Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Material design and testing”

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

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Current status of the Iosipescu shear test method

During the past several years, considerable study of the Iosipescu shear test method has been conducted by a number of investigators, including the present authors. Several different test fixture designs have been developed, and variations of the specimen size and notch configuration have been considered. Materials with properties ranging from isotropic to highly orthotropic have been tested. The response of such materials has also been predicted using finite element techniques, and attempts have been made to correlate these predictions with available experimental data. This recent work is summarized here, with particular emphasis being given to the correlations and contradictions resulting from the published works of these various investigators.

Adams, Donald F.↗
NASA NTRS2012

Experimental Studies of Carbon Nanotube Materials for Space Radiators

Game ]changing propulsion systems are often enabled by novel designs using advanced materials. Radiator performance dictates power output for nuclear electric propulsion (NEP) systems. Carbon nanotubes (CNT) and carbon fiber materials have the potential to offer significant improvements in thermal conductivity and mass properties. A test apparatus was developed to test advanced radiator designs. This test apparatus uses a resistance heater inside a graphite tube. Metallic tubes can be slipped over the graphite tube to simulate a heat pipe. Several sub ]scale test articles were fabricated using CNT cloth and pitch ]based carbon fibers, which were bonded to a metallic tube using an active braze material. The test articles were heated up to 600 C and an infrared (IR) camera captured the results. The test apparatus and experimental results are presented here.

SanSoucie, MIchael P.↗
NASA NTRS2005

Benchmark Calibration Tests Completed for Stirling Convertor Heater Head Life Assessment

A major phase of benchmark testing has been completed at the NASA Glenn Research Center (http://www.nasa.gov/glenn/), where a critical component of the Stirling Radioisotope Generator (SRG) is undergoing extensive experimentation to aid the development of an analytical life-prediction methodology. Two special-purpose test rigs subjected SRG heater-head pressure-vessel test articles to accelerated creep conditions, using the standard design temperatures to stay within the wall material s operating creep-response regime, but increasing wall stresses up to 7 times over the design point. This resulted in well-controlled "ballooning" of the heater-head hot end. The test plan was developed to provide critical input to analytical parameters in a reasonable period of time.

Krause, David L.↗
NASA NTRS2004

Preloading To Accelerate Slow-Crack-Growth Testing

An accelerated-testing methodology has been developed for measuring the slow-crack-growth (SCG) behavior of brittle materials. Like the prior methodology, the accelerated-testing methodology involves dynamic fatigue ( constant stress-rate) testing, in which a load or a displacement is applied to a specimen at a constant rate. SCG parameters or life prediction parameters needed for designing components made of the same material as that of the specimen are calculated from the relationship between (1) the strength of the material as measured in the test and (2) the applied stress rate used in the test. Despite its simplicity and convenience, dynamic fatigue testing as practiced heretofore has one major drawback: it is extremely time-consuming, especially at low stress rates. The present accelerated methodology reduces the time needed to test a specimen at a given rate of applied load, stress, or displacement. Instead of starting the test from zero applied load or displacement as in the prior methodology, one preloads the specimen and increases the applied load at the specified rate (see Figure 1). One might expect the preload to alter the results of the test and indeed it does, but fortunately, it is possible to account for the effect of the preload in interpreting the results. The accounting is done by calculating the normalized strength (defined as the strength in the presence of preload the strength in the absence of preload) as a function of (1) the preloading factor (defined as the preload stress the strength in the absence of preload) and (2) a SCG parameter, denoted n, that is used in a power-law crack-speed formulation. Figure 2 presents numerical results from this theoretical calculation.

Gyekenyesi, John P.↗
NASA NTRS2007

Robust Low-Cost Cathode for Commercial Applications

Under funding from the NASA Commercial Technology Office, a cathode assembly was designed, developed, fabricated, and tested for use in plasma sources for ground-based materials processing applications. The cathode development activity relied on the large prior NASA investment and successful development of high-current, high-efficiency, long-life hollow cathodes for use on the International Space Station Plasma Contactor System. The hollow cathode was designed and fabricated based on known engineering criteria and manufacturing processes for compatibility with the requirements of the plasma source. The transfer of NASA GRC-developed hollow cathode technology for use as an electron emitter in the commercial plasma source is anticipated to yield a significant increase in process control, while eliminating the present issues of electron emitter lifetime and contamination.

