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At least 613 records · Page 34

All sources NASA NTRS DOE OSTI

NASA NTRS2013

Contact Thermocouple Methodology and Evaluation for Temperature Measurement in the Laboratory

Laboratory testing of advanced aerospace components very often requires highly accurate temperature measurement and control devices, as well as methods to precisely analyze and predict the performance of such components. Analysis of test articles depends on accurate measurements of temperature across the specimen. Where possible, this task is accomplished using many thermocouples welded directly to the test specimen, which can produce results with great precision. However, it is known that thermocouple spot welds can initiate deleterious cracks in some materials, prohibiting the use of welded thermocouples. Such is the case for the nickel-based superalloy MarM-247, which is used in the high temperature, high pressure heater heads for the Advanced Stirling Converter component of the Advanced Stirling Radioisotope Generator space power system. To overcome this limitation, a method was developed that uses small diameter contact thermocouples to measure the temperature of heater head test articles with the same level of accuracy as welded thermocouples. This paper includes a brief introduction and a background describing the circumstances that compelled the development of the contact thermocouple measurement method. Next, the paper describes studies performed on contact thermocouple readings to determine the accuracy of results. It continues on to describe in detail the developed measurement method and the evaluation of results produced. A further study that evaluates the performance of different measurement output devices is also described. Finally, a brief conclusion and summary of results is provided.

thermocouple↗

DOE OSTI2022

Damage of prismatic lithium‐ion cells subject to bending: Test, model, and detection

Abstract The mechanically induced internal short circuit (ISC) is one of the major safety concerns of lithium‐ion batteries. Mechanical abuse tests are often performed to evaluate the integrity and safety of lithium‐ion batteries under mechanical loadings. Except for the widely explored compression‐dominated indentation tests, bending is another typical real‐world loading condition that is tension‐dominated. To investigate the mechanical damage and ISC behavior of batteries under bending, we carried out controlled three‐point bending tests in four progressive steps on prismatic battery cells with maximum deflections ranging from 38% to 76% of the cell thickness. None of the tested cells experienced an ISC. We then conducted 3D X‐ray computed tomography (CT) scanning on the bent cells after unloading. X‐ray CT images showed three out of the four tested cells have extensive cracking in the electrode layers at the bottom side (opposite to the loading head). This indicates that cracking does not necessarily lead to an ISC under bending. Electrochemical impedance spectroscopy was also measured on the bent cells and substantial changes were observed. Both the bulk resistance and charge‐transfer resistance increased significantly after bending, which could influence the battery performance and lifespan. We then developed a detailed finite (FE) element model to further investigate the mechanical deformation and failure mechanisms. The FE model successfully predicts the load–displacement response and reproduces the deformation patterns. The findings and the FE model developed in the present study provide useful insights and tools for the battery structure and crash safety design. image

25 ENERGY STORAGE↗

NASA NTRS2009

Architectural Effects on Impact Resistance of Uncoated MI SiC/SiC Composites

Impact tests were conducted on uncoated 2D and 2.5D MI SiC/SiC composite specimens at room temperature and 1316 C in air. The specimens were analyzed before and after impact using optical microscopy, pulsed thermography (PT) and computed tomography (CT). Preliminary results indicate the following. Both 2-D and 2.5D composites show increase in surface and volumetric damages with increasing impact velocity. However, 2-D composites are prone to delamination cracks. In both 2D and 2.5D composites, the magnitude of impact damage at a fixed impact velocity is slightly greater at room temperature than at 1315 C. At a fixed projectile velocity and test temperature, the depth of penetration of the projectile into the substrate is significantly lower in 2.5D composites than in 2D composites. Fiber architecture plays a significant role controlling impact damage in MI SiC/SiC composites.

Bhatt, R. T.↗

DOE OSTI2024

In-Situ Species Concentration Measurements In Ammonia-Mix Flames Using Ftir Spectroscopy

