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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.

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At least 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Design and Testing of Braided Composite Fan Case Materials and Components

Triaxial braid composite materials are beginning to be used in fan cases for commercial gas turbine engines. The primary benefit for the use of composite materials is reduced weight and the associated reduction in fuel consumption. However, there are also cost benefits in some applications. This paper presents a description of the braided composite materials and discusses aspects of the braiding process that can be utilized for efficient fabrication of composite cases. The paper also presents an approach that was developed for evaluating the braided composite materials and composite fan cases in a ballistic impact laboratory. Impact of composite panels with a soft projectile is used for materials evaluation. Impact of composite fan cases with fan blades or blade-like projectiles is used to evaluate containment capability. A post-impact structural load test is used to evaluate the capability of the impacted fan case to survive dynamic loads during engine spool down. Validation of these new test methods is demonstrated by comparison with results of engine blade-out tests.

Roberts, Gary D.↗
DOE OSTI2022

Towards Automated Design of Corrosion Resistant Alloy Coatings with an Autonomous Scanning Droplet Cell

We present an autonomous scanning droplet cell platform designed for on-demand alloy electrodeposition and real-time electrochemical characterization. Automation and machine learning are currently driving rapid innovation in high-throughput and autonomous materials design and discovery. We present two alloy design vignettes: one focusing on a multi-objective corrosion resistant alloy optimization and a study highlighting the complexity of the multimodal characterization needed to provide insight into the underlying structural and chemical factors that drive observed material behavior. This motivates a close coupling between autonomous research platforms and scientific machine learning methodology that blends mechanistic physical models and black box machine learning models. Lastly, we reflect on our early efforts in on-demand alloy deposition, highlighting some of the challenges. This emerging research area presents new opportunities to accelerate materials synthesis, evaluation, and hence discovery and design.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Evaluating uncertainty-based active learning for accelerating the generalization of molecular property prediction

Deep learning models have proven to be a powerful tool for the prediction of molecular properties for applications including drug design and the development of energy storage materials. However, in order to learn accurate and robust structure–property mappings, these models require large amounts of data which can be a challenge to collect given the time and resource-intensive nature of experimental material characterization efforts. Additionally, such models fail to generalize to new types of molecular structures that were not included in the model training data. The acceleration of material development through uncertainty-guided experimental design has the promise to significantly reduce the data requirements and enable faster generalization to new types of materials. To evaluate the potential of such approaches for electrolyte design applications, we perform comprehensive evaluation of existing uncertainty quantification methods on the prediction of two relevant molecular properties - aqueous solubility and redox potential. We develop novel evaluation methods to probe the utility of the uncertainty estimates for both in-domain and out-of-domain data sets. Finally, we leverage selected uncertainty estimation methods for active learning to evaluate their capacity to support experimental design.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1983

Evaluation of outer race tilt and lubrication on ball wear and SSME bearing life reductions

Several aspects of the SSME bearing operation were evaluated. The possibility of elastohydrodynamics (EHD) lubrication with a cryogenic fluid was analyzed. Films as thick as .61 microns were predicted with one theory which may be thick enough to provide hydrodynamic support. The film formation, however, is heavily dependent on good surface finish and a low bulk bearing temperature. Bearing dynamics to determine if the radial stiffness of a bearing which are dependent on bearing misalignment were analyzed. Four ball tests were conducted at several environmental conditions from an LN2 bath to 426 C in air. Surface coatings and ball materials are evaluated. Severe wear and high friction are measured for all ball materials except when the balls have surface lubricant coatings.

Kannel, J. W.↗
NASA NTRS1985

Modifications of system for elevated temperature tensile testing and stress-strain measurement of metal matrix composites

Composites consisting of tungsten alloy wires in superalloy matrices are being studied because they offer the potential for increased strength compared to current materials used at temperatures up to at least 1093 C (2000F). Previous research at the NASA Lewis Research Center and at other laboratories in the U.S., Europe, and Japan has demonstrated laboratory feasibility for fiber reinforced superalloys (FRS). The data for the mechanical and physical properties used to evaluate candidate materials is limited and a need exists for a more detailed and complete data base. The focus of this work is to develop a test procedure to provide a more complete FRS data base to quantitatively evaluate the composite's potential for component applications. This paper will describe and discuss the equipment and procedures under development to obtain elevated temperature tensile stress-strain, strength and modulus data for the first generation of tungsten fiber reinforced superalloy composite (TFRS) materials. Tensile stress-strain tests are conducted using a constant crosshead speed tensile testing machine and a modified load-strain measuring apparatus. Elevated temperature tensile tests are performed using a resistance wound commercial furnace capable of heating test specimens up to 1093 C (2000 F). Tensile stress-strain data are obtained for hollow tubular stainless steel specimens serving as a prototype for future composite specimens.