Patterson, Michael J.↗
NASA NTRS1999

Developments in Nano-Satellite Structural Subsystem Design at NASA-GSFC

The NASA-GSFC Nano-satellite Technology Development Program will enable flying constellations of tens to hundreds of nano-satellites for future NASA Space and Earth Science missions. Advanced technology components must be developed to make these future spacecraft compact, lightweight, low-power, low-cost, and survivable to a radiation environment over a two-year mission lifetime. This paper describes the efforts underway to develop lightweight, low cost, and multi-functional structures, serviceable designs, and robust mechanisms. As designs shrink, the integration of various subsystems becomes a vital necessity. This paper also addresses structurally integrated electrical power, attitude control, and thermal systems. These innovations bring associated fabrication, integration, and test challenges. Candidate structural materials and processes are examined and the merits of each are discussed. Design and fabrication processes include flat stock composite construction, cast aluminum-beryllium alloy, and an injection molded fiber-reinforced plastic. A viable constellation deployment scenario is described as well as a Phase-A Nano-satellite Pathfinder study.

Rossoni, Peter↗
NASA NTRSDate not supplied

Flammability Test Method for Materials Intended for Use as Fire Barriers in Crewed Habitats

In some crewed-spacecraft applications, onboard materials are intentionally selected to function as hazard control barriers to prevent powered hardware and/or ignited flammable items from igniting nearby flammable materials by acting as non-breaching, non-flammable containment (e.g., cargo transfer bags, zero gravity stowage racks, and jettison stowage bags on the International Space Station). Historically, flammability self-extinguishment testing of broad acreage or outermost layer materials alone was believed to be sufficient to verify overall flammability compliance. Though required, testing on design features such as threaded seams and zippers was not performed due to the incorrect assumption that flammability performance would not be impacted. However, recent coupon level testing of layups and configurations consisting of multiple materials have revealed that these features may be more susceptible to ignition and fire propagation than the bulk material. Additionally, configurational coupon ignition and propagation testing does not explicitly determine a material’s ability to provide protection to vulnerable flammable hardware. The need to evaluate this gap in assessing material or layup effectiveness as fire barriers between ignition sources and flammable materials led to the development of a new configuration-based fire barrier test. Test setup, relevant configurations, and test validation are discussed. The new barrier test method establishes a configuration for the test apparatus, identifies a conservative ignitor configuration, and defines pass/fail criteria. Test setup, relevant configurations, and test validation are discussed.

Susana Harper↗
NASA NTRS2016

Final Test Report: Hexavalent Chrome Free Coatings for Electronics Electromagnetic Interference (EMI) Shielding Effectiveness (SE)

The test results for Salt Spray Resistance, Static Heat and Humidity and Marine Environment can be found in Sections 3.1.3.3, 3.1.4.3 and 3.1.5.3 respectively. In summary, both the Metalast TCP and SurTec 650 Type 2 conversion coatings perform very similar to the incumbent Type 1 conversion coating against both 6061 and 5052 aluminum under all three test conditions. Significant prior work was performed to select the aluminum and conversion coating included within this test cycle; Reference - NASA GSDO Program Hexavalent Chrome Alternatives Final Pretreatments Test Report Task Order: NNH12AA45D September 01, 2013. As illustrated in the data, the 6061 aluminum panels SLIGHTLY out-performed the 5052 aluminum panels. Individual shielding effectiveness graphs for each panel are included within Appendix C and D. One other notable effect found during review of the data is that the Test Panels exposed to B117 Salt Fog reduced in shielding effectiveness significantly more than the Marine Environment Test Panels. The shielding effectiveness of the Marine Test Panels was approximately 20dB higher than the Test Panels that underwent B117 Salt Fog Exposure. The intent of this evaluation was not to maximize shielding effectiveness values. The same Parker Chomerics Cho-Seal 6503 gasket material was used for all panels with aluminum and conversion coating variants. A typical EMI gasket design for corrosive environments would be done quite differently. The intent was to execute a test that would provide the best possible evaluation of different aluminum materials and conversion coatings in corrosive environments. The test program achieved this intent. The fact that the two aluminums and two Type II conversion coatings performed similar to the incumbent Type 1 conversion coating is a positive outcome. It was desired to have an outcome that further differentiation the performance of two aluminum types and two conversion coating types but this could not be extracted by the test results. Further analysis of the test plates may be done by X-Ray Photoelectron Spectroscopy (XPS) or Electrochemical Impedance Spectroscopy (EIS). Feasibility of this is under review.