Hydrogen and ammonia represent two carbon-free fuel sources that could be used in place of current fossil energy sources in combustion systems. To develop optimized ammonia combustion systems, validated modeling tools are needed. In the open literature, it has been shown that the complex chemistry associated with fuel-bound nitrogen contained in ammonia differs greatly from natural gas or hydrogen combustion. As a result, several new chemical kinetic mechanisms have been developed. Many of these mechanisms have been validated experimentally, however this has primarily focused on bulk parameters such as laminar flame speed and ignition delay time. Critically, high quality measurements of species concentrations are needed under controlled conditions which are easily represented by simple models. In this paper, direct, in-situ measurements of species concentrations and gas temperature are performed in a laminar flat-flame burner. This arrangement enables comparison with 1D model predictions, better isolating chemical kinetics from the fluid dynamics. Quantitative species concentrations are determined by absorption spectroscopy using an FTIR spectrometer. Fuel compositions representative of cracked ammonia (NH 3 /H 2 ) and ammonia-natural gas (NH 3 /CH 4 ) are considered for rich and lean equivalence ratios. A major focus of the paper is on the selection of spectral features for nitric oxide and ammonia and correcting for large amounts of baseline H 2 O absorption.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Real-time Canister Welding Health Monitoring and Prediction System for Spent Fuel Dry Storage

In this report, the salt mist corrosion testing at controlled temperature was carried out successfully on 304L SS submerged arc welded coupons by Unifog Dispersion Tower at ORNL. Corrosion in-situ monitoring system from Intelligent Automation, Inc. (IAI) was setup in the corrosion test and running smoothly to record signals during the corrosion test. Parts and device selection, sensors attachment, and experimental procedures are discussed. There wasn’t any visible corrosion or crack propagation on the weld coupon after about a month of corrosion testing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1984

Micro-elastohydrodynamic Lubrication

Conventional elastohydrodynamics, which is based on assumption of smooth surfaces, is reviewed briefly to show its insufficiency for explaining the failure processes in these contacts. For conditions approaching failure, lubrication breakdown occurs locally at asperity contacts where the lubrication behavior is controlled by micro-elastohydrodynamic lubrication (Micro-EHL). Description is given to the film formation mechanisms in micro-EHL conjunctions. An assessment is made to the level of film thickness due to normal approach and sliding of a single asperity and due to asperlty-asperlty collision between two asperities; Possible influence of the micro-EHL to incipient scuffing failure, surface crack propagation and wear are discussed.

H S Cheng↗

NASA NTRS2004

Effect of Specimen Thickness on Mechanical Behavior of SiC/SiC Composites

Potential composite applications in aerospace and transportation application systems have different thickness requirements. For example, space applications such as nozzle ramps or heat exchangers use very thin (less than 1 mm) structures whereas turbine blades need very thick parts greater than or equal to cm). There has been little investigation into the effect of thickness on stress-strain behavior or elevated temperature tensile properties controlled by oxidation. In this study, composites consisting of woven Hi-NicalonTM fibers, a carbon interphase, and CVI Sic matrix were fabricated with different numbers of plies to provide variable thickness. The composites ranged from a single ply (approximately 0.4 mm) to thirty-six plies (approximately 1 cm). Tensile tests were performed at room temperature with acoustic emission used to monitor matrix crack behavior. Elevated temperature tensile stress-rupture tests were performed in air. Considerably different room and elevated temperature tensile behavior was observed that will be discussed with respect to the effect of thickness on matrix crack formation, matrix crack growth and oxidation diffusion kinetics.

Morscher, Gregory N.↗

NASA NTRS2007

RDS-21 Face-Gear Surface Durability Tests

Experimental fatigue tests were performed to determine the surface durability life of a face gear in mesh with a tapered spur involute pinion. Twenty-four sets of gears were tested at three load levels: 7200, 8185, and 9075 lb-in face gear torque, and 2190 to 3280 rpm face gear speed. The gears were carburized and ground, shot-peened and vibro-honed, and made from VIM-VAR Pyrowear 53 steel per AMS 6308. The tests produced 17 gear tooth spalling failures and 7 suspensions. For all the failed sets, spalling occurred on at least one tooth of all the pinions. In some cases, the spalling initiated a crack in the pinion teeth which progressed to tooth fracture. Also, spalling occurred on some face gear teeth. The AGMA endurance allowable stress for a tapered spur involute pinion in mesh with a face gear was determined to be 275 ksi for the material tested. For the application of a tapered spur involute pinion in mesh with a face gear, proper face gear shim controlled the desired gear tooth contact pattern while proper pinion shim was an effective way of adjusting backlash without severely affecting the contact pattern.

