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At least 649 records · Page 36

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NASA NTRS2004

Reduced Order Methods for Prediction of Thermal-Acoustic Fatigue

The goal of this investigation is to assess the quality of high-cycle-fatigue life estimation via a reduced order method, for structures undergoing random nonlinear vibrations in a presence of thermal loading. Modal reduction is performed with several different suites of basis functions. After numerically solving the reduced order system equations of motion, the physical displacement time history is obtained by an inverse transformation and stresses are recovered. Stress ranges obtained through the rainflow counting procedure are used in a linear damage accumulation method to yield fatigue estimates. Fatigue life estimates obtained using various basis functions in the reduced order method are compared with those obtained from numerical simulation in physical degrees-of-freedom.

Przekop, A.↗

NASA NTRS2005

Finite Element Analysis of Adaptive-Stiffening and Shape-Control SMA Hybrid Composites

The usage of shape memory materials has extended rapidly to many fields, including medical devices, actuators, composites, structures and MEMS devices. For these various applications, shape memory alloys (SMAs) are available in various forms: bulk, wire, ribbon, thin film, and porous. In this work, the focus is on SMA hybrid composites with adaptive-stiffening or morphing functions. These composites are created by using SMA ribbons or wires embedded in a polymeric based composite panel/beam. Adaptive stiffening or morphing is activated via selective resistance heating or uniform thermal loads. To simulate the thermomechanical behavior of these composites, a SMA model was implemented using ABAQUS user element interface and finite element simulations of the systems were studied. Several examples are presented which show that the implemented model can be a very useful design and simulation tool for SMA hybrid composites.

Gao, Xiu-Jie↗

NASA NTRS1996

Spherical Joint Piston and Connecting Rod Developed

Under an interagency agreement with the Department of Energy, the NASA Lewis Research Center manages a Heavy-Duty Diesel Engine Technology (HDET) research program. The overall program objectives are to reduce fuel consumption through increased engine efficiency, reduce engine exhaust emissions, and provide options for the use of alternative fuels. The program is administered with a balance of research contracts, university research grants, and focused in-house research. The Cummins Engine Company participates in the HDET program under a cost-sharing research contract. Cummins is researching and developing in-cylinder component technologies for heavy-duty diesel engines. An objective of the Cummins research is to develop technologies for a low-emissions, 55-percent thermal efficiency (LE-55) engine. The best current-production engines in this class achieve about 46-percent thermal efficiency. Federal emissions regulations are driving this technology. Regulations for heavy duty diesel engines were tightened in 1994, more demanding emissions regulations are scheduled for 1998, and another step is planned for 2002. The LE-55 engine emissions goal is set at half of the 1998 regulation level and is consistent with plans for 2002 emissions regulations. LE-55 engine design requirements to meet the efficiency target dictate a need to operate at higher peak cylinder pressures. A key technology being developed and evaluated under the Cummins Engine Company LE-55 engine concept is the spherical joint piston and connecting rod. Unlike conventional piston and connecting rod arrangements which are joined by a pin forming a hinged joint, the spherical joint piston and connecting rod use a ball-and-socket joint. The ball-and-socket arrangement enables the piston to have an axisymmetric design allowing rotation within the cylinder. The potential benefits of piston symmetry and rotation are reduced scuffing, improved piston ring sealing, improved lubrication, mechanical and thermal load symmetry, reduced bearing stresses, reduced running clearances, and reduced oil consumption. The spherical joint piston is a monolithic, squeeze-cast, fiber-reinforced aluminum piston. The connecting rod has a ball end that seats on a spherical saddle within the piston and is retained by a pair of aluminum bronze holder rings. The holder rings are secured by a threaded ring that mates with the piston. As part of the ongoing research and development activity, the Cummins Engine Company successfully completed a 100-hr test of the spherical joint piston and connecting rod at LE- 55 peak steady-state engine conditions. In addition, a 100-hr transient cycle test that varied engine conditions between LE-55 no-load and LE-55 full-load was successfully completed.

