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NASA NTRS1981

Mission load dynamic tests of two undensified Space shuttle thermal protection system tiles

Two tests of undensified Space Shuttle thermal protection tiles under combined static and dynamic loads were conducted. The tiles had a density of approximately 144 Kg/cum (LI900 tiles) and were mounted on a strain isolation pad which was 0.41 cm (.160 inch) thick. A combined static and dynamic mission stress histogram representative of the W-3 area of the wing of the orbiter vehicle was applied. The stress histogram was provided by the space shuttle project. Results presented include: tabulation of measured peak and root-mean-square (RMS) accelerations in both compression and tension; peak SIP stress in compression and tension, peak and RMS amplitude response ratios; lateral to vertical response ratios; response time histories; peak stress distributions (histograms), and SIP extension measured both with and without static tension at various mission times.

Leatherwood, J. D.↗

DOE OSTI2025

Critical impact of experimentally-driven strut level anisotropic material models in advanced stress analysis of additively manufactured lattice structures

The rapid acceleration in materials discovery may overshadow the importance of thoroughly understanding the mechanical performance of newly developed materials in demanding environments. The recent interest in combining parametric studies with machine learning techniques to explore how changes in specific processing parameters or model inputs affect the overall behavior of a material system can only be truly beneficial if the governing constitutive relations describing material behavior are accurately established. In this study, we demonstrate the critical impact of accurately representing strut-level anisotropic material behavior in advanced stress analysis of additively manufactured lattice structures (AMLS). We introduce a systematic experimental and modeling approach for developing strut-level anisotropic elastoplastic material models that account for the influence of microstructural features such as porosity, texture, and surface roughness on the development of local anisotropic mechanical properties, which vary with strut orientation relative to the build direction (BD). As a result the presented material model captures and relates the statistics of spatially varying struts’ microstructural features to the local stress distribution. Our findings suggest that incorporating strut-level anisotropic material behavior into unit cell analysis significantly influences the load distribution and evolution of local stresses within the structure. Therefore, accounting for this anisotropy is critical for developing an understanding of unit cell behavior and performance, including subsequent topology/component design optimization based on this analysis.

Sahoo, Subhadip [University of Arizona]↗

DOE OSTI2014

Electromigration induced Kirkendall void growth in Sn-3.5Ag/Cu solder joints

Effects of electric current flow on the Kirkendall void formation at solder joints were investigated using Sn-3.5Ag/Cu joints specially designed to have localized nucleation of Kirkendall voids at the Cu{sub 3}Sn/Cu interface. Under the current density of 1 × 10{sup 4} A/cm{sup 2}, kinetics of Kirkendall void growth and intermetallic compound thickening were affected by the electromigration (EM), and both showed the polarity effect. Cu{sub 6}Sn{sub 5} showed a strong susceptibility to the polarity effect, while Cu{sub 3}Sn did not. The electromigration force induced additional tensile (or compressive) stress at the cathode (or anode), which accelerated (or decelerated) the void growth. From the measurements of the fraction of void at the Cu{sub 3}Sn/Cu interface on SEM micrographs and analysis of the kinetics of void growth, the magnitude of the local stress induced by EM was estimated to be 9 MPa at the anode and −7 MPa at the cathode.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2021

High-Fidelity Simulation of Turbulent Flow Past a Gaussian Bump

A spanwise-periodic computation of a turbulent flow past a Gaussian bump is performed in the form of a hybrid direct numerical simulation and wall-resolved large-eddy simulation. A fourth-order spatially-accurate flow solver is employed to perform the simulation, using 10.2 billion grid points for a Reynolds number of 170000 based on the bump height. The key findings from the simulation are reported in the acceleration and deceleration flow regions associated with the bump shape. Significant anisotropy in the normal Reynolds stresses, along both the wall-normal and streamwise directions, is observed within the acceleration region. The ratio between the Reynolds shear stress and turbulent kinetic energy in that region also experiences significant deviations from the norms of a zero pressure gradient turbulent boundary layer. The chosen Reynolds number generates strong flow separation in the adverse pressure gradient region, which is in contrast with a previous simulation at half the Reynolds number that only indicated incipient separation. An internal layer generated in the acceleration region evolves into a free shear layer that develops in the deceleration region and separates. Proper modeling of this inner layer appears crucial to predict the flow separation. Surface curvature effects on the attached flow development are also discussed.

