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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Structural Analysis

NASTRAN basically performs complex analyses of a structural design and predicts how various elements of the design will react to many different conditions of stress and strain. NASTRAN applications include almost every kind of structure and construction, and the program's substructuring capability allows different segments of a structure to be modeled jointly after having been modeled separately. NASTRAN permits the effects of control systems, aerodynamic transfer functions and other nonstructural problems, such as static response to thermal expansion, to be incorporated in the solution of the structural problem. Examples of industrial users of NASTRAN include DeVlieg-Sundstrand, Belvidere, Illinois, Texas Instruments, Temple, Texas and Texas Instrument's Central Research Laboratories. NASTRAN is available to private industry through NASA's Computer Software Management and Information Center.

Source record↗
NASA NTRS2006

Flextensional Single Crystal Piezoelectric Actuators for Membrane Deformable Mirrors

Large aperture and light weight space telescopes requires adaptive optics with deformable mirrors capable of large amplitude aberration corrections at a broad temperature range for space applications including NASA missions such as SAFIR, TPF, Con-X, etc. The single crystal piezoelectric actuators produced at TRS offer large stroke, low hysteresis, and an excellent cryogenic strain response. Specifically, the recently developed low profile, low voltage flextensional single crystal piezoelectric actuators with dimensions of 18 x 5 x 1 mm showed stroke larger than 95 microns under 300 V. Furthermore, flextensional actuator retained approx. 40-50% of its room temperature strain at liquid Nitrogen environment. In this paper, ATILA FEM design of flextensional actuators, actuator fabrication, and characterization results will be presented for the future work on membrane deformable mirror.

Jiang, Xiaoning↗
NASA NTRS2010

nBn and pBp infrared detectors with graded barrier layer, graded absorption layer, or chirped strained layer super lattice absorption layer

An nBn detector is described where for some embodiments the barrier layer has a concentration gradient, for some embodiments the absorption layer has a concentration gradient, and for some embodiments the absorption layer is a chirped strained layer super lattice. The use of a graded barrier or absorption layer, or the use of a chirped strained layer super lattice for the absorption layer, allows for design of the energy bands so that the valence band may be aligned across the device. Other embodiments are described and claimed.

Gunapala, Sarath D.↗
DOE OSTI2021

Recommendation for Limiting Conditions for ASME BPVC Section III Division 5 Allowable Stress Criteria

Section III, Division 5 of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) specifies rules for elevated temperature nuclear reactors. Time dependent allowable stresses are an important aspect of the high temperature design models and are related to the time to 1% strain, time to rupture, and time to onset of tertiary creep. The time to onset of tertiary creep criterion has an overly strong negative influence on the allowable stresses for some structural materials, likely due to very limited datasets and misidentification of microstructural changes rather than onset of significant creep damage, as tertiary creep is meant to represent. It is recommended that the onset of tertiary creep be determined through an alloy specific ratio between onset of tertiary creep and creep rupture time, which would give access to the significantly larger creep rupture time datasets.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Integration of proteomics and metabolomics into the Design, Build, Test, Learn cycle to improve 3-hydroxypropionic acid production in Aspergillus pseudoterreus

Biological engineering of microorganisms to produce value-added chemicals is a promising route to sustainable manufacturing. However, overproduction of metabolic intermediates at high titer, rate, and yield from inexpensive substrates is challenging in non-model systems where limited information is available regarding metabolic flux and its control in production conditions. Integrated multi-omic analyses of engineered strains offers an in-depth look at metabolites and proteins directly involved in growth and production of target and non-target bioproducts. Here we applied multi-omic analyses to overproduction of the polymer precursor 3-hydroxypropionic acid (3HP) in the filamentous fungus Aspergillus pseudoterreus. A synthetic pathway consisting of aspartate decarboxylase, beta-alanine pyruvate transaminase, and 3HP dehydrogenase was designed and built for A. pseudoterreus. Strains with single- and multi-copy integration events were isolated and multi-omics analysis consisting of intracellular and extracellular metabolomics and targeted and global proteomics was used to interrogate the strains in shake-flask and bioreactor conditions. Production of a variety of co-products (organic acids and glycerol) and oxidative degradation of 3HP were identified as metabolic pathways competing with 3HP production. Intracellular accumulation of nitrogen as 2,4-diaminobutanoate was identified as an off-target nitrogen sink that may also limit flux through the engineered 3HP pathway. Elimination of the high-expression oxidative 3HP degradation pathway by deletion of a putative malonate semialdehyde dehydrogenase improved the yield of 3HP by 3.4× after 10 days in shake-flask culture. This is the first report of 3HP production in a filamentous fungus amenable to industrial scale biomanufacturing of organic acids at high titer and low pH.