Kessel, Kurt R.↗
NASA NTRS2015

DebriSat: The New Hypervelocity Impact Test for Satellite Breakup Fragment Characterization

To replicate a hyper-velocity fragmentation event using modern-day spacecraft materials and construction techniques to better improve the existing DoD and NASA breakup models: DebriSat is intended to be representative of modern LEO satellites. Major design decisions were reviewed and approved by Aerospace subject matter experts from different disciplines. DebriSat includes 7 major subsystems. Attitude determination and control system (ADCS), command and data handling (C&DH), electrical power system (EPS), payload, propulsion, telemetry tracking and command (TT&C), and thermal management. To reduce cost, most components are emulated based on existing design of flight hardware and fabricated with the same materials. center dotA key laboratory-based test, Satellite Orbital debris Characterization Impact Test (SOCIT), supporting the development of the DoD and NASA satellite breakup models was conducted at AEDC in 1992. Breakup models based on SOCIT have supported many applications and matched on-orbit events reasonably well over the years.

Cowardin, Heather↗
NASA NTRS1984

Long Life Nickel Electrodes for a Nickel-hydrogen Cell: Cycle Life Tests

In order to develop a long life nickel electrode for a Ni/H2 cell, cycle life tests of nickel electrodes were carried out in Hi/H2 boiler plate cells. A 19 test cell matrix was made of various nickel electrode designs including three levels each of plaque mechanical strength, median pore size of the plaque, and active material loading. Test cells were cycled to the end of their life (0.5v) in a 45-minute low earth orbit cycle regime at 80% depth-of-discharge. The results show that the active material loading level affects the cycle life the most with the optimum loading at 1.6 g/cc void. Mechanical strength did not affect the cycle life noticeably in the bend strength range of 400 to 700 psi. The best plaque type appears to be one which is made of INCO nickel powder type 287 and has a median pore size of 13 micron.

Lim, H. S.↗
NASA NTRS1985

Long life nickel electrodes for a nickel-hydrogen cell: Cycle life tests

In order to develop a long life nickel electrode for a Ni/H2 cell, the cycle life of nickel electrodes was tested in Ni/H2 boiler plate cells. A 19 test cell matrix was made of various nickel electrode designs including three levels each of plaque mechanical strength, median pore size of the plaque, and active material loading. Test cells were cycled to the end of their life (0.5v) in a 45 minute low Earth orbit cycle regime at 80% depth-of-discharge. It is shown that the active material loading level affects the cycle life the most with the optimum loading at 1.6 g/cc void. Mechanical strength does not affect the cycle life noticeably in the bend strength range of 400 to 700 psi. It is found that the best plaque is made of INCO nickel powder type 287 and has median pore size of 13 micron.