Turbulent Boundary Layer↗

DOE OSTI2019

Rate-dependent phase transition of high density polyethylene

Quasi-static and dynamic tension tests are conducted on a widely used semicrystalline polymer, high density polyethylene (HDPE), to explore the strain rate effects on phase transition. HDPE exhibits considerable strain-rate hardening. In situ , high-speed x-ray diffraction demonstrates a martensitic transformation from the orthorhombic to monoclinic phase during both loading conditions. However, compared to quasi-static loading, the phase transition occurs at a lower bulk strain but higher stress under dynamic loading (strain rate 5100 s –1 ), suggesting strain-rate-accelerated phase transition dynamics. Furthermore, evolutions of lattice strain with bulk stress indicate different roles of amorphous and crystalline phases in deformation under different strain rates.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Tunable thermoelectric transport in nanomeshes via elastic strain engineering

Recent experimental explorations of silicon nanomeshes have shown that the unique metastructures exhibit reduced thermal conductivity while preserving bulk electrical conductivity via feature sizes between relevant phonon and electron mean free paths, aiding in the continued promise that nanometer-scale engineering may further enhance thermoelectric behavior. Here, we introduce a strategy for tuning thermoelectric transport phenomena in semiconductor nanomeshes via heterogeneous elastic strain engineering, using silicon as a model material for demonstration of the concept. By combining analytical models for electron mobility in uniformly stressed silicon with finite element analysis of strained silicon nanomeshes in a lumped physical model, we show that the nonuniform and multiaxial strain fields defined by the nanomesh geometry give rise to spatially varying band shifts and warping, which in aggregate accelerate electron transport along directions of applied stress. This allows for global electrical conductivity and Seebeck enhancements beyond those of homogenous samples under equivalent far-field stresses, ultimately increasing thermoelectric power factor nearly 50% over unstrained samples. The proposed concept and structures—generic to a wide class of materials with large dynamic ranges of elastic strain in nanoscale volumes—may enable a new pathway for active and tunable control of transport properties relevant to waste heat scavenging and thermal management.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2014

Superoxide reduction by a superoxide reductase lacking the highly conserved lysine residue

Superoxide reductases (SORs) are the most recently identified superoxide detoxification systems, being found in microorganisms from the three domains of life. These enzymes are characterized by a catalytic mononuclear iron site, with one cysteine and four histidine ligands of the ferrous active form. A lysine residue in the –EKHVP– motif, located close to the active site, has been considered to be essential for the enzyme function, by contributing to the positive surface patch that attracts the superoxide anion and by controlling the chemistry of the catalytic mechanism through a hydrogen bond network. However, we show here that this residue is substituted by non-equivalent amino acids in several putative SORs from Archaea and unicellular Eukarya. In this work, we focus on mechanistic and spectroscopic studies of one of these less common enzymes, the SOR from the hyperthermophilic crenarchaeon Ignicoccus hospitalis . We employ pulse radiolysis fast kinetics and spectroscopic approaches to study the wild-type enzyme (₋E₂₃T₂₄HVP₋), and two mutants, T24K and E23A, the later mimicking enzymes lacking both the lysine and glutamate (a ferric ion ligand) of the motif. The efficiency of the wild type protein and mutants in reducing superoxide is comparable to other SORs, revealing the robustness of these enzymes to single mutations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2020

Impact of environmental variables on the degradation of photovoltaic components and perspectives for the reliability assessment methodology

