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At least 739 records · Page 41

All sources NASA NTRS DOE OSTI

NASA NTRS2015

Relation Between Residual and Hoop Stresses and Rolling Bearing Fatigue Life

Rolling-element bearings operated at high speed or high vibration may require a tight interference fit between the bore of the bearing and shaft to prevent rotation of the bearing bore around the shaft and fretting damage at the interfaces. Previous work showed that the hoop stresses resulting from tight interference fits can reduce bearing lives by as much as 65 percent. Where tight interference fits are required, case-carburized steel such as AISI 9310 or M50 NiL is often used because the compressive residual stresses inhibit subsurface crack formation and the ductile core inhibits inner-ring fracture. The presence of compressive residual stress and its combination with hoop stress also modifies the Hertz stress-life relation. This paper analyzes the beneficial effect of residual stresses on rolling-element bearing fatigue life in the presence of high hoop stresses for three bearing steels. These additional stresses were superimposed on Hertzian principal stresses to calculate the inner-race maximum shearing stress and the resulting fatigue life of the bearing. The load-life exponent p and Hertz stress-life exponent n increase in the presence of compressive residual stress, which yields increased life, particularly at lower stress levels. The Zaretsky life equation is described and is shown to predict longer bearing lives and greater load- and stress-life exponents, which better predicts observed life of bearings made from vacuum-processed steel.

Fatigue↗

DOE OSTI2011

DEVELOPMENT OF AN APPROACH TO MODELING LOADING AND ELUTION OF SPHERICAL RESORCINOL FORMALDEHYDE ION-EXCHANGE RESIN

The current strategy for removal of cesium from the Hanford waste stream is ion-exchange using spherical Resorcinol-Formaldehyde (sRF) resin. The original resin of choice was granular SuperLig 644 resin and during testing of this resin several operational issues were identified. For example, the granular material had a high angle of internal friction resulting in fragmentation of resin particles along its edges during cycling and adverse hydraulic performance. Efforts to replace SuperLig 644 were undertaken and one candidate was the granular Resorcinol-Formaldehyde (RF) resin where experience with this cation exchanger dates back to the late 1940's. To minimize hydraulic concerns a spherical version of RF was developed and several different chemically produced batches were created. The 5E-370/641 batch of sRF was selected and for the last decade numerous studies have been performed (e.g., batch contact tests, column loading and elution tests). The Waste Treatment Plant (WTP) flowsheet shows that the aqueous phase waste stream will have a wide range of ionic concentrations (e.g., during the loading step 0-3 M free OH, 5+ M Na, 0-1 M K, 0-3 M NO{sub 3}). Several steps are required in the ion-exchange process to achieve the required Cs separation factors: loading, displacement, washing, elution, and regeneration. The sRF resin will be operated over a wide range in pH (i.e., pH of 12-14 during the loading step and pH of 0.01-1 during the elution step). During some of these steps very high levels of counter-ions and co-ions will be present within the aqueous phase. Alternative process feeds are under consideration as well (e.g., sodium levels as high as 8 M and column operation up to 45 C during loading, reduced and recycled HNO{sub 3} during elution). In order to model the performance of sRF resin through an entire ion-exchange cycle, a more robust isotherm model is required. To achieve this more robust isotherm model requires knowledge of the numbers and kinds of fixed ionogenic groups that make up sRF. Recent literature reviews and scoping titration tests strongly indicate that sRF is a polyfunctional cation exchange resin with at least three dominant types of ring groups playing a role in its isotherm behavior over the wide pH range of operations. Also three types of fixed ionogenic acid groups are present: sulfonic (SO{sub 3}H{sup -}) groups; carboxylic (COOH{sup -}) groups, and resorcylic (OH{sup -}) groups. It is this premise that we are working under in the development of a robust isotherm model for sRF over its entire planned pH operating range. The application of prototypic isotherms for modeling ion-exchange column behavior is demonstrated in Section 3 of this report. This preliminary work served to focus the development effort on the use of a mass-action based isotherm. In Section 4 of this report, the foundational material required to develop a robust isotherm model for sRF is provided. The paths taken, and choices made, are given for the reader to better understand our current status with respect to this goal and to highlight our most recent understanding of sRF exchange equilibria. Our ultimate goal is to update the CERMOD code (Aleman and Hamm, 2007) with a robust isotherm model for sRF that spans the entire pH and concentration ranges of planned operations. The isotherm model will then be used in the VERSE-LC code to model an entire ion-exchange cycle.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Hazard Analysis for 90 MeV Booster Injection Energy Limit