Lim, H. S.↗
NASA NTRS2008

Return to Mercury: A Comparison of Solar Simulation and Flight Data for the MESSENGER Spacecraft

The MErcury, Surface, Space, ENvironment GEochemistry and Ranging (MESSENGER) spacecraft is a NASA Discovery Mission spacecraft developed and operated by the Johns Hopkins University Applied Physics Laboratory. It was launched on August 3, 2004 and is currently on a course for Mercury orbit insertion in March 2011. To date the mission trajectory has taken the spacecraft to minimum solar distances of 0.332 and 0.313 AU and on January 14, 2008 the first flyby of Mercury in 33 years. From launch through the latest perihelion passage temperature performance data has been collected for the sun facing Digital Sun Sensors (DSS), the sun facing phased array and low gain (omni) antennas, the solar arrays, the sunshade and the two sun facing attitude control 4.4 N thrusters. Prior to launch, extensive solar simulation testing was conducted at the Glenn Research Center, Tank 6 solar simulation facility in Cleveland Ohio. Flight hardware qualification units representing these Sun exposed components were tested in solar environments that represented near mission minimum solar distance as to verify the thermal designs and the material used in fabrication. The paper will review the thermal designs of these components and their thermal performance to date as compared to the solar simulation testing.

Ercol, Carl J.↗
NASA NTRS1999

NASA Ames Research Center R and D Services Directorate Biomedical Systems Development

The Ames Research Center R&D Services Directorate teams with NASA, other government agencies and/or industry investigators for the development, design, fabrication, manufacturing and qualification testing of space-flight and ground-based experiment hardware for biomedical and general aerospace applications. In recent years, biomedical research hardware and software has been developed to support space-flight and ground-based experiment needs including the E 132 Biotelemetry system for the Research Animal Holding Facility (RAHF), E 100 Neurolab neuro-vestibular investigation systems, the Autogenic Feedback Systems, and the Standard Interface Glove Box (SIGB) experiment workstation module. Centrifuges, motion simulators, habitat design, environmental control systems, and other unique experiment modules and fixtures have also been developed. A discussion of engineered systems and capabilities will be provided to promote understanding of possibilities for future system designs in biomedical applications. In addition, an overview of existing engineered products will be shown. Examples of hardware and literature that demonstrate the organization's capabilities will be displayed. The Ames Research Center R&D Services Directorate is available to support the development of new hardware and software systems or adaptation of existing systems to meet the needs of academic, commercial/industrial, and government research requirements. The Ames R&D Services Directorate can provide specialized support for: System concept definition and feasibility Mathematical modeling and simulation of system performance Prototype hardware development Hardware and software design Data acquisition systems Graphical user interface development Motion control design Hardware fabrication and high-fidelity machining Composite materials development and application design Electronic/electrical system design and fabrication System performance verification testing and qualification.

Pollitt, J.↗
NASA NTRS2016

Below Ambient and Cryogenic Thermal Testing

Methods and apparatus for the testing of below-ambient temperature thermal insulation systems have been developed based on boiloff calorimetry. Boiloff calorimetry provides a direct measure of heat flow for below-ambient temperature conditions. The effective thermal conductivity (ke) and heat flux (q) of a test specimen are calculated for a fixed environmental condition (warm boundary temperature; cold boundary temperature; ambient or vacuum pressure). Through its heat of vaporization, liquid nitrogen (LN2) serves as the energy meter. Different apparatus have been built for flat-plate, cylindrical, and pipeline test specimens. Boundary temperatures can range from 353 K down to 77 K (80 C to -196 C). By interposing different insulation layers on the cold boundary, the cryogenic boiloff method is suitable for a wide range of below-ambient temperature applications. A cylindrical apparatus, Cryostat-100, as well as the pipeline test apparatus, Cryostat-P100, are thermally guarded and directly measure absolute thermal performance in watts. Pipe insulation systems can be mechanical, double-walled, or vacuum-jacketed including materials such as foams, cellular glass, aerogel blankets, clam-shell panels, and multilayer insulation. Two test pipelines, 12-meter-long, are mounted between two cold box assemblies. The test pipeline diameter is from 25-mm to 76-mm while the maximum outside diameter including insulation is up to 204-mm. The cold pipe tester design and test methods are discussed, as well as results for select thermal insulation materials. Progress toward a comparative type, bench-top cold pipe tester (Cryostat-P200) is also discussed.