Backsheet cracking has been a major issue observed in the field; however, standardized qualification tests, such as IEC61215, are inadequate to reliably identify such failures of PV modules due to the lack of the critical weathering factors applied sequentially or in combination, such as those found in the service environments. To address this problem, in this work we investigated the effects of various environmental variables on the degradation and failure behaviors of the polyamide-based backsheet in PV modules retrieved from five different locations, encompassing a variety of climates, including humid subtropical, hot-summer Mediterranean, tropical savanna climate and hot arid. The correlations between the degradation indicators and the weathering variables were further demonstrated by principle components analysis (PCA). We found strong relationships between: carbonyl formation and reflected solar radiation; hydroxyl formation and module temperature; yellowness and NO2 concentration, while no simple correlation could be found between a specific weathering factor and cracking. By introducing additional stress factors to the aged polyamide-based backsheet films with the novel 'fragmentation test', we successfully reproduced the field cracking behaviour. This study has demonstrated that different degradation modes of PV components respond differently to the environmental stresses encountered in service. Thereby, any accelerated laboratory test based on a single set condition or lacking key environmental variables would be inadequate to assess the long-term performance of PV modules and components. A new reliability-based methodology is proposed to quantitatively link laboratory testing with field results for the service life prediction of PV materials.

14 SOLAR ENERGY↗

DOE OSTI2023

Proto-neutron star convection and the neutrino-driven wind: implications for the r-process

The neutrino-driven wind from proto-neutron stars is a proposed site for r-process nucleosynthesis, although most previous work has found that a wind heated only by neutrinos cannot produce the third r-process peak. However, several groups have noted that introducing a secondary heating source within the wind can change the hydrodynamic conditions sufficiently for a strong r-process to proceed. One possible secondary heating source is gravito-acoustic waves, generated by convection inside the proto-neutron star. As these waves propagate into the wind, they can both accelerate the wind and shock and deposit energy into the wind. Additionally, the acceleration of the wind by these waves can reduce the total number of neutrino captures and thereby reduce the final electron fraction of the wind. In neutron rich conditions, all of these effects can make conditions more favourable for r-process nucleosynthesis. Here, we present a systematic investigation of the impact of these convection-generated gravito-acoustic waves within the wind on potential nucleosynthesis. We find that wave effects in the wind can generate conditions favourable for a strong r-process, even when the energy flux in the waves is a factor of 10 –4 smaller than the total neutrino energy flux and the wind is marginally neutron rich. Nevertheless, this depends strongly on the radius at which the waves become non-linear and form shocks. We also find that both entropy production after shock formation and the acceleration of the wind due to stresses produced by the waves prior to shock formation impact the structure and nucleosynthesis of these winds.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1973

Effect of artificial gravity on thermoregulation, respiratory metabolism and intermediary metabolism of animals

Metabolic alterations in animals exposed to radial acceleration are reported. Temperatures in acutely stressed animals dropped profoundly in correlation with decreased food consumption. Repeated exposure of the acutely stressed animal caused a decrease in hypothermic response whereas deceleration or reduction of G load did not significantly change body temperatures. Adrenal corticosteroids affected significantly the animal's recovery rate. No changes occured in body temperature patterns of chronically centrifuged animals after full adaptation; their respiratory rate increased very significantly in terms of CO2 output as did their glucose uptake by muscle tissues and their insulin responsiveness or sensitivity.

Oyama, J.↗

NASA NTRS1981

Fatigue crack growth in 7475-T651 aluminum alloy plate in hard vacuum and water vapor

Compact specimens of 25 mm thick aluminum alloy plate were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Crack growth rates were determined at frequencies of 1 Hz and 10 Hz in hard vacuum and laboratory air, and in mixtures of water vapor and nitrogen at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. A significant effect of water vapor on fatigue crack growth rates was observed at the lowest water vapor pressure tested. Crack rates changed little for pressures up to 1.03 kPa, but abruptly accelerated at higher pressures. At low stress intensity factor ranges, cracking rates at the lowest and highest water vapor pressure tested were, respectively, two and five times higher than rates in vacuum. Although a frequency was observed in laboratory air, cracking rates in water vapor and vacuum are insensitive to a ten-fold change in frequency. Surfaces of specimens tested in water vapor and vacuum exhibited different amounts of residual deformation. Reduced deformation on the fracture surfaces of the specimens tested in water vapor suggests embrittlement of the plastic zone ahead of the crack tip as a result of environmental interaction.