The NSLS-II booster is designed to accelerate 200 MeV electrons to an energy of 3 GeV to serve as a full energy injector for the NSLS-II storage ring. Electrons are supplied to the booster from the NSLS-II linac. The NSLS-II booster was specified to accept electrons with an energy as low as 170 MeV. The supplemental shielding is designed to shield all energies from 150 MeV to the booster’s maximum energy of 3.2 GeV. Due to the shielding design, the NSLS-II PPS system guarantees that the beam energy must be above 151 MeV upon transport to the booster ring for injection. Recently, problems with the linac klystrons have come to the point that operating the NSLS-II linac below the 150 MeV may be the only possible way for the linac to deliver electrons to the booster. If the NSLS-II linac were limited to operate on only 1 klystron, at full power only 120 MeV beam energy would be possible. The nominal operating energy would be 100 MeV to leave overhead for beam loading compensation and to not stress the last remaining klystron any more than necessary. Since this is below the design of the booster shielding, the supplemental shielding needs to be analyzed to ensure that it is sufficient for lower energy beams. In this report, we discuss the impact of lowering the booster injection energy to 90 MeV on the supplemental shielding. Issues relating to how the booster will perform at this lower energy are not discussed.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Experiments on stiffened conical shell structures using cast epoxy models

Description of a casting technique for fabricating high-quality plastic structural models, and review of results regarding the use of such specimens to parametrically study the effect of base ring stiffness on the critical buckling pressure of a ring-stiffened conical shell. The fabrication technique involves machining a metal mold to the desired configuration and vacuum-drawing the plastic material into the mold. A room-temperature curing translucent thermoset epoxy was the casting material selected. A shell of revolution computer program which employs a nonlinear axisymmetric prebuckling strain field to obtain a bifurcation buckling solution was used to guide the selection of congifurations tested. The shell experimentally exhibited asymmetric collapse behavior, and the ultimate load was considerably higher than the analytical bifurcation prediction. The asymmetric buckling mode shape, however, initially appeared at a pressure near the analysis bifurcation solution.

Williams, J. G.↗

NASA NTRS1985

Small centrifugal pumps for low thrust rockets

This paper presents the results of a combined analytical and experimental investigation of low specific speed pumps for potential use as components of propellant feed systems for low thrust rocket engines. Shrouded impellers and open face impellers were tested in volute type and vaned diffuser type pumps. Full- and partial-emission diffusers and full- and partial-admission impellers were tested. Axial and radial loads, head and efficiency versus flow, and cavitation tests were conducted. Predicted performance of two pumps are compared when pumping water and liquid hydrogen. Detailed pressure loss and parasitic power values are presented for two pump configurations. Partial-emission diffusers were found to permit use of larger impeller and diffuser passages with a minimal performance penalty. Normal manufacturing tolerances were found to result in substantial power requirement variation with only a small pressure rise change. Impeller wear ring leakage was found to reduce pump pressure rise to an increasing degree as the pump flowrate was decreased.

Gulbrandsen, N. C.↗

NASA NTRS2000

The 'Pro-Drug' RibCys Decreases The Mutagenicity of High LET Radiation in Cultured Mammalian Cells

We have initiated studies aimed at reducing the mutational effects of high LET radiation such as Fe-56 ions and C-12 ions with certain drugs. The mutagenicity of high LET (143 keV/micrometer) Fe-56 or C-12 ions (LET = 100 keV/micrometer) was quantified at the CD59 locus of human-hamster hybrid AL cells. RibCys [2,S)-D-ribo-(1',2',3',4'- Tetrahydroxybutyl)-thiazolidine-4(R)-ca riboxylic acid], formed by condensation of L-cysteine with D-ribose, is designed so that the sulfhydryl amino acid L-cysteine is released intracellularly via nonenzymatic ring opening and hydrolysis leading to increased levels of glutathione (GSH). RibCys (4 or 10 mM), present during irradiation and a few hours post-irradiation, significantly decreased the yield of CD59(-) mutants induced by radiation. RibCys did not affect the clonogenic survival of irradiated cells, nor was it mutagenic itself. These results, together with the minimal side effects reported in mice and pigs, indicate that RibCys may be useful, perhaps even when used prophylactically, in reducing the load of mutations created by high LET radiation in astronauts or other exposed individuals. RibCys is an attractive drug that may reduce the risk of carcinogenesis in people exposed to high LET radiation.