Diaz, J. O.↗
DOE OSTI2024

Promoting regulatory acceptance of combined ion and neutron irradiation testing of nuclear reactor materials: Modeling and software considerations

As the needs for the nuclear energy industry continue to evolve in the 21st century, timely adoption of new technological solutions acceptable to regulatory agencies is critical. Quantitative prediction of radiation damage in materials and its impact on mechanical properties is a key component of licensing and regulatory decisions regarding nuclear power plants. Accelerated testing methodologies such as combined ion and neutron irradiation data sets are crucial for the development and deployment of new materials and new manufacturing methods (e.g., additive manufacturing). However, regulatory acceptance of accelerated testing methodologies is necessary for their adoption. Further, the present work discusses the fundamental basis for comparing ion- and neutron-induced material microstructures, the theory behind interpreting radiation damage across length and time scales and radiation types, and the codes, standards, and quality assurance concerns surrounding different modeling methods and software. In particular, recommendations are given as to the path forward that will enable national laboratories, academia, and industry to develop the modeling and software basis for regulatory acceptance of the combined use of ion and neutron irradiation for material performance evaluation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Computational Estimation by Scientific Data Mining with Classical Methods to Automate Learning Strategies of Scientists

Experimental results are often plotted as 2-dimensional graphical plots (aka graphs) in scientific domains depicting dependent versus independent variables to aid visual analysis of processes. Repeatedly performing laboratory experiments consumes significant time and resources, motivating the need for computational estimation. The goals are to estimate the graph obtained in an experiment given its input conditions, and to estimate the conditions that would lead to a desired graph. Existing estimation approaches often do not meet accuracy and efficiency needs of targeted applications. We develop a computational estimation approach called AutoDomainMine that integrates clustering and classification over complex scientific data in a framework so as to automate classical learning methods of scientists. Knowledge discovered thereby from a database of existing experiments serves as the basis for estimation. Challenges include preserving domain semantics in clustering, finding matching strategies in classification, striking a good balance between elaboration and conciseness while displaying estimation results based on needs of targeted users, and deriving objective measures to capture subjective user interests. These and other challenges are addressed in this work. The AutoDomainMine approach is used to build a computational estimation system, rigorously evaluated with real data in Materials Science. Our evaluation confirms that AutoDomainMine provides desired accuracy and efficiency in computational estimation. It is extendable to other science and engineering domains as proved by adaptation of its sub-processes within fields such as Bioinformatics and Nanotechnology.

Computer Science↗
DOE OSTI2024

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors initially deployed were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗
NASA NTRS1978

Fire resistivity and toxicity studies of candidate aircraft passenger seat materials

Fire resistivity studies were conducted on a wide range of candidate nonmetallic materials being considered for the construction of improved fire resistant aircraft passenger seats. These materials were evaluated on the basis of FAA airworthiness burn and smoke generation tests, colorfastness, limiting oxygen index, and animal toxicity tests. Physical, mechanical, and aesthetic properties were also assessed. Candidate seat materials that have significantly improved thermal response to various thermal loads corresponding to reasonable fire threats as they relate to in-flight fire situations, are identified.

Fewell, L. L.↗
NASA NTRS1980

Advanced thermoelectric material development at JPL

A large number of planetary missions under consideration for the next two decades will be using radioisotope thermoelectric generators to provide the necessary spacecraft electrical power. Performance, reliability, lifetime and cost of these RTGs are expected to be more demanding and will require the development of advanced thermoelectric materials. An advanced thermoelectric materials development program is being conducted by JPL and is the subject of this paper. Under this program, alloys of rare earth chalcogenides have been synthesized and their thermoelectric properties evaluated. The selection of specific compounds on which the program is currently concentrating is influenced by criteria such as low thermal conductivity, reasonably high operating temperatures (not less than 1000 C) and stability of the compounds. The paper discusses the rationale, approach and current status of the program. In addition, the thermoelectric and thermophysical property measurement used to evaluate the materials are described. The preliminary results and analysis of these experimental data are also given.