Dicus, D. L.↗

NASA NTRS1989

Detection of potential space station control/structure interaction with CO-ST-IN

The NASA Lewis Research Center is concerned with the potential of interaction between space station controllers and the solar PV array structures. The models required to handle this problem are very large, and automated methods were developed for the transfer of data between structural dynamic and control system analysis software. These methods emphasize the need to achieve accurate coupled analysis results while using as small a model as possible. Specific tools which help the analyst in this regard include modal order techniques, the use of mode acceleration to calculate internal loads and stresses and the transfer of Craig-Bampton components to reduce problems associated with modal sufficiency. These techniques were applied to a space station model with 366 modes below 1 Hz. Attitude control, and alpha and beta joint control were simulated. The inclusion of alpha and beta joint controllers is important when examining overall space station dynamics. An initial choice of control parameters does indicate a potential for control/structure interaction during reboost. As expected this is exacerbated by increasing the rate gain and decreasing the hysteresis of the reaction control system (RCS) in order to improve rigid body performance.

Carney, Kelly↗

NASA NTRS1991

Analysis of Spacelab 3 residual acceleration data

A data reduction plan is being developed to efficiently process residual acceleration data, making such data more accessible to principal investigators of low-gravity experiments. Accelerometer data collected during the Spacelab 3 mission is being processed using a prototype version of this plan. The plan addresses various aspects of acceleration data analysis: the identification of disturbances that are intolerable to experiments, the investigation of acceleration orientations, the definition and characterization of the background acceleration corresponding to a given experiment time line, the isolation and examination of particular significant disturbances, and the identification of disturbance sources. Acceleration magnitude, frequency, and orientation are discussed: transient accelerations can have magnitudes as large as 0.01 g with frequency components no greater than 0.001 g. These accelerations fluctuate rapidly in orientation. The occurrence of disturbance sources in an orbiter is tentatively identified as a random process, whereas the response of the orbiter to given accelerations is considered deterministic. The need to continue monitoring of residual accelerations in orbiting space laboratories is stressed.

Rogers, Melissa J. B.↗

NASA NTRS2008

Structural Benchmark Creep Testing for the Advanced Stirling Convertor Heater Head

The National Aeronautics and Space Administration (NASA) has identified the high efficiency Advanced Stirling Radioisotope Generator (ASRG) as a candidate power source for use on long duration Science missions such as lunar applications, Mars rovers, and deep space missions. For the inherent long life times required, a structurally significant design limit for the heater head component of the ASRG Advanced Stirling Convertor (ASC) is creep deformation induced at low stress levels and high temperatures. Demonstrating proof of adequate margins on creep deformation and rupture for the operating conditions and the MarM-247 material of construction is a challenge that the NASA Glenn Research Center is addressing. The combined analytical and experimental program ensures integrity and high reliability of the heater head for its 17-year design life. The life assessment approach starts with an extensive series of uniaxial creep tests on thin MarM-247 specimens that comprise the same chemistry, microstructure, and heat treatment processing as the heater head itself. This effort addresses a scarcity of openly available creep properties for the material as well as for the virtual absence of understanding of the effect on creep properties due to very thin walls, fine grains, low stress levels, and high-temperature fabrication steps. The approach continues with a considerable analytical effort, both deterministically to evaluate the median creep life using nonlinear finite element analysis, and probabilistically to calculate the heater head s reliability to a higher degree. Finally, the approach includes a substantial structural benchmark creep testing activity to calibrate and validate the analytical work. This last element provides high fidelity testing of prototypical heater head test articles; the testing includes the relevant material issues and the essential multiaxial stress state, and applies prototypical and accelerated temperature profiles for timely results in a highly controlled laboratory environment. This paper focuses on the last element and presents a preliminary methodology for creep rate prediction, the experimental methods, test challenges, and results from benchmark testing of a trial MarM-247 heater head test article. The results compare favorably with the analytical strain predictions. A description of other test findings is provided, and recommendations for future test procedures are suggested. The manuscript concludes with describing the potential impact of the heater head creep life assessment and benchmark testing effort on the ASC program.

