece. Beams including halogen atoms are preferably used to achieve anisotropic etching with good selectivity at satisfactory etch rates. Surface damage and undercutting are minimized.

Minton, Timothy K.↗

NASA NTRS2009

Determination of Pass/Fail Criteria for Promoted Combustion Testing

Promoted ignition testing is used to determine the relative flammability of metal rods in oxygen-enriched atmospheres. In these tests, a promoter is used to ignite each metal rod to start the sample burning. Experiments were performed to better understand the promoted ignition test by obtaining insight into the effect a burning promoter has on the preheating of a test sample. Test samples of several metallic materials were prepared and coupled to fast-responding thermocouples along their length. Various ignition promoters were used to ignite the test samples. The thermocouple measurements and test video was synchronized to determine temperature increase with respect to time and length along each test sample. A recommended length of test sample that must be consumed to be considered a flammable material was determined based on the preheated zone measured from these tests. This length was determined to be 30 mm (1.18 in.). Validation of this length and its rationale are presented.

Sparks, Kyle M.↗

NASA NTRS2009

Heat rejection sublimator

A sublimator includes a sublimation plate having a thermal element disposed adjacent to a feed water channel and a control point disposed between at least a portion of the thermal element and a large pore substrate. The control point includes a sintered metal material. A method of dissipating heat using a sublimator includes a sublimation plate having a thermal element and a control point. The thermal element is disposed adjacent to a feed water channel and the control point is disposed between at least a portion of the thermal element and a large pore substrate. The method includes controlling a flow rate of feed water to the large pore substrate at the control point and supplying heated coolant to the thermal element. Sublimation occurs in the large pore substrate and the controlling of the flow rate of feed water is independent of time. A sublimator includes a sublimation plate having a thermal element disposed adjacent to a feed water channel and a control point disposed between at least a portion of the thermal element and a large pore substrate. The control point restricts a flow rate of feed water from the feed water channel to the large pore substrate independent of time.

Dingell, Charles W.↗

NASA NTRS2003

Promoted Ignition and Burning Tests of Stainless Steel in Flowing and Nonflowing Oxygen

The Industry-Sponsored Metals Combustion Test Program 96-1 was coordinated through Wendell Hull & Associates, Inc. on behalf of several contributing companies, and all design and testing was performed at the NASA White Sands Test Facility. Phase I of this test program studied the threshold pressure for self-sustained burning of various types and sizes of stain less steel rods in nonflowing oxygen, as observed in Standard Test Method for Determining the Combustion Behavior of Metallic Materials in Oxygen-Enriched Atmospheres (ASTM G 124-95). Phase II studied the ignition and propagation of burning of 316L stainless steel rods and pipe in flowing gaseous oxygen. The test sample configurations were chosen to replicate previous promoted ignition and burning tests as well as to represent geometries and cross-sectional thicknesses common in industrial piping applications. The gas pressw'es and velocities for the test matrix were selected to generally compare with CGA G-4.4 guidelines for the use of stain less steel in oxygen service. This paper summarizes the results from the Phase I nonflowing oxygen tests and presents in detail the results of the Phase II flowing oxygen tests. The maximum sample burn-length is shown as a function of test pressure in Phase 1 and also as a function of gas velocity in Phase IT. These results indicate that flowing oxygen, under the given test conditions, significantly affects maximum sample burn length as compared to nonflowing oxygen. Supplementary flowing oxygen test data on stainless steel rods from a follow-up test program are consistent with these results and are presented herein.

Forsyth, Elliot T.↗

NASA NTRS2011

Design and Analysis of a Stiffened Composite Structure Repair Concept

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. Since the repair concept is a bolted repair using metal components, it can easily be applied in the operational environment. Initial analyses are aimed at validating the finite element modeling approach by comparing with available test data. Once confidence in the analysis approach is established several repair configurations are explored and the most efficient one presented. Repairs involving damage to the top of the stiffener alone are considered in addition to repairs involving a damaged stiffener, flange and underlying skin. High fidelity finite element modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic metallic material properties and geometrically nonlinear analysis are utilized in the effort. The results of the analysis are presented and factors influencing the design are assessed and discussed.

Przekop, Adam↗

NASA NTRS2010

Ceramic Integration Technologies for Advanced Energy Systems: Critical Needs, Technical Challenges, and Opportunities

Advanced ceramic integration technologies dramatically impact the energy landscape due to wide scale application of ceramics in all aspects of alternative energy production, storage, distribution, conservation, and efficiency. Examples include fuel cells, thermoelectrics, photovoltaics, gas turbine propulsion systems, distribution and transmission systems based on superconductors, nuclear power generation and waste disposal. Ceramic integration technologies play a key role in fabrication and manufacturing of large and complex shaped parts with multifunctional properties. However, the development of robust and reliable integrated systems with optimum performance requires the understanding of many thermochemical and thermomechanical factors, particularly for high temperature applications. In this presentation, various needs, challenges, and opportunities in design, fabrication, and testing of integrated similar (ceramic ceramic) and dissimilar (ceramic metal) material www.nasa.gov 45 ceramic-ceramic-systems have been discussed. Experimental results for bonding and integration of SiC based Micro-Electro-Mechanical-Systems (MEMS) LDI fuel injector and advanced ceramics and composites for gas turbine applications are presented.