Stapfer, G.↗
NASA NTRS1992

SP-100 radiator design trade study

A design trade study of the SP-100 heat rejection subsystem (HRSS) was made. A system code was used to evaluate the sensitivity of the HRSS mass and performance to changes. Variations in heat pipe diameter and cross-section, fin length and thickness, armor thickness, and overall configuration and materials were evaluated. The analysis indicates that the minimum system mass occurs for the case with many small diameter heat pipes, with ducting that maximizes the fraction of the heat pipe evaporator perimeter in contact with it.

Ewell, Richard↗
NASA NTRS1998

Wide Panel Testing Technique for Evaluating Repair Weld Strengths

This paper describes a new tensile testing technique for evaluating the overall effect of a repair weld on the strength of a welded joint. Previously, repair weld strengths have been evaluated using one-inch width tensile specimens, but this technique does not capture all of the effects that result from a repair. The new technique involves testing of "wide panel" tensile specimens which contain the full length of a repair weld within a longer initial weld, allowing the specimen to capture the combined effects of residual stresses, local strength degradation, and load redistribution around a repair. The development of strains in the repair area of standard aluminum alloy specimens and new high-performance aluminum-lithium alloy specimens was observed and evaluated using photoelastic material. The results of this evaluation show an increased sensitivity to repair welding residual stresses in the aluminum-lithium alloy specimens.

Rogers, Patrick R.↗
NASA NTRS2002

Development Of A Novel Discontinuously-Reinforced Aluminum For Space Applications

Discontinuously-reinforced aluminum (DRA) has been used in aerospace structures such as Ventral Fins and Fan Exit Guide Vanes owing to its superior specific stiffness, specific strength, wear resistance, and thermal resistance as compared to the unreinforced aluminum alloys. In order to reduce engine weight, DRA materials are now being considered for space applications. Higher specific strength at ambient and cryogenic temperatures is one of the main requirements in certain rocket applications. The commercial DRA materials use 6xxx and 2xxx precipitation hardened aluminum alloys as matrices which have limited strengths. Therefore, an aluminum alloy which can provide significantly higher ambient and cryogenic strengths is required. In this paper, a novel aluminum alloy based on Al-Sc-X composition with improved ambient and cryogenic temperature strengthening capability is proposed. In addition, this alloy showed promise for improved strength at elevated temperature. The monolithic alloy and the composite with 15 volume percent SiC and B4C particles were processed using a powder metallurgy approach. The influence of processing parameters on the microstructures and mechanical properties of the monolithic and composite materials is discussed. The alloy showed very high strength and moderate ductility. The influence of hydrogen on the properties of monolithic and composite materials is discussed. The thermal stability of these materials is also evaluated. The strength of the material is discussed in terms of solid solution strengthening, Orowan strengthening, and antiphase boundary strengthening models.

Pandey, A. B.↗
DOE OSTI2024

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three deployed rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system (Elium from Arkema). Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗
NASA NTRS1976

Material development aspects of an oxidation protection system for a reinforced carbon-carbon composite

The paper describes the procedures which led to selection of a diffusion-coated siliconized oxidation-resistant reinforced carbon-carbon composite as a candidate for use in the leading edge structure of the Space Shuttle for the purpose of providing thermal protection. Materials were evaluated on the basis of oxidation-inhibitor performance, strength properties, and fabricability. Compounds of titanium, tantalum, zirconium, silicon, hafnium, aluminum, and boron were compounded with the reinforced carbon-carbon material in two different processing techniques to discover an oxidation-inhibited system which provided multicycle protection at temperatures up to 4000 F. Details of the manufacture and testing of the reinforced carbon-carbon composites are provided.

Rogers, D. C.↗
NASA NTRS1993

Advanced Solid Rocket Motor nozzle development status

This paper presents a status update of the design and development of an improved nozzle for the Advanced Solid Rocket Motor (ASRM). The ASRM nozzle incorporates advanced state-of-the-art design features and materials which contribute to enhanced safety, reliability, performance, and producibility for the space shuttle boosters. During 1992 the nozzle design progressed through a successful Preliminary Design Review (PDR). An improved ablative material development program also culminated in the selection of new standard and low density carbon cloth phenolic prepreg offering reduced variability and improved process attributes. A subscale motor test series to evaluate new materials and design features was also completed. An overview update of the matured design characteristics, supporting analysis, key development-program results and program status and plans is reported.

Kearney, W. J.↗