Fesmire, James E.↗
NASA NTRS1993

LUTE primary mirror materials and design study report

The major objective of the Lunar Ultraviolet Telescope Experiment (LUTE) Primary Mirror Materials and Design Study is to investigate the feasibility of the LUTE telescope primary mirror. A systematic approach to accomplish this key goal was taken by first understanding the optical, thermal, and structural requirements and then deriving the critical primary mirror-level requirements for ground testing, launch, and lunar operations. After summarizing the results in those requirements which drove the selection of material and the design for the primary mirror are discussed. Most important of these are the optical design which was assumed to be the MSFC baseline (i.e. 3 mirror optical system), telescope wavefront error (WFE) allocations, the telescope weight budget, and the LUTE operational temperature ranges. Mechanical load levels, reflectance and microroughness issues, and options for the LUTE metering structure were discussed and an outline for the LUTE telescope sub-system design specification was initiated. The primary mirror analysis and results are presented. The six material substrate candidates are discussed and four distinct mirror geometries which are considered are shown. With these materials and configurations together with varying the location of the mirror support points, a total of 42 possible primary mirror designs resulted. The polishability of each substrate candidate was investigated and a usage history of 0.5 meter and larger precision cryogenic mirrors (the operational low end LUTE temperature of 60 K is the reason we feel a survey of cryogenic mirrors is appropriate) that were flown or tested are presented.

Ruthven, Greg↗
NASA NTRS1997

Design Protocols and Analytical Strategies that Incorporate Structural Reliability Models

Ceramic matrix composites (CMC) and intermetallic materials (e.g., single crystal nickel aluminide) are high performance materials that exhibit attractive mechanical, thermal and chemical properties. These materials are critically important in advancing certain performance aspects of gas turbine engines. From an aerospace engineer's perspective the new generation of ceramic composites and intermetallics offers a significant potential for raising the thrust/weight ratio and reducing NO(x) emissions of gas turbine engines. These aspects have increased interest in utilizing these materials in the hot sections of turbine engines. However, as these materials evolve and their performance characteristics improve a persistent need exists for state-of-the-art analytical methods that predict the response of components fabricated from CMC and intermetallic material systems. This need provided the motivation for the technology developed under this research effort. Continuous ceramic fiber composites exhibit an increase in work of fracture, which allows for "graceful" rather than catastrophic failure. When loaded in the fiber direction, these composites retain substantial strength capacity beyond the initiation of transverse matrix cracking despite the fact that neither of its constituents would exhibit such behavior if tested alone. As additional load is applied beyond first matrix cracking, the matrix tends to break in a series of cracks bridged by the ceramic fibers. Any additional load is born increasingly by the fibers until the ultimate strength of the composite is reached. Thus modeling efforts supported under this research effort have focused on predicting this sort of behavior. For single crystal intermetallics the issues that motivated the technology development involved questions relating to material behavior and component design. Thus the research effort supported by this grant had to determine the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; map a simplistic failure strength envelope of the material; develop a statistically based reliability computer algorithm, verify the reliability model and computer algorithm, and model stator vanes for rig tests. Thus establishing design protocols that enable the engineer to analyze and predict the mechanical behavior of ceramic composites and intermetallics would mitigate the prototype (trial and error) approach currently used by the engineering community. The primary objective of the research effort supported by this short term grant is the continued creation of enabling technologies for the macroanalysis of components fabricated from ceramic composites and intermetallic material systems. The creation of enabling technologies aids in shortening the product development cycle of components fabricated from the new high technology materials.

Duffy, Stephen F.↗
NASA NTRS2018

Lessons Learned from Recent Testing in the Nuclear Thermal Rocket Element Environmental Simulator

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility is designed to perform realistic non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and fuel materials. Although the NTREES facility cannot reproduce the neutron and gamma environment of an operating NTR, it can simulate the thermal hydraulic environment within an NTR fuel element to provide critical information on material performance and compatibility. The NTREES facility is currently being reconfigured with an all new suite of pyrometers, a new coil and feedthrough design along with a new gas sampling system for the mass spectrometer. Also new is the ability to perform chamber purges using argon. All of these modifications are the result of experiences gained through several years of testing various NTR components under a wide range of operating conditions. The testing details and the lessons learned from those tests are discussed in this presentation.

Emrich, William J., Jr.↗