Pomraning, Kyle R.↗
DOE OSTI2025

Low-nickel cathode chemistry for sustainable and high-energy lithium-ion batteries

The transition to sustainable energy storage demands lithium-ion batteries with high energy density and reduced reliance on critical metals such as nickel (Ni), yet current strategies to increase capacity have largely depended on raising Ni content, leading to escalating supply risks, rising costs and sustainability concerns. More critically, Ni-rich cathodes suffer from rapid electrochemical degradation driven by structural instability, creating an insurmountable trade-off between capacity and cycle life. Here, in this study, we introduce a low-Ni chemistry cathode, Li(Li 0.05 Ni 0.57 Mn 0.31 Co 0.07 )O 2 , with a radial phase integration design that overcomes these limitations, enabling a remarkable Ni usage reduction (Ni < 0.6) while demonstrating high capacity (215 mAh g −1 ) and markedly improved cyclability (~97% retention over 400 cycles) compared to conventional high-Ni cathodes (Ni = 0.8). Advanced X-ray and electron microscopy analyses reveal that the designed cathode exhibits a highly reversible oxygen anionic redox, benefiting from a structurally stable surface and minimizing irreversible phase transitions. Moreover, the integrated structure substantially mitigates lattice strain and improves mechanical stability even under harsh conditions. In conclusion, this advance offers a general design principle for developing next-generation cathodes that combine resource efficiency with long-term electrochemical reliability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A MEMS dynamic mechanical analyzer for in situ viscoelastic characterization of 3D printed nanostructures

Cellular metamaterial structures with sub-micron features have shown the ability to become excellent energy absorbing materials for impact mitigation due to the enhanced mechanical properties of materials at the nanoscale. However, in order to optimize the design of these energy absorbing metamaterial structures we need to be able to measure the dynamic properties of the sub-micron features such as storage and loss moduli and the loss factor. Therefore, at scale testing is required to capture the scale, temperature, and strain rate dependent material properties of these nanoscale materials. This study presents the design, fabrication, and calibration of a MEMS-based dynamic mechanical analyzer (DMA) that can be directly integrated with the two photon lithography (TPL) process commonly used to fabricate metamaterial structures with nanoscale features. The MEMS-based DMA consists of a chevron style thermal actuator used to generate a tensile load on the structure and two differential capacitive sensors on each side of the structure used to measure load and displacement. This design demonstrated 1.5 ± 0.75 nm displacement resolution and 104 ± 52 nN load resolution, respectively. Dynamic mechanical analysis was successfully conducted on a single nanowire feature printed between the load and displacement stages of the MEMS device with testing frequencies ranging between 0.01–10 Hz and testing temperatures ranging between 22 °C–47 °C. These initial tests on an exemplar TPL part demonstrate that the printed nanowire behaves as a viscoelastic material wherein the transition from glassy to viscous behavior has already set in at the room temperature.

42 ENGINEERING↗
NASA NTRS2009

Thermal-Structural Analysis of PICA Tiles for Solar Tower Test

Thermal protection materials used in spacecraft heatshields are subjected to severe thermal and mechanical loading environments during re-entry into earth atmosphere. In order to investigate the reliability of PICA tiles in the presence of high thermal gradients as well as mechanical loads, the authors designed and conducted solar-tower tests. This paper presents the design and analysis work for this tests series. Coupled non-linear thermal-mechanical finite element analyses was conducted to estimate in-depth temperature distribution and stress contours for various cases. The first set of analyses performed on isolated PICA tile showed that stresses generated during the tests were below the PICA allowable limit and should not lead to any catastrophic failure during the test. The tests results were consistent with analytical predictions. The temperature distribution and magnitude of the measured strains were also consistent with predicted values. The second test series is designed to test the arrayed PICA tiles with various gap-filler materials. A nonlinear contact method is used to model the complex geometry with various tiles. The analyses for these coupons predict the stress contours in PICA and inside gap fillers. Suitable mechanical loads for this architecture will be predicted, which can be applied during the test to exceed the allowable limits and demonstrate failure modes. Thermocouple and strain-gauge data obtained from the solar tower tests will be used for subsequent analyses and validation of FEM models.

