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The mechanical properties, load tests, and stress analysis of the Spartan Release Engagement Mechanism (REM) is presented. The fracture properties of the components of the unit are also discussed. Detailed engineering drawings are included.
The mechanical performance of accident-tolerant fuel (ATF) cladding candidates in light-water reactors (LWRs) must be similar to or better than that of current conventional nuclear fuel claddings to reduce dose to the public and ensure a that the core coolable geometry is maintained during a postulated reactivity-initiated accident (RIA) in light-water reactors (LWRs). During an RIA event, the rapid thermal expansion of nuclear fuel can deform the cladding once the fuel–cladding gap closes. In some cases, the pellet–cladding mechanical interaction (PCMI) can induce mechanical failure in ATF candidates. Thus, the mechanical response of ATF cladding must be investigated by mimicking the conditions of RIA and potentially performing Transient Reactor Test (TREAT) experiments to establish or verify the safety envelope. The work presented in this report investigated the failure behavior of as-received, hydrided, and chromium-coated (Cr-coated) Zircaloy-4 (Zry-4) cladding tube under strain-driven mechanical conditions, mimicking postulated RIA loading conditions. Mechanical testing was performed at 300°C via modified burst test (MBT) equipment with pulse width control previously developed under the Department of Energy’s (DOE’s) Advanced Fuel Campaign (AFC). The mechanical strains were determined using 2D digital image correlation (DIC) techniques. The base Zry-4 acquired by Cameco Inc. was in stress-relieved annealed (SRA) condition. Because of the observed large deformation of the cladding tubes, the failure strain definition was updated for the MBT, which can also be applied to other tube tests where significant bulging (out-of-plane deformation) is present. The failure strain was determined to be affected by the speed of the test or the RIA event. As the RIA-like event duration decreased from 75 to 15 ms, the failure strain decreased 5, 7 and 1% for as-received, hydrided, and Cr-coated specimens, respectively. Fractography on the Cr-coated specimens indicated the presence of two failure mechanisms: (i) crenulation at the outer surface of the coating due to the tensile tractional forces along with coatings grain microstructure and (ii) formation of critical defect at the coating/cladding interface that initiated coating rupture after severe plastic deformation of the Zry- 4 substrate. Based on the MBT results and fractography observations, performing mechanical property testing at high strain rates—in particular on Cr-coated tubes—and semi-integral TREAT experiments are required future efforts to ensure ATF cladding performance during transients. The testing recommended would also inform the development of long-term generalized cladding technologies.
The HST Super Light Weight Interchangeable Carrier Static Test program calls for a total of 15 load cases with an average of 9 simultaneous push/pull locations per load case. This testing program represents the most complex static test ever attempted at Goddard Space Flight Center. Many unique multi-pull fixtures were designed to apply the simultaneous loading. Additionally, a total of 600 channels of data required processing for each loadcase. A total of 1100 separate strain gages were installed on SLIC. A team of 15 trained technicians were needed to apply test loads via mechanical hand pumps for several load cases. All 15 load cases were successfully conducted within 15 weeks. The ManTech team successfully tested all SLIC 1200 interface clips to the required testing loads. Several unique designs were needed to address testing challenges as loadline interference, Payload Safety, payload flexibility and opposing load applications.
Gravity-off-loading of deployable spacecraft mechanisms during ground testing is a long-standing problem. Deployable structures which are usually too weak to support their own weight under gravity require a means of gravity-off-loading as they unfurl. Conventional solutions to this problem have been helium-filled balloons or mechanical pulley/counterweight systems. These approaches, however, suffer from the deleterious effects of added inertia or friction forces. The changing form factor of the deployable structure itself and the need to track the trajectory of the center of gravity also pose a challenge to these conventional technologies. This paper presents a novel testing apparatus for high-fidelity zero-gravity simulation for special application to deployable space structures such as solar arrays, magnetometer booms, and robotic arms in class 100,000 clean room environments
Understanding the mechanical behaviors of batteries is critical to improve battery safety since mechanical failure may directly lead to short-circuits. Nevertheless, mechanical modeling of batteries is challenging since a cell usually contains multiple thin layers with drastically different material properties, and they exhibit different responses under different loading conditions. In this work, we developed a mechanical model for a large-format pouch cell, where the cell is represented by thick shell elements that are not only computationally efficient but also account for different thickness and material properties of individual components. Moreover, the mechanical properties of active materials in electrodes are described by a continuous surface cap model that can capture both compaction and shear deformation modes and can include strain rate effect and damage. Furthermore, to evaluate the model capabilities, we conducted abuse tests under various loading conditions (quasi-static compression, shear and impact). It is shown that the model prediction of load-displacement relationship and failure condition agree with experimental results, which demonstrates that the developed model can capture the mechanical behaviors of a cell in different abuse events. Details of element formulation, material parameters evaluation and test setup are presented. Capabilities, limitations and future directions of model development are also discussed.