Lenarczyk, M.↗

NASA NTRS2013

High-Performance, Low-Temperature-Operating, Long-Lifetime Aerospace Lubricants

The synthesis and characterization of six new ionic liquids, with fluoroether moeties on the imidazolium ring, each with vapor pressures shown to be <10(exp -7 Torr at 25 C, have been demonstrated. Thermal stability of the ionic liquids up to 250 C was demonstrated. The ionic liquids had no measurable influence upon viscosity upon addition to perfluoropolyether (PFPE) base fluids. They also had no measureable influence upon corrosion on steel substrates upon addition to base fluids. In general, 13 to 34% lower COFs (coefficients of friction), and 30 to 80% higher OK load of base fluids upon addition of the ionic liquids was shown. The compound consists of a 1,3-disubstituted imidazolium cation. The substituents comprise perfluoroether groups. A bis(trifluoromethanesulfonyl) imide anion counterbalances the charge. The fluorinated groups are intended to enhance dispersion of the ionic liquid in the PFPE base fluid. The presence of weak Van der Waals forces associated with fluorine atoms will limit interaction of the substituents on adjacent ions. The longer interionic distances will reduce the heat of melting and viscosity, and will increase dispersion capabilities.

Bergeron, Bryan↗

DOE OSTI2023

Multiaxial Plastic Deformation of Zircaloy-4 Nuclear Fuel Cladding Tubes

Here, this work is motivated by the desire to devise an internal pressure test that can mimic a displacement-controlled loading scenario and demonstrate how to apply the multiaxial stress and strain data from the test to develop an elastic/plastic constitutive model for a thin-walled tubular component. This is achieved by conducting simultaneous measurements of tangential and axial strain during the pressure test and integrating these strain measures into a feedback loop with the pressure controller. It is shown how data from such a test can be used to develop a large mechanical property data set relevant to biaxial loading conditions. The data obtained have high confidence evidenced by their low variability and alignment with other literature studies. Additionally, data from these internal pressure tests combined with full-tube axial tensile tests allow for the derivation of the Hill anisotropic yield function. The developed Hill yield function is validated by comparing the plastic strain ratios from the full-tube tension tests and by comparing the predicted yield stress in the tangential direction with measured values from ring tension tests in a previous study.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1979

Dynamic properties of elastomer cartridge specimens under a rotating load

This paper presents the results of a program of analysis and test to determine the dynamic properties of elastomer cartridges operating under a rotating load. These measured properties were compared to predictions based on results of unidirectional tests with the same elastomer material. The test method for the dynamic stiffness and damping measurements was essentially the same as the Base Excitation Resonant Mass Method. The primary difference is that the exciting force used for these most recent tests was exerted by rotating unbalance in a rotational test rig rather than a shake table. The specimens tested were: two rectangular cross-section, continuous ring cartridges of different cross-section and three cylindrical button cartridges of different button thickness. Tests were performed for strains from about 0.0001 to about 0.01 (double amplitude). Material properties and prediction equations determined from reciprocating tests were used to make numerical predictions of stiffness, damping, and loss coefficient for the test elements, with encouraging results. Strain was shown to be an important parameter in determining these dynamic properties, particularly damping and loss coefficient.

Darlow, M. S.↗

NASA NTRS1985

Variable length strut with longitudinal compliance and locking capability

A variable length strut device is illustrated for connecting two associated structures which includes an outer load bearing shell, a drive assembly, a length varying compliance assembly positioned by drive assembly, and a strut rod locking assembly. The load bearing shell includes a connecting part adapted for connection to a first associated structure. A strut connection rod has a connecting part adapted for connection to a second associated structure and a distal end having a piston driver slidably carried in a housing of compliance assembly. Two compliance pistons act in opposing directions on the piston driver to provide longitudinal compliance in a compliance mode of operation. Locking assembly includes locking balls which are urged in a locking ring as locking bolt is urged to the left by fluid pressure. Microswitches sense the displacement of pistons away from the internal ring to bring the pistons to a neutral position wherein the pistons are in contact with the internal ring when it is desired to do so as affected by a control source.