Krause, David L.↗

NASA NTRS2016

Model-Based Fatigue Prognosis of Fiber-Reinforced Laminates Exhibiting Concurrent Damage Mechanisms

Prognostics of large composite structures is a topic of increasing interest in the field of structural health monitoring for aerospace, civil, and mechanical systems. Along with recent advancements in real-time structural health data acquisition and processing for damage detection and characterization, model-based stochastic methods for life prediction are showing promising results in the literature. Among various model-based approaches, particle-filtering algorithms are particularly capable in coping with uncertainties associated with the process. These include uncertainties about information on the damage extent and the inherent uncertainties of the damage propagation process. Some efforts have shown successful applications of particle filtering-based frameworks for predicting the matrix crack evolution and structural stiffness degradation caused by repetitive fatigue loads. Effects of other damage modes such as delamination, however, are not incorporated in these works. It is well established that delamination and matrix cracks not only co-exist in most laminate structures during the fatigue degradation process but also affect each other's progression. Furthermore, delamination significantly alters the stress-state in the laminates and accelerates the material degradation leading to catastrophic failure. Therefore, the work presented herein proposes a particle filtering-based framework for predicting a structure's remaining useful life with consideration of multiple co-existing damage-mechanisms. The framework uses an energy-based model from the composite modeling literature. The multiple damage-mode model has been shown to suitably estimate the energy release rate of cross-ply laminates as affected by matrix cracks and delamination modes. The model is also able to estimate the reduction in stiffness of the damaged laminate. This information is then used in the algorithms for life prediction capabilities. First, a brief summary of the energy-based damage model is provided. Then, the paper describes how the model is embedded within the prognostic framework and how the prognostics performance is assessed using observations from run-to-failure experiments

Prognostics↗

DOE OSTI2017

Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling down were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.

36 MATERIALS SCIENCE↗

NASA NTRS2005

Impact of Device Scaling on Deep Sub-micron Transistor Reliability: A Study of Reliability Trends using SRAM

As microelectronics are scaled in to the deep sub-micron regime, users of advanced technology CMOS, particularly in high-reliability applications, should reassess how scaling effects impact long-term reliability. An experimental based reliability study of industrial grade SRAMs, consisting of three different technology nodes, is proposed to substantiate current acceleration models for temperature and voltage life-stress relationships. This reliability study utilizes step-stress techniques to evaluate memory technologies (0.25mum, 0.15mum, and 0.13mum) embedded in many of today's high-reliability space/aerospace applications. Two acceleration modeling approaches are presented to relate experimental FIT calculations to Mfr's qualification data.

CMOS integrated circuits↗

NASA NTRS1992

Physical effects at the cellular level under altered gravity conditions

Several modifications of differentiated functions of animal cells cultivated in vitro have been reported when cultures have been exposed to increased or decreased inertial acceleration fields by centrifugation, clinorotation, and orbital space flight. Variables modified by clinorotation conditions include inertial acceleration, convection, hydrostatic pressure, sedimentation, and shear stress, which also affect transport processes in the extracellular chemical environment. Autocrine, paracrine and endocrine substances, to which cells are responsive via specific receptors, are usually transported in vitro (and possibly in certain embryos) by convection and in vivo by a circulatory system or ciliary action. Increased inertial acceleration increases convective flow, while microgravity nearly abolishes it. In the latter case the extracellular transport of macromolecules is governed by diffusion. By making certain assumptions it is possible to calculate the Peclet number, the ratio of convective transport to diffusive transport. Some, but not all, responses of cells in vitro to modified inertial environments could be manifestations of modified extracellular convective flow.

Todd, Paul↗