Stiffened composite panels proposed for fuselage and wing design utilize a variety of stiffener-to-skin attachment concepts including mechanical fasteners. The attachment concept is an important factor influencing the panel's strength and can govern its performance following local damage. Mechanical fasteners can be an effective method for preventing stiffener-skin separation. One potential failure mode for bolted panels occurs when the bolts pull through the stiffener attachment flange or skin. The resulting loss of support by the skin to the stiffener and by the stiffener to the skin can result in local buckling and subsequent panel collapse. The characteristic failure modes associated with bolt push-through failure are described and the results of a parametric study of the effects that different material systems, boundary conditions, and laminates have on the forces and displacements required to cause damage and bolt pushthrough failure are presented.
An analytical rationale for the sensitivity-insensitivity of dispersion-strengthened systems to process history is provided. In particular, the research was focussed upon the influence of the particle-matrix interface bond in TD-Nickel and TD-Nichrome, and the manner in which the differences in both elastic constants and thermal expansion coefficients between these phases stress this interface when these alloys are subjected to mechanical and thermal loads upon the mechanical properties of these alloys.
Future large infrared space telescopes, such as the James Webb Space Telescope (JWST), will require deployable sunshields to provide passive cooling for optics and instruments. Deployable sunshield structures for such applications typically consist of multiple thin-film membrane layers supported by deployable booms. The mechanical design of the sunshield must accommodate thermal strains due to layer-to-layer temperature differences as well as potentially large in-plane temperature gradients within individual film layers. This paper describes a thermal-structural analysis for predicting the stress state in a thin-film membrane subject to both mechanical thermal loads that could aid in the mechanical design of future sunshield structures. First the temperature field predicted by a thermal analysis is mapped to a structural finite element model, and then the structural response is predicted using a nonlinear static analysis. The structural model uses membrane elements in conjunction with a tension field material model to predict the response of the thin-film membrane layer. The tension field material model accounts for no-compression behavior associated with wrinkling and slackness. This approach was used to study the problem of a single membrane layer from the NASA reference concept for the JWST sunshield. Results from the analysis show that the membrane can experience a loss of tensile preload due to the presence of an in-plane temperature gradient representative of the cold-side layer temperature distribution predicted for the reference concept JWST.
The commercial HyperSizer aerospace-composite-material-structure-sizing software has been enhanced by incorporating capabilities for representing coupled thermal, piezoelectric, and piezomagnetic effects on the levels of plies, laminates, and stiffened panels. This enhancement is based on a formulation similar to that of the pre-existing HyperSizer capability for representing thermal effects. As a result of this enhancement, the electric and/or magnetic response of a material or structure to a mechanical or thermal load, or its mechanical response to an applied electric or magnetic field can be predicted. In another major enhancement, a capability for representing micromechanical effects has been added by establishment of a linkage between HyperSizer and Glenn Research Center s Micromechanics Analysis Code With Generalized Method of Cells (MAC/GMC) computer program, which was described in several prior NASA Tech Briefs articles. The linkage enables Hyper- Sizer to localize to the fiber and matrix level rather than only to the ply level, making it possible to predict local failures and to predict properties of plies from those of the component fiber and matrix materials. Advanced graphical user interfaces and database structures have been developed to support the new HyperSizer micromechanics capabilities.
A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multifactor interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.
This article presents an application of the Kalman filtering technique to estimate loads on a wind turbine. The approach combines a mechanical model and a set of measurements to estimate signals that are not available in the measurements, such as wind speed, thrust, tower position, and tower loads. The model is severalfold faster than real time and is intended to be run online, for instance, to evaluate real-time fatigue life consumption of a field turbine using a digital twin, perform condition monitoring, or assess loads for dedicated control strategies. The mechanical model is built using a Rayleigh–Ritz approach and a set of joint coordinates. We present a general method and illustrate it using a 2-degrees-of-freedom (DOF) model of a wind turbine and using rotor speed, generator torque, pitch, and tower-top acceleration as measurement signals. The different components of the model are tested individually. The overall method is evaluated by computing the errors in estimated tower-bottom-equivalent moment from a set of simulations. From this preliminary study, it appears that the tower-bottom-equivalent moment is obtained with about 10 % accuracy. The limitation of the model and the required steps forward are discussed.
Thick rubber components are employed by the Army to carry large loads. In tanks, rubber covers road wheels and track systems to protect roadways. It is difficult for design engineers to simulate the details of the hysteretic heating for large strain viscoelastic deformations. In this study, an approximation to the viscoelastic energy dissipated per unit time is investigated for use in estimating mechanically induced viscoelastic heating. Coupled thermo-mechanical simulations of large cyclic deformations of rubber cylinders are presented. The cylinders are first compressed axially and then cyclically loaded about the compressed state. Details of the algorithm and some computational issues are discussed. The coupled analyses are conducted for tall and short rubber cylinders both with and without imbedded metal disks.