Belew, R. R.↗

NASA NTRSDate not supplied

3D Woven Composite End Ring Structure: Design Development and Verification Testing

The National Aeronautics and Space Administration (NASA) Space Technology and Mission Directorate (STMD) is advancing composite technologies for exploration missions. The Composite Technology for Exploration (CTE) project goal is to advance lightweight joint concepts for Space Launch System (SLS) class structures. To this end CTE is developing and demonstrating a 3D woven carbon /epoxy composite joint design co-bonded in a circumferential end ring configuration, applied to a SLS sized conceptual payload attachment structure. This joint is a lightweight alternative to heavy and costly metallic joints. The 3D woven joint development advances lightweight joint technologies through material and structural design, material and joint analyses, and fabrication, as well as demonstration through building block testing. Prior limited building block tests are mentioned. In this paper, new sub-element-scale test results are described that demonstrate the structural capability well beyond design limit load. Then, results for a sub-component test article with a 889 mm joint subjected to combined loads are presented.

Kenneth N Segal↗

DOE OSTI2014

Discrete Element Modeling Results of Proppant Rearrangement in the Cooke Conductivity Cell

The study of propped fracture conductivity began in earnest with the development of the Cooke cell which later became part of the initial API standard. Subsequent developments included a patented multicell design to conduct 4 tests in a press at the same time. Other modifications have been used by various investigators. Recent studies by the Stim-Lab proppant consortium have indicated that the flow field across a Cooke proppant conductivity testing cell may not be uniform as initially believed which resulted is significantly different conductivity results. Post test analysis of low temperature metal alloy injections at the termination of proppant testing prior to the release of the applied stress suggest that higher flow is to be expected along the sides and top of the proppant pack than compared to the middle of the pack. To evaluate these experimental findings, a physics-based two-dimensional (2-D) discrete element model (DEM) was developed and applied to simulate proppant rearrangement during stress loading in the Cooke conductivity cell and the resulting porosity field. Analysis of these simulations are critical to understanding the impact of modification to the testing cell as well as understanding key proppant conductivity issues such as how these effects are manifested in proppant concentration testing results. The 2-D DEM model was constructed to represent a realistic cross section of the Cooke cell with a distribution of four material properties, three that represented the Cooke cell (steel, sandstone,square rings), and one representing the proppant. In principle, Cooke cell materials can be approximated as assemblies of independent discrete elements (particles) of various sizes and material properties that interact via cohesive interactions, repulsive forces, and frictional forces. The macroscopic behavior can then be modeled as the collective behavior of many interacting discrete elements. This DEM model is particularly suitable for modeling proppant mechanical interactions subjected to an applied stress, where the experimental cell is represented as a cohesive body composed of a large number of discrete elements, and proppants can be modeled as the individual discrete particles with various sizes (following the proppant size distribution-density function used in the test) that exhibit no cohesive strength between the particles. Initial 2-D DEM modeling results suggest that proppant rearrangement and non-uniform stress distribution across the proppant pack results in significant non-uniform porosity distribution across the Cooke cell. Larger porosities develop along the edge of the proppant pack beneath the square ring seal and would result in a disproportionate higher flow field along these edges as compared to the middle of the proppant pack. These results suggest that reported conductivity values determined by the Cooke cell may be biased to overestimate the actual conductivity of the proppant at high stresses and that modifications to the standard Cooke cell will affect the magnitude of this bias.

03 NATURAL GAS↗

DOE OSTI2024

Unraveling Reactivity Differences: Room-Temperature Ring-Opening Metathesis Polymerization (ROMP) versus Frontal ROMP

Here, in this study, we explore the distinct reactivity patterns between frontal ring-opening metathesis polymerization (FROMP) and room-temperature solventless ring-opening metathesis polymerization (ROMP). Despite their shared mechanism, we find that FROMP is less sensitive to inhibitor concentration than room-temperature ROMP. By increasing the initiator-to-monomer ratio for a fixed inhibitor/initiator quantity, we find reduction in the ROMP background reactivity at room temperature (i.e., increased resin pot life). At elevated temperatures where inhibitor dissociation prevails, accelerated frontal polymerization rates are observed because of the concentrated presence of the initiator. Surprisingly, the strategy of employing higher initiator loading enhances both pot life and front speeds, which leads to FROMP rates exceeding prior reported values by over 5 times. This counterintuitive behavior is attributed to an increase in the proximity of the inhibitor to the initiator within the bulk resin and to whether the temperature favors coordination or dissociation of the inhibitor. A rapid method was developed for assessing resin pot life, and a straightforward model for active initiator behavior was established. Modified resin systems enabled direct ink writing of robust thermoset structures at rates much faster than previously possible.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Design and Analysis of the US ITER Central Solenoid Module Lifting Fixture