Lewicki, David G.↗

NASA NTRSDate not supplied

The oxidation state of sulfur in lunar apatites in meteorites versus Apollo rocks

Sulfur can be present in apatite mineral grains as S6+ [1], S2- [2], or a mixture of the two [3, 4]. The proportion of S6+ to S2- present in the apatite is thought to be predominantly controlled by the prevailing oxygen fugacity (fO2) conditions during crystallization (along with temperature, pressure, and major element composition; [2-4]). Measurements of apatites and proximal residual glass in the lunar basalts 12039 and 10044 by X-ray absorption near-edge structure (XANES) spectroscopy show that sulfur occurs as S2- in both the mesostasis glass and apatite when measurements are performed far from cracks or pits in the thin section [2], consistent with other mineralogical indications of low fO2 (∆IW-1) during petrogenesis. However, analyses of apatite grains in both samples that were acquired near cracks or pits in the thin section sometimes revealed minor but nonnegligible spectral evidence for the presence of S6+ (e.g., S6+/ΣS > 0.03; [2]). This evidence was interpreted as either primary S2- altered to S6+ in the thin section, or S6+ of secondary origin, deposited in the fractures of the samples [2, 5]. It is unknown whether this alteration is lunar or terrestrial in origin, with implications for lunar petrogenesis if lunar [e.g., 5], or sample handling and curation if terrestrial [e.g., 6]. Note: Extended abstract on document.

M. Brounce↗

DOE OSTI2024

In-Situ Species Concentration Measurements in Ammonia-Mix Flames Using FTIR Spectroscopy

Hydrogen and ammonia represent two carbon-free fuel sources that could be used in place of current fossil energy sources in combustion systems. To develop optimized ammonia combustion systems, validated modeling tools are needed. In the open literature, it has been shown that the complex chemistry associated with fuel-bound nitrogen contained in ammonia differs greatly from natural gas or hydrogen combustion. As a result, several new chemical kinetic mechanisms have been developed. Many of these mechanisms have been validated experimentally, however this has primarily focused on bulk parameters such as laminar flame speed and ignition delay time. Critically, high quality measurements of species concentrations are needed under controlled conditions which are easily represented by simple models. In this paper, direct, in-situ measurements of species concentrations and gas temperature are performed in a laminar flat-flame burner. This arrangement enables comparison with 1D model predictions, better isolating chemical kinetics from the fluid dynamics. Quantitative species concentrations are determined by absorption spectroscopy using an FTIR spectrometer. Fuel compositions representative of cracked ammonia (NH3/H2) and ammonia-natural gas (NH3/CH4) are considered for rich and lean equivalence ratios. A major focus of the paper is on the selection of spectral features for nitric oxide and ammonia and correcting for large amounts of baseline H2O absorption.

Bedick, Clinton↗

DOE OSTI2022

Control of High-Temperature Static and Transient Thermomechanical Behavior of SiMo Ductile Iron by Al Alloying

Abstract Silicon and molybdenum ( SiMo ) ductile iron is commonly used for exhaust manifolds because these components experience thermal cycling in oxidizing environment, which requires resistance to fatigue during transient thermomechanical loads. Previous studies have demonstrated that alloying elements, such as Al , to SiMo ductile iron reduces the amount of surface degradation during static high-temperature exposure. However, deterioration of sphericity of the graphite nodules and a decrease in ductility could affect the tendency of cracking during thermal cycling. In this article, the effect of Al alloying on static and transient thermomechanical behavior of SiMo ductile iron was investigated to optimize the amount of Al alloying. A thermodynamic approach was used to confirm the effect of the Al alloying on the phase transformations in two SiMo cast irons, alloyed by 1.8% Al and 3% Al . These two alloys were cast in a laboratory along with the baseline SiMo ductile iron. Several experimental methods were used to evaluate the dimensional stability, physical properties, static oxidation, and failure resistance during constrained thermal cycling testing to compare their high-temperature capability. Experimental results verified that Al alloying increases the temperature range and decreases volume change during eutectoid transformation, which together with enhancement of oxidation protection improved the dimensional stability. Thermocycling tests showed that the number of cycles to failure depends on the amount of Al alloying and the applied high-temperature exposure during each cycle. SEM/EDX, high-resolution TEM and µCT analysis were used to verify the mechanism resulting from the Al alloying protection. It was shown that an optimal level of Al alloying for balancing oxidation and thermal cracking resistance depends on thermomechanical conditions of application.