The reduction of the aerodynamic load that acts on a generic rotorcraft fuselage by the application of active flow control was investigated in a wind tunnel test conducted on an approximately 1/3-scale powered rotorcraft model simulating forward flight. The aerodynamic mechanisms that make these reductions, in both the drag and the download, possible were examined in detail through the use of the measured surface pressure distribution on the fuselage, velocity field measurements made in the wake directly behind the ramp of the fuselage and computational simulations. The fuselage tested was the ROBIN-mod7, which was equipped with a series of eight slots located on the ramp section through which flow control excitation was introduced. These slots were arranged in a U-shaped pattern located slightly downstream of the baseline separation line and parallel to it. The flow control excitation took the form of either synthetic jets, also known as zero-net-mass-flux blowing, and steady blowing. The same set of slots were used for both types of excitation. The differences between the two excitation types and between flow control excitation from different combinations of slots were examined. The flow control is shown to alter the size of the wake and its trajectory relative to the ramp and the tailboom and it is these changes to the wake that result in a reduction in the aerodynamic load.
It is found that the standard expressions for elastic stress and displacement in the crack-tip region (i.e., the so-called singular solution) cannot be considered to be approximations that are acceptable in a completely general sense. This conclusion is best illustrated by the instance of a biaxially loaded infinite sheet with a flat horizontal central crack, where the effect of load applied parallel to the plane of the crack appears entirely in the second terms of the series representations for local stresses and displacements. An elastoplastic finite-element analysis of the same biaxially loaded finite specimen geometry shows that the global energy release rate, the J-integral, the plastic stress and strain intensity factors (in the sense of Hilton and Hutchinson), and the size of the crack border region plastic yield, all have pronounced biaxial load dependence.
Skeletal unloading leads to decreased bone formation and decreased bone mass. Bone resorption is uncoupled from bone formation, contributing to the bone loss. During spaceflight bone is lost principally from the bones most loaded in the 1-g environment, and some redistribution of bone from the lower extremities to the head appears to take place. Although changes in calcitropic hormones have been demonstrated during skeletal unloading (PTH and 1,25(OH)2D decrease), it remains unclear whether such changes account for or are in response to the changes in bone formation and resorption. Bed rest studies with human volunteers and hindlimb elevation studies with rats have provided useful data to help explain the changes in bone formation during spaceflight. These models of skeletal unloading reproduce a number of the conditions associated with microgravity, and the findings from such studies confirm many of the observations made during spaceflight. Determining the mechanism(s) by which loading of bone is sensed and translated into a signal(s) controlling bone formation remains the holy grail in this field. Such investigations couple biophysics to biochemistry to cell and molecular biology. Although studies with cell cultures have revealed biochemical responses to mechanical loads comparable to that seen in intact bone, it seems likely that matrix-cell interactions underlie much of the mechanocoupling. The role for systemic hormones such as PTH, GH, and 1,25(OH)2D compared to locally produced factors such as IGF-I, PTHrP, BMPs, and TGF-beta in modulating the cellular response to load remains unclear. As the mechanism(s) by which bone responds to mechanical load with increased bone formation are further elucidated, applications of this knowledge to other etiologies of osteoporosis are likely to develop. Skeletal unloading provides a perturbation in bone mineral homeostasis that can be used to understand the mechanisms by which bone mineral homeostasis is maintained, with the expectation that such understanding will lead to effective treatment for disuse osteoporosis.
Reusable mechanical pin puller relatively simple spring-loaded trigger mechanism. Designed to save money and increase safety as substitute for costly and potentially dangerous pyrotechnic pin pullers used in development and testing of deployment mechanisms.
This research has been concerned with load diffusion in composite structures. Fundamental solid mechanics studies were carried out to provide a basis for assessing the complicated modeling necessary for large scale structures used by NASA. An understanding of the fundamental mechanisms of load diffusion in composite subcomponents is essential in developing primary composite structures. Analytical models of load diffusion behavior are extremely valuable in building an intuitive base for developing refined modeling strategies and assessing results from finite element analyses. The decay behavior of stresses and other field quantities provides a significant aid towards this process. The results are also amendable to parameter study with a large parameter space and should be useful in structural tailoring studies.
Skeletal unloading leads to decreased bone formation and decreased bone mass. Bone resorption is uncoupled from bone formation, contributing to the bone loss. During space flight bone is lost principally from the bones most loaded in the 1 g environment. Determining the mechanism(s) by which loading of bone is sensed and translated into a signal(s) controlling bone formation remains the holy grail in this field. It seems likely that matrix/cell interactions will underlie much of the mechanocoupling. Integrins are a prime mediator of such interactions. The role for systemic hormones such as PTH, GH and 1,25(OH)2D compared to locally produced factors such as IGF-I, PTHrP, BMPs and TGF beta in modulating the cellular response to load remains unclear. Our studies demonstrate that skeletal unloading leads to resistance to the anabolic actions of IGF-I on bone as a result of failure of IGF-I to activate its own signaling pathways. This is associated with a reduction in integrin expression, suggesting crosstalk between these two pathways. As the mechanism(s) by which bone responds to changes in mechanical load with changes in bone formation is further elucidated, applications of this knowledge to other etiologies of osteoporosis are likely to develop. Skeletal unloading provides a perturbation in bone mineral homeostasis that can be used to understand the mechanisms by which bone mineral homeostasis is maintained, and that such understanding will lead to effective treatment for disuse osteoporosis in addition to preventive measures for the bone loss that accompanies space travel.