Source record↗

NASA NTRS2000

Modular Low-Heater-Power Cathode/Electron Gun Assembly for Microwave and Millimeter Wave Traveling Wave Tubes

A low-cost, low-mass, electrically efficient, modular cathode/electron gun assembly has been developed by FDE Inc. of Beaverton, Oregon, under a Small Business Innovation Research (SBIR) contract with the NASA Glenn Research Center at Lewis Field. This new assembly offers significant improvements in the design and manufacture of microwave and millimeter wave traveling-wave tubes (TWT's) used for radar and communications. It incorporates a novel, low-heater-power, reduced size and mass, high-performance barium dispenser type thermionic cathode and provides for easy integration of the cathode into a large variety of conventional TWT circuits. Among the applications are TWT's for Earth-orbiting communication satellites and for deep space communications, where future missions will require smaller spacecraft, higher data transfer rates (higher frequencies and radiofrequency output power), and greater electrical efficiency. A particularly important TWT application is in the microwave power module (a hybrid microwave/millimeter wave amplifier consisting of a low-noise solid-state driver, a small TWT, and an electronic power conditioner integrated into a single compact package), where electrical efficiency and thermal loading are critical factors and lower cost is needed for successful commercialization. The design and fabrication are based on practices used in producing cathode ray tubes (CRT's), which is one of the most competitive and efficient manufacturing operations in the world today. The approach used in the design and manufacture of thermionic cathodes and electron guns for CRT's has been optimized for fully automated production, standardization of parts, and minimization of costs. It is applicable to the production of similar components for microwave tubes, with the additional benefits of low mass and significantly lower cathode heater power (less than half that of dispenser cathodes presently used in TWT s). Modular cathode/electron gun assembly. The modular cathode/electron gun assembly consists of four subassemblies the cathode, the focus electrode, the header (including the electrical feedthroughs), and the gun envelope (including the anode) a diagram of which is shown. The modular construction offers a number of significant advantages, including flexibility of design, interchangeability of parts, and a drop-in final assembly procedure for quick and accurate alignment. The gun can accommodate cathodes ranging in size from 0.050 to 0.250-in. in diameter and is applicable to TWT's over a broad range of sizes and operating parameters, requiring the substitution of only a few parts: that is, the cathode, focus electrode, and anode. The die-pressed cathode pellets can be made with either flat or concave (Pierce gun design) emitting surfaces. The gun can be either gridded (pulse operation) or ungridded (continuous operation). Important factors contributing to low cost are the greater use of CRT materials and parts, the standardization of processes (welding and mechanical capture), and tooling amenable to automated production. Examples are the use of simple shapes, drawn or stamped metal parts, and parts joined by welding or mechanical capture. Feasibility was successfully demonstrated in the retrofit and testing of a commercial Kaband (22-GHz) TWT. The modular cathode/electron gun assembly was computer modeled to replicate the performance of the original electron gun and fabricated largely from existing CRT parts. Significant test results included demonstration of low heater power (1.5-W, 1010 C brightness temperature for a 0.085-in.-diameter cathode), mechanical ruggedness (100g shock and vibration tests in accordance with military specifications (MIL specs)), and a very fast warmup. The results of these tests indicate that the low-cost CRT manufacturing approach can be used without sacrificing performance and reliability.

Wintucky, Edwin G.↗

NASA NTRS2000

Novel High Gas-Temperature Calibration System Demonstrated

Accurate measurement of high gas temperatures, typically above 1300 K, has always presented challenges to researchers. Thermocouples often perturb the local gas flow and temperature field; they provide indirect information; and at high temperatures, they require large corrections so that actual gas temperatures can be determined. The physical and chemical stability of thermocouples to withstand the thermal loads and reactive environments prevailing at high temperatures naturally limits their life and maximum use temperature. Optical systems have their own drawbacks since accurate results depend on well-characterized emissivity, optical thickness, and gas composition information. These properties are rarely well known, especially in high-temperature, chemically reacting environments. In addition, optical systems usually require independent calibrations, which often involve the use of thermocouples, and hence, suffer from their aforementioned limitations. A new technique developed by researchers at the NASA Glenn Research Center at Lewis Field exploits an abrupt increase in the emittance of optically thin materials at their unique melting temperatures for a direct determination of gas temperature. Pure metallic-oxide fibers, varying in diameter from 60 to 400 mm, have been used in measurements over a temperature range of 2050 to 2700 K. The accuracy and reproducibility of the technique is estimated to be 15 K: that is, within the uncertainty in the melting points of the materials. Other fiber materials with different, but unique, melting points could be used to extend the technique over a larger temperature range.