36 MATERIALS SCIENCE↗

NASA NTRS1982

Orbital evolution of the Galilean satellites

The orbital motions of the Galilean satellites exert dramatic control over their physical properties (most notably Io's) through tidal heating. In turn, tidal dissipation in the satellites, as well as in Jupiter, has governed the evolution of the orbits and, in particular, of the Laplace resonance. If the system started out of the resonance and evolved into it, forced eccentricities would have increased with time. Hence, the tidal melting of Io and the cracking of Europa'a surface may have occurred relatively recently. This theory requires that Jupiter's tidal dissipation factor be greater than about two million, a rather low value (high rate of tidal dissipation) compared with most models of Jovian interior processes. Alternatively, the system may have started even deeper in the resonance than it is today, a scenario which is consistent with larger values of the tidal dissipation factor. This model, with its correspondingly large initial forced eccentricities, would imply (1) that Io melted early and fast, and may have remained molten with only a thin solid skin until the present and (2) that the water mantles of both Europa and Ganymede remained largely molten for considerably longer than Callisto did, but later froze as their eccentricities and tidal heating decreased.

Greenberg, R.↗

NASA NTRS1974

Interfaces in directionally solidified eutectics

Consideration of the interface between the phases in directionally solidified eutectic structures with respect to its morphology, crystallography, stability, and overall response to internal and external stress fields. Yielding behavior in such eutectic structures is shown to be controlled by several possible mechanisms. Two that can be related to the interface in directionally-solidified eutectic alloys are: (1) the interaction of slip dislocations with interface dislocations of the semicoherent boundaries, and (2) restrictions of allowable deformation mechanisms in two contiguous phases due to orientation effects. Evidence found thus far for elastic-plastic eutectic composites indicates that interfaces are capable of diverting fatigue cracks parallel to the loading axis.

Hertzberg, R. W.↗

NASA NTRSDate not supplied

Extending ISS Life Beyond 2030

The United States On-orbit Segment (USOS) of the International Space Station (ISS) was designed to meet a 15-year on-orbit life. Since the first hardware was launched in late 1998, the ISS would have reached its end of life in 2013. With the realization that the ISS would be needed well into the next decade, and beyond, a multi-disciplinary effort was undertaken to extend the ISS’ life through 2028 and to show that further extension to 2040 and beyond is not only feasible but achievable. Currently, NASA and the ISS international partners have agreed to extend its operations through 2030. This collaborative effort ensures that the ISS will continue to serve as a hub for scientific research, international cooperation, and educational endeavors for the next decade. Maintaining a continuous human presence in Low Earth Orbit (LEO) is desirable for testing new LEO, lunar, and deep-space technologies; conducting scientific research in micro-gravity for the benefit of life on Earth; and enabling a seamless transition of capabilities to one or more commercially owned and operated destinations. This paper provides an overview of the ISS life extension project with a particular focus on the analytical approach used to assess the primary structure. This analytical approach includes future operations planning, critical location screening, on-orbit dynamic load simulation, on-orbit optical property degradation studies, on-orbit thermal analyses, spectra generation, crack model idealization, fracture analyses, and post processing. Structural life results and identification of the most critical on-orbit events are presented. Also addressed are life extension approaches for other affected sub-systems, including: 1. Secondary Structure. 2. Materials. Evaluations consider environmental exposure to atomic oxygen, ionizing and gamma radiation, fluids, etc. Life limited materials, wear, and usage effects are also considered. 3. Environmental Control and Life Support Systems, including oxygen supply and generation, water recovery and management, and regenerative hardware. Evaluations are performed to determine which hardware can be run to failure and which are assessed for life extension. 4. Electrical power system. ISS is powered by eight channels of solar arrays and an electrical energy storage system providing 357 kWh power. Power generation and balance analyses are performed considering hardware degradation and increasing power demand. 5. Logistics and maintenance. Analyses are performed to determine critical spares required to maintain functionality. Consideration is given to supply chain health, obsolescence issues, onboard stowage availability, and up-mass capability. The successful life extension results have built confidence to safely operate, maintain and enhance the ISS well beyond the current decade. Extending the operational life of the ISS maintains an international presence in LEO and serves to avoid a gap in capability necessary to fulfill the exploration and research needs of NASA, international partners, and industry without interruption until a commercial space station is operational.