Agrawal, Parul↗
NASA NTRS1989

Test methods and design allowables for fibrous composites. Volume 2

Topics discussed include extreme/hostile environment testing, establishing design allowables, and property/behavior specific testing. Papers are presented on environmental effects on the high strain rate properties of graphite/epoxy composite, the low-temperature performance of short-fiber reinforced thermoplastics, the abrasive wear behavior of unidirectional and woven graphite fiber/PEEK, test methods for determining design allowables for fiber reinforced composites, and statistical methods for calculating material allowables for MIL-HDBK-17. Attention is also given to a test method to measure the response of composite materials under reversed cyclic loads, a through-the-thickness strength specimen for composites, the use of torsion tubes to measure in-plane shear properties of filament-wound composites, the influlence of test fixture design on the Iosipescu shear test for fiber composite materials, and a method for monitoring in-plane shear modulus in fatigue testing of composites.

Chamis, Christos C.↗
NASA NTRS2016

Unsteady Aerodynamic Force Sensing from Measured Strain

A simple approach for computing unsteady aerodynamic forces from simulated measured strain data is proposed in this study. First, the deflection and slope of the structure are computed from the unsteady strain using the two-step approach. Velocities and accelerations of the structure are computed using the autoregressive moving average model, on-line parameter estimator, low-pass filter, and a least-squares curve fitting method together with analytical derivatives with respect to time. Finally, aerodynamic forces over the wing are computed using modal aerodynamic influence coefficient matrices, a rational function approximation, and a time-marching algorithm. A cantilevered rectangular wing built and tested at the NASA Langley Research Center (Hampton, Virginia, USA) in 1959 is used to validate the simple approach. Unsteady aerodynamic forces as well as wing deflections, velocities, accelerations, and strains are computed using the CFL3D computational fluid dynamics (CFD) code and an MSC/NASTRAN code (MSC Software Corporation, Newport Beach, California, USA), and these CFL3D-based results are assumed as measured quantities. Based on the measured strains, wing deflections, velocities, accelerations, and aerodynamic forces are computed using the proposed approach. These computed deflections, velocities, accelerations, and unsteady aerodynamic forces are compared with the CFL3D/NASTRAN-based results. In general, computed aerodynamic forces based on the lifting surface theory in subsonic speeds are in good agreement with the target aerodynamic forces generated using CFL3D code with the Euler equation. Excellent aeroelastic responses are obtained even with unsteady strain data under the signal to noise ratio of -9.8dB. The deflections, velocities, and accelerations at each sensor location are independent of structural and aerodynamic models. Therefore, the distributed strain data together with the current proposed approaches can be used as distributed deflection, velocity, and acceleration sensors. This research demonstrates the feasibility of obtaining induced drag and lift forces through the use of distributed sensor technology with measured strain data. An active induced drag control system thus can be designed using the two computed aerodynamic forces, induced drag and lift, to improve the fuel efficiency of an aircraft. Interpolation elements between structural finite element grids and the CFD grids and centroids are successfully incorporated with the unsteady aeroelastic computation scheme. The most critical technology for the success of the proposed approach is the robust on-line parameter estimator, since the least-squares curve fitting method depends heavily on aeroelastic system frequencies and damping factors.

shape sensing↗
NASA NTRS1986

Mode 1 delamination growth in adhesively bonded joints under static and fatigue loads

The objective of this investigation was to characterize the pure mode 1 delamination growth in metal to metal adhesively bonded joints under static and fatigue loading conditions, using FM 73 adhesive. Double cantilever beam specimens (DCB) were used for pure mode 1 tests. Aluminum 2024-T3 adherends were bonded with FM 73 adhesive. Delamination was introduced during fabrication by inserting a Teflon film between the two adherends. The mode 1 strain energy release rate G sub I sub c was obtained directly from static DCB tests conducted in accordance with the ASTM designation D1876-12. Constant amplitude fatigue tests on DCB specimens were conducted to determine the relationship between delamination growth rate da/dN and strain energy release rate G sub I sub c for a pure mode 1 delamination growth. It is found that the debond propagation rate in adhesive joints using FM 73 is more sensitive to errors in design load than is typical crack growth rate in metallic structures.