The central solenoid (CS) consists of six large high field superconducting magnets (also known as modules) approximately 4 m in diameter and 2 m tall that weigh approximately 120 tonnes each. These large and complex modules create challenges during assembly of the CS that require the development of custom assembly tooling such as the CS lifting fixture. The CS module lifting fixture is designed to lift and stack the six CS modules in the assembly building on the ITER site. Because of its unique design, fabrication, and assembly features, no lifting attachments could be incorporated within or under the CS modules. This limitation motivated the development of a friction-based lift fixture. The design and evaluation of the CS module lifting fixture considered both worker safety and investment protection, and the assessments were performed to international codes and standards. The CS module lifting fixture consists of two principal subassemblies: spider assembly and ring weldment. These subassemblies allow the frictional force to be augmented by the mechanical advantage of shallow-angle wedges. Large radial preloads created by both screw jack assemblies and the weight of a CS module develop frictional forces capable of performing a lift with a safety factor of at least 2. The design effort resulted in the use of low friction linear bearings on angle surfaces to ensure constant pressure, integrated jacks for pretensioning the fixture prior to lifting, and load pin strain gauges for monitoring the normal force. Testing of various materials and surface treatments led to the selection of laminated aluminum and rubber pads as the friction interface on the CS lifting fixture side and a grit-blasted Nitronic 50 stainless steel band on the CS module side. A redundant lifting method using the module slings between the spider and module is also utilized after the initial friction lift. The CS lifting fixture provides a safe and reliable solution for lifting and stacking the CS module during assembly.

Morris, Eric↗

DOE OSTI2017

Development of a 100 kV pulse generator for driving an electron scanner used in proton beam profile measurements

The Spallation Neutron Source (SNS) utilizes an electron scanner in the accumulator ring for nondestructive transverse profiling of the proton beam. The electron scanner consists of a high voltage pulse generator driving an electron gun, a medium voltage ramp generator, and a CCD camera. A new high voltage pulse generator that provides negative 100 kV pulses with rise times of less than 200 ns, +/-0.5% flattop of greater than 100 ns has been designed, delivered, and undergone extensive testing. The pulse generator has been operationally verified with the existing control system and simulated loads. Full system testing with the actual electron scanner is planned. This paper details the requirements, design, setup, and test results of the high voltage pulse generator.

Morris, B↗

NASA NTRS1990

Thermal plasma in outer planet magnetospheres

The plasma environments of the outer planets are a study in contrasts. The magnetosphere of Jupiter is dominated by the prodigious plasma output of Io, with losses due to diffusion driven by mass loading. At Saturn, the small icy satellites are the major sources of plasma for the inner magnetosphere. The low mass loading rates there imply that the densities of the plasma tori are limited by dissociative recombination, rather than diffusive transport. At Uranus, the icy satellites are negligible plasma sources compared to the input from the extended neutral hydrogen cloud and the ionosphere. Convection driven by the solar wind penetrates deep into the inner magnetosphere because of the unique orientation of the rotation axis of Uranus. The expected magnetosphere of Neptune is similar to that of Saturn and Jupiter, with Triton, the ring arcs, and the planet as possible plasma sources. The Voyager 2 encounter with Neptune holds out the hope of a passage through a nonterrestrial auroral region, a unique event in planetary exploration.