design life↗

NASA NTRS1985

Influence of the resin on interlaminar mixed-mode fracture

Both literature review data and new data on toughness behavior of seven matrix and adhesive systems in four types of tests were studied in order to assess the influence of the resin on interlaminar fracture. Mixed mode (i.e., various combinations of opening mode 1, G sub 1, and shearing mode 2; G sub 2) fracture toughness data showed that the mixed mode relationship for failure appears to be linear in terms of G sub 1 and G sub 2. The study further indicates that fracture of brittle resins is controlled by the G sub 1 component, and that fracture of many tough resins is controlled by total strain-energy release rate, G sub T. Regarding the relation of polymer structure and the mixed mode fracture: high mode 1 toughness requires resin dilatation; dilatation is low in unmodified epoxies at room temperature/dry conditions; dilatation is higher in plasticized epoxies, heated epoxies, and in modified epoxies; modification improves mode 2 toughness only slightly compared with mode 1 improvements. Analytical aspects of the cracked lap shear test specimen were explored.

Johnson, W. S.↗

NASA NTRS1987

Influence of the resin on interlaminar mixed-mode fracture

Johnson, W. S.↗

NASA NTRS2011

Burst Pressure Failure of Titanium Tanks Damaged by Secondary Plumes from Hypervelocity Impacts on Aluminum Shields

Metallic pressure tanks used in space missions are inherently vulnerable to hypervelocity impacts from micrometeoroids and orbital debris; thereby knowledge of impact damage and its effect on the tank integrity is crucial to a spacecraft risk assessment. This paper describes tests that have been performed to assess the effects of hypervelocity impact (HVI) damage on Titanium alloy (Ti-6Al-4V) pressure vessels burst pressure and characteristics. The tests consisted of a pair of HVI impact tests on water-filled Ti-6Al-4V tanks (water being used as a surrogate to the actual propellant) and subsequent burst tests as well as a burst test on an undamaged control tank. The tanks were placed behind Aluminum (Al) shields and then each was impacted with a 7 km/s projectile. The resulting impact debris plumes partially penetrated the Ti-6Al-4V tank surfaces resulting in a distribution of craters. During the burst tests, the tank that failed at a lower burst pressure did appear to have the failure initiating at a crater site with observed spall cracks. A fracture mechanics analysis showed that the tanks failure at the impact location may have been due to a spall crack that formed upon impact of a fragmentation on the Titanium surface. This result was corroborated with a finite element analysis from calculated Von-Mises and hoop stresses.

Nahra, Henry↗

NASA NTRS2012

In-Situ Nondestructive Evaluation of Kevlar(Registered Trademark)and Carbon Fiber Reinforced Composite Micromechanics for Improved Composite Overwrapped Pressure Vessel Health Monitoring

NASA has been faced with recertification and life extension issues for epoxy-impregnated Kevlar 49 (K/Ep) and carbon (C/Ep) composite overwrapped pressure vessels (COPVs) used in various systems on the Space Shuttle and International Space Station, respectively. Each COPV has varying criticality, damage and repair histories, time at pressure, and pressure cycles. COPVs are of particular concern due to the insidious and catastrophic burst-before-leak failure mode caused by stress rupture (SR) of the composite overwrap. SR life has been defined [1] as the minimum time during which the composite maintains structural integrity considering the combined effects of stress level(s), time at stress level(s), and associated environment. SR has none of the features of predictability associated with metal pressure vessels, such as crack geometry, growth rate and size, or other features that lend themselves to nondestructive evaluation (NDE). In essence, the variability or surprise factor associated with SR cannot be eliminated. C/Ep COPVs are also susceptible to impact damage that can lead to reduced burst pressure even when the amount of damage to the COPV is below the visual detection threshold [2], thus necessitating implementation of a mechanical damage control plan [1]. Last, COPVs can also fail prematurely due to material or design noncompliance. In each case (SR, impact or noncompliance), out-of-family behavior is expected leading to a higher probability of failure at a given stress, hence, greater uncertainty in performance. For these reasons, NASA has been actively engaged in research to develop NDE methods that can be used during post-manufacture qualification, in-service inspection, and in-situ structural health monitoring. Acoustic emission (AE) is one of the more promising NDE techniques for detecting and monitoring, in real-time, the strain energy release and corresponding stress-wave propagation produced by actively growing flaws and defects in composite materials [3,4,5,6,7,8]. To gain further insight into the mechanisms responsible for composite rupture, broadband modal acoustic emission analysis was used. Also, since AE data reduction proved to be very time consuming, specialized data reduction software was written to automate the process.

Waller, Jess↗