Biswas, S. C.↗
NASA NTRS2015

Injury Risk Assessment of Extravehicular Mobility Unit (EMU) Phase VI and Series 4000 Gloves During Extravehicular Activity (EVA) Hand Manipulation Tasks

Functional Extravehicular Mobility Units (EMUs) with high precision gloves are essential for the success of Extravehicular Activity (EVA). Previous research done at NASA has shown that total strength capabilities and performance are reduced when wearing a pressurized EMU. The goal of this project was to characterize the human-space suit glove interaction and assess the risk of injury during common EVA hand manipulation tasks, including pushing, pinching and gripping objects. A custom third generation sensor garment was designed to incorporate a combination of sensors, including force sensitive resistors, strain gauge sensors, and shear force sensors. The combination of sensors was used to measure the forces acting on the finger nails, finger pads, finger tips, as well as the knuckle joints. In addition to measuring the forces, data was collected on the temperature, humidity, skin conductance, and blood perfusion of the hands. Testing compared both the Phase VI and Series 4000 glove against an ungloved condition. The ungloved test was performed wearing the sensor garment only. The project outcomes identified critical landmarks that experienced higher workloads and are more likely to suffer injuries. These critical landmarks varied as a function of space suit glove and task performed. The results showed that less forces were acting on the hands while wearing the Phase VI glove as compared to wearing the Series 4000 glove. Based on our findings, the engineering division can utilize these methods for optimizing the current space suit glove and designing next generation gloves to prevent injuries and optimize hand mobility and comfort.

Kilby, Melissa↗
NASA NTRS1999

Nondestructive Strain Measurement System Used to Determine Surface Strain on Fibers

Small-diameter structural fibers are being considered as reinforcements for high temperature ceramic matrix composite materials, and thus they require characterization. At the NASA Lewis Research Center, a nondestructive optical technique was used to determine surface strain on a structural fiber, in real time, as it was pulled in a tensile test machine. With this technique, interference or speckle patterns from the laser illuminated fiber test specimen are recorded. As the fiber is pulled, its speckle pattern shifts in proportion to the strain, translation, and rotation components of the sample deformation. Shifting speckle patterns are detected in real time by two linear charge-coupled discharge (CCD) camera arrays, and the images are processed by a hardware correlator. Surface strain is selectively detected on fibers with diameters on the order of 100 mm and can be resolved to 19 microstrain. This system was designed to be robust and compact and generally does not require surface preparation of the structural fibers. For strain detection, two laser beams are positioned incident on the structural fiber being tested, as shown in the photograph, where the test specimen is mounted in a tensile test machine via two coupons. As the fiber is pulled, the speckle pattern produced from each laser beam is detected by one of two CCD arrays located inside the tube on the right side of the photograph.

Tuma, Margaret L.↗
DOE OSTI2025

THE DESIGN OF RADIAL HONEYCOMB LATTICES FOR IMPACT ENERGY ABSORPTION IN RADIOACTIVE MATERIALS PACKAGES

In this research we present a variation on the corrugation technique of honeycomb lattices, for cylindrical honeycombs, making them much easier to design for impact energy absorption in radioactive materials packages. This variation, termed radial honeycomb lattices, eliminates the residual strain and saddle effect. The use of honeycomb lattices provides advantages over the typically used foams. While foams are effective at absorbing impact energy, they can burn, their material properties are difficult to control, they can degrade over time, and procurement of raw materials can be dependent on timing of manufacturer batch runs. While the weaknesses of foam are strengths for honeycomb lattices, lattices have a different set of problems. Typically, when cylindrical honeycomb lattices are manufactured, they are manufactured flat, wrapped around a mandrel of the desired radius, and then brazed. This approach introduces residual strains, resulting in the saddle effect, which limits both the radial thickness and cylinder length. The radial honeycomb lattice approach presented here makes the design of thicker and longer cylinder honeycombs possible. To address these issues, we propose a honeycomb lattice which changes in cross-section from the inner to the outer radius of the cylinder. This causes the lattice to automatically wrap into a cylinder as it exits the corrugating gears. The theoretically bounding case, of a square cross-section at the inner radius, transitioning through a hexagon, to a diamond cross-section at the outer radius, results in a maximum thickness of approximately 41% of the inner radius. Full mathematical derivations, implemented in computer code, allow for the design of an entire radial honeycomb lattice, including the corrugating gears. To accomplish this only the radial thickness, inner cross-section shape, cell size, and nominal gear radius need to be specified, making the design of these lattices very efficient. Radial honeycomb lattice prototypes have demonstrated that the honeycomb does indeed wrap into a cylinder as intended, without the saddle effect, and can therefore be used to create thick-walled cylinders of any length. These design improvements make cylindrical honeycomb lattices much more accessible as a design element for radioactive materials packages