Belcher, J. W.↗

NASA NTRS2010

Foldable Instrumented Bits for Ultrasonic/Sonic Penetrators

Long tool bits are undergoing development that can be stowed compactly until used as rock- or ground-penetrating probes actuated by ultrasonic/sonic mechanisms. These bits are designed to be folded or rolled into compact form for transport to exploration sites, where they are to be connected to their ultrasonic/ sonic actuation mechanisms and unfolded or unrolled to their full lengths for penetrating ground or rock to relatively large depths. These bits can be designed to acquire rock or soil samples and/or to be equipped with sensors for measuring properties of rock or soil in situ. These bits can also be designed to be withdrawn from the ground, restowed, and transported for reuse at different exploration sites. Apparatuses based on the concept of a probe actuated by an ultrasonic/sonic mechanism have been described in numerous prior NASA Tech Briefs articles, the most recent and relevant being "Ultrasonic/ Sonic Impacting Penetrators" (NPO-41666) NASA Tech Briefs, Vol. 32, No. 4 (April 2008), page 58. All of those apparatuses are variations on the basic theme of the earliest ones, denoted ultrasonic/sonic drill corers (USDCs). To recapitulate: An apparatus of this type includes a lightweight, low-power, piezoelectrically driven actuator in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that the size of the axial force needed to make the tool bit advance into soil, rock, or another material of interest is much smaller than in ordinary twist drilling, ordinary hammering, or ordinary steady pushing. Examples of properties that could be measured by use of an instrumented tool bit include electrical conductivity, permittivity, magnetic field, magnetic permeability, temperature, and any other properties that can be measured by fiber-optic sensors. The problem of instrumenting a probe of this type is simplified, relative to the problem of attaching electrodes in a rotating drill bit, in two ways: (1) Unlike a rotating drill bit, a bit of this type does not have flutes, which would compound the problem of ensuring contact between sensors and the side wall of a hole; and (2) there is no need for slip rings for electrical contact between sensor electronic circuitry and external circuitry because, unlike a rotating drill, a tool bit of this type is not rotated continuously during operation. One design for a tool bit of the present type is a segmented bit with a segmented, hinged support structure (see figure). The bit and its ultrasonic/sonic actuator are supported by a slider/guiding fixture, and its displacement and preload are controlled by a motor. For deployment from the folded configuration, a spring-loaded mechanism rotates the lower segment about the hinges, causing the lower segment to become axially aligned with the upper segment. A latching mechanism then locks the segments of the bit and the corresponding segments of the slider/guiding fixture. Then the entire resulting assembly is maneuvered into position for drilling into the ground. Another design provides for a bit comprising multiple tubular segments with an inner alignment string, similar to a foldable tent pole comprising multiple tubular segments with an inner elastic cable connecting the two ends. At the beginning of deployment, all segments except the first (lowermost) one remain folded, and the ultrasonic/sonic actuator is clamped to the top of the lowermost segment and used to drive this segment into the ground. When the first segment has penetrated to a specified depth, the second segment is connected to the upper end of the first segment to form a longer rigid tubular bit and the actuator is moved to the upper end of the second segnt. The process as described thus far is repeated, adding segments until the desired depth of penetration has been attained. Yet other designs provide for bits in the form of bistable circular- or rectangular- cross-section tubes that can be stowed compactly like rolls of flat tape and become rigidified upon extension to full length, in a manner partly similar to that of a common steel tape measure. Albeit not marketed for use in tool bits, a bistable reeled composite product that transforms itself from a flat coil to a rigid tube of circular cross section when unrolled, is commercially available under the trade name RolaTube(TradeMark) and serves as a model for the further development of tool bits of this subtype.

Bar-Cohen, Yoseph↗

NASA NTRS2011

Monolithic Flexure Pre-Stressed Ultrasonic Horns

High-power ultrasonic actuators are generally assembled with a horn, backing, stress bolt, piezoelectric rings, and electrodes. The manufacturing process is complex, expensive, difficult, and time-consuming. The internal stress bolt needs to be insulated and presents a potential internal discharge point, which can decrease actuator life. Also, the introduction of a center hole for the bolt causes many failures, reducing the throughput of the manufactured actuators. A new design has been developed for producing ultrasonic horn actuators. This design consists of using flexures rather than stress bolts, allowing one to apply pre-load to the piezoelectric material. It also allows one to manufacture them from a single material/plate, rapid prototype them, or make an array in a plate or 3D structure. The actuator is easily assembled, and application of pre-stress greater than 25 MPa was demonstrated. The horn consists of external flexures that eliminate the need for the conventional stress bolt internal to the piezoelectric, and reduces the related complexity. The stress bolts are required in existing horns to provide prestress on piezoelectric stacks when driven at high power levels. In addition, the manufacturing process benefits from the amenability to produce horn structures with internal cavities. The removal of the pre-stress bolt removes a potential internal electric discharge point in the actuator. In addition, it significantly reduces the chances of mechanical failure in the piezoelectric stacks that result from the hole surface in conventional piezoelectric actuators. The novel features of this disclosure are: 1. A design that can be manufactured from a single piece of metal using EDM, precision machining, or rapid prototyping. 2. Increased electromechanical coupling of the horn actuator. 3. Higher energy density. 4. A monolithic structure of a horn that consists of an external flexure or flexures that can be used to pre-stress a solid piezoelectric structure rather than a bolt, which requires a through hole in the piezoelectric material. 5. A flexure system with low stiffness that accommodates mechanical creep with minor reduction in pre-stress.

Sherrit, Stewart↗