Gokoglu, Suleyman A.↗

NASA NTRS2001

MEMS Device Being Developed for Active Cooling and Temperature Control

High-capacity cooling options remain limited for many small-scale applications such as microelectronic components, miniature sensors, and microsystems. A microelectromechanical system (MEMS) is currently under development at the NASA Glenn Research Center to meet this need. It uses a thermodynamic cycle to provide cooling or heating directly to a thermally loaded surface. The device can be used strictly in the cooling mode, or it can be switched between cooling and heating modes in milliseconds for precise temperature control. Fabrication and assembly are accomplished by wet etching and wafer bonding techniques routinely used in the semiconductor processing industry. Benefits of the MEMS cooler include scalability to fractions of a millimeter, modularity for increased capacity and staging to low temperatures, simple interfaces and limited failure modes, and minimal induced vibration.

Moran, Matthew E.↗

NASA NTRS2005

Hydrogen Permeability of Polymer Matrix Composites at Cryogenic Temperatures

This paper presents experimental methods and results of an ongoing study of the correlation between damage state and hydrogen gas permeability of laminated composite materials under mechanical strains and thermal loads. A specimen made from IM-7/977-2 composite material has been mechanically cycled at room temperature to induce microcrack damage. Crack density and tensile modulus were observed as functions of number of cycles. Damage development was found to occur most quickly in the off-axis plies near the outside of the laminate. Permeability measurements were made after 170,000 cycles and 430,000 cycles. Leak rate was found to depend on applied mechanical strain, crack density, and test temperature.

Grenoble, Ray W.↗

NASA NTRS2003

Delamination Mechanisms of Thermal and Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced ceramic thermal harrier coatings will play an increasingly important role In future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability issue remains a major concern with the ever-increasing temperature requirements. In this paper, thermal cyclic response and delamination failure modes of a ZrO2-8wt%Y2O3 and mullite/BSAS thermaVenvironmenta1 barrier coating system on SiC/SiC ceramic matrix composites were investigated using a laser high-heat-flux technique. The coating degradation and delamination processes were monitored in real time by measuring coating apparent conductivity changes during the cyclic tests under realistic engine temperature and stress gradients, utilizing the fact that delamination cracking causes an apparent decrease in the measured thermal conductivity. The ceramic coating crack initiation and propagation driving forces under the cyclic thermal loads, in conjunction with the mechanical testing results, will be discussed.

Zhu, Dongming↗

NASA NTRS2005

Distributed sensing of Composite Over-wrapped Pressure Vessels using Fiber-Bragg Gratings

The increasing use of advanced composite materials in the wide range of applications including Space Structures is a great impetus to the development of smart materials. These materials offer a wide range of possibilities within the space program. But before they can be reliably incorporated into space flight applications, additional understanding is required in the area of damage tolerance of these materials. Efforts to enhance our understanding of failure modes, mechanical properties, long and short term environmental effects, cyclic damage accumulation and residual strength are needed. Thus we have employed the use of fiber optical sensors which offers an excellent opportunity exploit these materials through monitoring and characterizing their mechanical properties and thus the integrity of structures made from such materials during their life cycle. Use of these optical innovations provides an insight into structures that have not been available in the past, as well as the technology available to provide real time health monitoring throughout its life cycle. The embedded fiber optical sensor shows a clearly detectable sensitivity to changes in the near strain and stress fields of the host structure promoted by mechanical or thermal loading or, in certain conditions, structural damage. The last ten years have seen a large increase in the use of FBG based monitoring systems in a broad range of applications. Fiber Bragg gratings are use to monitor the structural properties of composite pressure vessels. These gratings optically inscribed into the core of a single mode fiber are used as a tool to monitor the stress strain relation in composite structures. The fiber Bragg sensors are both embedded within the composite laminates and bonded to the surface of the vessel with varying orientations with respect to the carbon fiber in the epoxy matrix. The response of these fiber-optic sensors is investigated by pressurizing the cylinder up to its burst pressure of around 4400 psi. This is done at both ambient and cryogenic temperatures using water and liquid nitrogen. The recorded response is compared with the response from conventional strain gauge also present on the vessel. Additionally, several vessels were tested that had been damaged to simulate different type of events, such as cut tow, delimitation and impact damage.