Singh, Mrityunjay↗

NASA NTRS2011

Reliability Based Design for a Raked Wing Tip of an Airframe

A reliability-based optimization methodology has been developed to design the raked wing tip of the Boeing 767-400 extended range airliner made of composite and metallic materials. Design is formulated for an accepted level of risk or reliability. The design variables, weight and the constraints became functions of reliability. Uncertainties in the load, strength and the material properties, as well as the design variables, were modeled as random parameters with specified distributions, like normal, Weibull or Gumbel functions. The objective function and constraint, or a failure mode, became derived functions of the risk-level. Solution to the problem produced the optimum design with weight, variables and constraints as a function of the risk-level. Optimum weight versus reliability traced out an inverted-S shaped graph. The center of the graph corresponded to a 50 percent probability of success, or one failure in two samples. Under some assumptions, this design would be quite close to the deterministic optimum solution. The weight increased when reliability exceeded 50 percent, and decreased when the reliability was compromised. A design could be selected depending on the level of risk acceptable to a situation. The optimization process achieved up to a 20-percent reduction in weight over traditional design.

Patnaik, Surya N.↗

NASA NTRS2012

Missions to Near-Earth Asteroids: Implications for Exploration, Science, Resource Utilization, and Planetary Defense

Introduction: In 2009 the Augustine Commission identified near-Earth asteroids (NEAs) as high profile destinations for human exploration missions beyond the Earth-Moon system as part of the Flexible Path. More recently the U.S. presidential administration directed NASA to include NEAs as destinations for future human exploration with the goal of sending astronauts to a NEA in the mid to late 2020s. This directive became part of the official National Space Policy of the United States of America as of June 28, 2010. NEA Space-Based Survey and Robotic Precursor Missions: The most suitable targets for human missions are NEAs in Earth-like orbits with long synodic periods. However, these mission candidates are often not observable from Earth until the timeframe of their most favorable human mission opportunities, which does not provide an appropriate amount of time for mission development. A space-based survey telescope could more efficiently find these targets in a timely, affordable manner. Such a system is not only able to discover new objects, but also track and characterize objects of interest for human space flight consideration. Those objects with characteristic signatures representative of volatile-rich or metallic materials will be considered as top candidates for further investigation due to their potential for resource utilization and scientific discovery. Once suitable candidates have been identified, precursor spacecraft are required to perform basic reconnaissance of a few NEAs under consideration for the human-led mission. Robotic spacecraft will assess targets for potential hazards that may pose a risk to the deep space transportation vehicle, its deployable assets, and the crew. Additionally, the information obtained about the NEA's basic physical characteristics will be crucial for planning operational activities, designing in-depth scientific/engineering investigations, and identifying sites on the NEA for sample collection. Human Exploration Considerations: These missions would be the first human expeditions to interplanetary bodies beyond the Earth-Moon system and would prove useful for testing technologies required for human missions to Mars, Phobos and Deimos, and other Solar System destinations. Current analyses of operational concepts suggest that stay times of 15 to 30 days may be possible at a NEA with total mission duration limits of 180 days or less. Hence, these missions would undoubtedly provide a great deal of technical and engineering data on spacecraft operations for future human space exploration while simultaneously conducting detailed investigations of these primitive objects with instruments and equipment that exceed the mass and power capabilities delivered by robotic spacecraft. All of these activities will be vital for refinement of resource characterization/identification and development of extraction/utilization technologies to be used on airless bodies under low- or micro-gravity conditions. In addition, gaining enhanced understanding of a NEA s geotechnical properties and its gross internal structure will assist the development of hazard mitigation techniques for planetary defense. Conclusions: The scientific, resource utilization, and hazard mitigation benefits, along with the programmatic and operational benefits of a human venture beyond the Earth-Moon system, make a piloted sample return mission to a NEA using NASA s proposed human exploration systems a compelling endeavor.

Abell, P. A.↗

NASA NTRS2013

Simulation Based Investigation of Hidden Delamination Damage Detection in CFRP Composites

Guided wave (GW) based damage detection methods have shown promise in structural health monitoring (SHM) and hybrid SHM-nondestructive evaluation (NDE) techniques. Much previous GW work in the aerospace field has been primarily focused on metallic materials, with a growing focus on composite materials. The work presented in this paper demonstrates how realistic three-dimensional (3D) GW simulations can aid in the development of GW based damage characterization techniques for aerospace composites. 3D elastodynamic finite integration technique is implemented to model GW interaction with realistic delamination damage. A local wavenumber technique is applied to simulation data in order to investigate the detectability of hidden delamination damage to enable accurate characterization of damage extent.

Leckey, Cara A. C.↗