Johnson, William R. [Savannah River National Labor↗
NASA NTRS1996

Continuum Fatigue Damage Modeling for Critical Design, Control, and Fault Prognosis

This paper develops a simplified continuum (continuous with respect to time, stress, etc.) fatigue damage model for use in critical design, Life Extending Control and fault prognosis. The work is based on the local strain cyclic damage modeling method. New nonlinear explicit equation forms of cyclic damage in terms of stress amplitude are derived to facilitate the continuum modelling. Stress based continuum models are derived. Extension to plastic strain-strain rate models is also presented. Progress toward a non-zero mean stress based is presented. Also new nonlinear explicit equation forms in terms of stress amplitude are derived for this case. Application of the various models to design, control, and fault prognosis is considered.

Lorenzo, Carl F.↗
DOE OSTI2022

Tailoring Negative Thermal Expansion via Tunable Induced Strain in La–Fe–Si-Based Multifunctional Material

Zero thermal expansion (ZTE) composites are typically designed by combining positive (PTE) with negative thermal expansion (NTE) materials acting as compensators and have many diverse applications, including in high-precision instrumentation and biomedical devices. La(Fe 1-x ,Si x )13-based compounds display several remarkable properties, such as giant magnetocaloric effect and very large NTE at room-temperature. Both are linked via strong magnetovolume coupling, which leads to sharp magnetic and volume changes occurring simultaneously across first-order phase transitions; the abrupt nature of these changes makes them unsuitable as thermal expansion compensators. To make these materials more useful practically, the mechanisms controlling the temperature over which this transition occurs and the magnitude of contraction need to be controlled. In this work, ball-milling was used to decrease particles and crystallite sizes and increase the strain in LaFe 11.9 Mn 0.27 Si 1.29 H x alloys. Such size and strain tuning effectively broadened the temperature over which this transition occurs. The material’s NTE operational temperature window was expanded, and its peak was suppressed by up to 85%. This work demonstrates that induced strain is the key mechanism controlling these materials’ phase transitions. This allows the optimization of their thermal expansion towards room-temperature ZTE-applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Utah FORGE 5-2557: Trixial Shear and Wellbore Breakout Tests Report and Data

Included are a report and data from triaxial shear tests on simulated Sierra White fault gouge and a borehole stimulation experiment. This serves as a progress report for the Role of Fluid and Temperature in Fracture Mechanics and Coupled Thermo-Hydro-Mechanical-Chemical (THMC) Processes for Enhanced Geothermal Systems project by Purdue University (Utah FORGE R&D project 5-2557). Tests were done with Sierra White granite (SWG) to investigate slip mechanisms and to evaluate the fracture initiation and propagation from a geothermal borehole. Raw data is provided alongside a report on all experimental testing protocols, experimental design, and results.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

A thermodynamically consistent finite strain phase field approach to ductile fracture considering multi-axial stress states

Phase field models for ductile fracture have gained significant attention in the last two decades due to their ability in implicitly tracking the nucleation and propagation of cracks. However, most crack phase field formulations for elastoplastic solids focus only on the effects of plastic deformation, and do not consider the different multi-axial stress states that may arise in practical designs. In this work, a thermodynamically consistent phase field approach coupled with finite strain plasticity, considering multi-axial stress states is presented. In order to account for the coupling between plasticity and stress states, the Stress-Weighted Ductile Fracture Model (SWDFM) is utilized. The SWDFM represents a criterion for predicting ductile crack initiation under both monotonic and cyclic loadings based on histories of an internal plastic variable, stress triaxiality, and the Lode angle parameter. The excellent performance of the SWDFM for predicting ductile crack initiation motivates for its incorporation into a phase field approach for predicting both crack initiation and propagation through degradation of the fracture toughness. Moreover, based on the second law of thermodynamics, exact requirements are imposed on the rate at which the fracture toughness can evolve. Here, a novel function for degrading the plastic yield surface during the evolution of damage is introduced. This function, in line with experimental observations, leads to an accumulation of plastic deformation in damaged regions of a solid, and avoids numerical instabilities arising from concentrations of large plastic deformations in severely damaged regions. For validating the proposed model, results of computational simulations are compared to data from selected tests considering different multi-axial stress states. Comparisons of the numerical results with data from laboratory experiments demonstrate the capabilities of the proposed framework.

42 ENGINEERING↗