Grant, Joseph↗

NASA NTRS1990

Delamination Mechanisms of Thermal and Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced ceramic thermal barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability issue remains a major concern with the ever-increasing temperature requirements. In this paper, thermal cyclic response and delamination failure modes of a ZrO2-8wt%Y2O3 and mullite/BSAS thermal/environmental barrier coating system on SiC/SiC ceramic matrix composites were investigated using a laser high-heat-flux technique. The coating degradation and delamination processes were monitored in real time by measuring coating apparent conductivity changes during the cyclic tests under realistic engine temperature and stress gradients, utilizing the fact that delamination cracking causes an apparent decrease in the measured thermal conductivity. The ceramic coating crack initiation and propagation driving forces under the cyclic thermal loads, in conjunction with the mechanical testing results, will be discussed.

Zhu, Dongming↗

NASA NTRS2000

Radio Frequency (RF) Micro-Electromechanical Systems (MEMS) Switches for Space Communications

Micro-electromechanical systems (MEMS) is an emerging technology for radio frequency (RF) systems because it has the potential to dramatically decrease loss and improve efficiency. In this paper, we address the design and fabrication of novel MEMS switches being developed at NASA Glenn Research Center. Two types of switches are being developed: a microstrip series single pole single throw (SPST) switch and a coplanar waveguide (CPW) series SPST and single pole double throw (SPDT) switches. These are being fabricated as an integral part of 50 Ohm microstrip and CPW RF integrated circuits using microfabrication techniques. The construction of the switch relies on a cantilever beam that is partially supported by a dielectric post. The cantilever beam is electro-magnetically actuated. To decrease stiction, a Si3N4 thin film is deposited over the contact area. Thus, when the switch is closed, the ON-state insertion loss is governed by the parallel plate capacitance formed by the two contacts. The isolation in the OFF-state is governed by the parasitic capacitance when the cantilever is in the up position. RF MEMS switches have been demonstrated with 80% lower insertion loss than conventional solid state devices (GaAs Metal Semiconductor Field Effect Transistors (MESFETs) and Silicon PIN diodes) based switches. For example, a conventional GaAs five-bit phase shifter which is required for beam steering in a phased array antenna has approximately 7 dB of insertion loss at 26.5 GHz where as a comparable MEMS based phase shifter is expected to have only 2 dB of insertion loss. This translates into 56% lower power dissipation and therefore decreases the thermal load on the spacecraft and also reduces the power amplifier requirements. These benefits will enable NASA to build the next generation of deep space science crafts and micro/nano satellites.

Simons, Rainee N.↗

NASA NTRS2003

Oxidation of Carbon Fibers in a Cracked Ceramic Matrix Composite Modeled as a Function of Temperature

The oxidation model simulates the oxidation of the reinforcing carbon fibers within a ceramic matrix composite material containing as-fabricated microcracks. The physics-based oxidation model uses theoretically and experimentally determined variables as input for the model. The model simulates the ingress of oxygen through microcracks into a two-dimensional plane within the composite material. Model input includes temperature, oxygen concentration, the reaction rate constant, the diffusion coefficient, and the crack opening width as a function of the mechanical and thermal loads. The model is run in an iterative process for a two-dimensional grid system in which oxygen diffuses through the porous and cracked regions of the material and reacts with carbon in short time steps. The model allows the local oxygen concentrations and carbon volumes from the edge to the interior of the composite to be determined over time. Oxidation damage predicted by the model was compared with that observed from microstructural analysis of experimentally tested composite material to validate the model for two temperatures of interest. When the model is run for low-temperature conditions, the kinetics are reaction controlled. Carbon and oxygen reactions occur relatively slowly. Therefore, oxygen can bypass the carbon near the outer edge and diffuse into the interior so that it saturates the entire composite at relatively high concentrations. The kinetics are limited by the reaction rate between carbon and oxygen. This results in an interior that has high local concentrations of oxygen and a similar amount of consumed carbon throughout the cross section. When the model is run for high-temperature conditions, the kinetics are diffusion controlled. Carbon and oxygen reactions occur very quickly. The carbon consumes oxygen as soon as it is supplied. The kinetics are limited by the relatively slow rate at which oxygen is supplied in comparison to the relatively fast rate at which carbon and oxygen reactions occur. This results in a sharp gradient in oxygen concentration from the edge where it is supplied to the nearest source of carbon, which is where the oxygen is quickly consumed. A moving reaction front is seen in which the outlaying carbon is consumed before the next inner layer of carbon begins to react.

Halbig, Michael C.↗

NASA NTRS2005

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

Analytical and experimental studies conducted at the NASA, Langley Research Center (LaRC) for investigating integrated cryogenic propellant tank systems for a reusable launch vehicle (RLV) are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, thermal protection system (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Johnson, Theodore F.↗

NASA NTRS2005

Software Developed for Analyzing High- Speed Rolling-Element Bearings

COBRA-AHS (Computer Optimized Ball & Roller Bearing Analysis--Advanced High Speed, J.V. Poplawski & Associates, Bethlehem, PA) is used for the design and analysis of rolling element bearings operating at high speeds under complex mechanical and thermal loading. The code estimates bearing fatigue life by calculating three-dimensional subsurface stress fields developed within the bearing raceways. It provides a state-of-the-art interactive design environment for bearing engineers within a single easy-to-use design-analysis package. The code analyzes flexible or rigid shaft systems containing up to five bearings acted upon by radial, thrust, and moment loads in 5 degrees of freedom. Bearing types include high-speed ball, cylindrical roller, and tapered roller bearings. COBRA-AHS is the first major upgrade in 30 years of such commercially available bearing software. The upgrade was developed under a Small Business Innovation Research contract from the NASA Glenn Research Center, and incorporates the results of 30 years of NASA and industry bearing research and technology.

Fleming, David P.↗

NASA NTRS2005

Completed Beltrami-Michell Formulation in Polar Coordinates

A set of conditions had not been formulated on the boundary of an elastic continuum since the time of Saint-Venant. This limitation prevented the formulation of a direct stress calculation method in elasticity for a continuum with a displacement boundary condition. The missed condition, referred to as the boundary compatibility condition, is now formulated in polar coordinates. The augmentation of the new condition completes the Beltrami-Michell formulation in polar coordinates. The completed formulation that includes equilibrium equations and a compatibility condition in the field as well as the traction and boundary compatibility condition is derived from the stationary condition of the variational functional of the integrated force method. The new method is illustrated by solving an example of a mixed boundary value problem for mechanical as well as thermal loads.

Patnaik, Surya N.↗

NASA NTRS2005

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.

Hilburger, Mark W.↗

NASA NTRS2006

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Hilburger, Mark W.↗

NASA NTRS2006

Integrated Modeling of Advanced Opto-Mechanical Systems

The design of optical hardware for space applications is particularly challenging when developing high performance, novel systems that have no precedent. Integrated modeling and analysis of such opto-mechanical systems seeks to describe the end-to-end performance of the hardware using mission-relevant metrics. This multidisciplinary analysis might start with thermal disturbances from observation maneuvers, compute the system temperatures, compute the distorted positions and shapes of the hardware and compute the resulting optical performance. Dynamic disturbances such as reaction wheel imbalance or inertia imbalance of optical delay lines might be applied to a structural dynamic model and used in a guidance and control analysis. Mission-relevant science metrics might include wavefront quality, pointing error or imaging stability. Assembling a tool chain that can be both nimble and effective when scaled to the high fidelity models of detail design has been challenging. An integrated thermal, mechanical and optical analysis capability suitable for detail design has been developed and verified through experimental measurement. This capability was used in the design of flight-like breadboard hardware and development of a test apparatus that established both the level of performance of the hardware and the validity of the analysis. The analysis includes prediction of the thermal environment of the test chamber, detailed temperature distributions on the breadboard hardware, fine scale deformations of the optical elements, and computation of the wavefront quality using geometric optics. A battery of tests were conducted to assess the experiment data acquisition, measurement and control system and to establish the performance of the hardware design and accuracy of the integrated modeling. Thermal loads that represent operational observing maneuvers were imposed and the hardware optical performance was measured and compared to analytical predictions.

optomechanical analysis↗