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At least 865 records · Page 48

Stress relaxation of low pressure plasma-sprayed NiCrAlY alloys

The stress relaxation behavior of three NiCrAlY alloys that are commonly used as bond coats for thermal barrier coatings (TBCs) has been directly measured. The relaxation study was conducted at temperatures of 800-1000 C and over a wide range of stresses. It was established that all three bond coat alloys relaxed quite rapidly at temperatures of 900 C and above. Since the upper use temperatures for bond coats in gas turbine engines are between 900 and 1000 C, bond coat relaxation is expected to occur in service. Therefore, relaxation of the bond coat has the potential to affect TBC life. Furthermore, the relaxation differences observed between the three alloys offers a possible explanation for the differences in TBC life observed for these bond coats. While bond coat relaxation is expected to occur for a TBC in service, the mechanism for a relaxation effect on TBC life, if it exists, is yet to be determined.

Brindley, W. J.↗

Probabilistic inspection strategies for minimizing service failures

The INSIM computer program is described which simulates the 'limited fatigue life' environment in which aircraft structures generally operate. The use of INSIM to develop inspection strategies which aim to minimize service failures is demonstrated. Damage-tolerance methodology, inspection thresholds and customized inspections are simulated using the probability of failure as the driving parameter.

Brot, Abraham↗

Satellite Servicing in Mission Design Studies at the NASA GSFC

Several NASA missions in various stages of development have undergone one-week studies in the National Aeronautics and Space Administration (NASA) Goddard Space Flight Center (GSFC) Integrated Mission Design Center (IMDC), mostly in preparation for proposals. The possible role of satellite servicing has been investigated for several of these missions, applying the lessons learned from Hubble Space Telescope (HST) servicing, taking into account the current state of the art, projecting into the future, and implementing NASA long-range plans, and is presented here. The general benefits and costs of injecting satellite servicing are detailed, including components such as mission timeline, mass, fuel, spacecraft design, risk abatement, life extension, and improved performance. The approach taken in addressing satellite servicing during IMDC studies is presented.

Leete, Stephen J.↗

Viscoplastic Constitutive Theory Demonstrated for Monolithic Ceramic Materials

Development of accurate three-dimensional (multiaxial) inelastic stress-strain models is critical in utilizing advanced ceramics for challenging 21st century high-temperature structural applications. The current state of the art uses elastic stress fields as a basis for both subcritical crack growth and creep life prediction efforts aimed at predicting the time dependent reliability response of ceramic components subjected to elevated service temperatures. However, to successfully design components that will meet tomorrow's challenging requirements, design engineers must recognize that elastic predictions are inaccurate for these materials when subjected to high-temperature service conditions such as those encountered in advanced heat engine components. Analytical life prediction methodologies developed for advanced ceramics and other brittle materials must employ accurate constitutive models that capture the inelastic response exhibited by these materials at elevated service temperatures. A constitutive model recently developed at the NASA Lewis Research Center helps address this issue by accounting for the time-dependent (inelastic) material deformation phenomena (e.g., creep, rate sensitivity, and stress relaxation) exhibited by monolithic ceramics exposed to high-temperature service conditions. In addition, the proposed formulation is based on a threshold function that is sensitive to hydrostatic stress and allows different behavior in tension and compression, reflecting experimental observations obtained for these material systems.

Janosik, Lesley A.↗

SiC/SiC Life Modeling at Intermediate Temperatures under NASA UEET

Within the NASA UEET program, physics-based residual strength and rupture life models are being developed for a variety of time-temperature-stress-environment conditions for SiC/SiC components such as combustor liners and vanes. During service, a tensile stress condition that could be life-limiting typically occurs on the 'cold side' of these components due to thermal gradients and attachment schemes. An intermediate temperature (600 to 1000 C) stress-rupture model has been developed based on the underlying physical processes, i.e., oxygen penetration through matrix cracks, oxidation of the BN interphase, and subsequent fiber-fiber fusion within crack-bridging tows that eventually fail in time due to time-dependent strength degradation of the weakest fibers. Modifications to the model will be discussed to incorporate different environmental conditions as well as changes in oxidation kinetics due to improved interphase concepts.

Morscher, Gregory N.↗

ECAR-8446 Rev 0 MARVEL BPVC Section III Division 5 HBB Fatigue Acceptance Tests

The objective of this analysis is to evaluate the fatigue and creep behavior of 316 SS materials used in the Primary Coolant System (PCS) and Guard Vessel System (GVS) for the first two years of MARVEL reactor operation. The analysis follows the requirements set forth in ASME BPVC Section III, Division 5, HBB-2800, which mandates a fatigue test if operational conditions exceed allowable thresholds. By determining whether the materials meet the HBB-T-1324(a) and HBB-T-1324(b) criteria, this evaluation establishes whether a fatigue test is necessary, as well as the maximum allowable operational hours and temperatures before fatigue testing would be required. The deliverables of this analysis include calculations validating compliance with fatigue acceptance criteria, determination of maximum operational limits for the two-year period, and identification of conditions under which a fatigue test would be necessary. This ensures that the PCS and GVS can operate safely without premature material degradation and align with the design life requirements outlined in SPC-70731. Additionally, this evaluation provides conservative estimates for Service Level B occurrences and their impact on allowable Service Level A hours and temperatures, offering guidance for future operational assessments and potential life extensions beyond the initial two-year period.

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Repairing a communications satellite on orbit

A review of past failures indicates that module exchange can satisfy most repair requirements of communications satellites. Emphasis is placed on the design of a serviceable communications satellites with 20 modules, on the development of an on-orbit servicer designed to remove failed modules from a body-stabilized spacecraft and to replace them with good modules, and on servicing operations. Benefits of servicing or repair include increased satellite availability, increased reliability, decreased life cycle costs, replacement of worn-out items, installation of updated equipment, and correction of design failures. The use of servicing instead of replacement could result in cost savings in excess of 40 percent. Significant savings are possible when the lifetime of a program is long relative to the satellite lifetime.

Gordon, G. D.↗

NASA Electric Vertical Takeoff and Landing (eVTOL) Aircraft Technology for Public Services – A White Paper

History has shown that our personal life is highly dependent on the technology that people have developed. A strategic scan of the aerospace environment at the beginning of the 21st century strongly suggests that the world might be approaching a new age of airpower—the era of electrified/hybrid aircraft propulsion. Undeniably, starting from the Montgolfier Brothers balloon flight in 1783, to the Wright Brothers piston engine flight in 1903, and the jet engine of the 1960s, or the space age of today, one can say that leaps in propulsion technology have marked the different ages of human flight. The technological advancements, brought at the beginning of 21st century by the revolution in data exchange, computational power, sensors, wireless communication, internet, and autonomy, contributed to the vision of this new age of propulsion we are approaching. Historically, conventional vertical takeoff and landing (VTOL) aircraft have been equipped with propulsion units relying on complex internal combustion machines (turbines, piston engines, for example), and complex mechanical arrangements (gearboxes, shafts, variable pitch propeller). By contrast, electric VTOL aircraft (eVTOL)1 rely on simpler propulsion units (electric motors and in some cases fixed-pitch propellers). This promotes redundancy and improves tolerance to failures, in turn improving safety. The use of simpler electric propulsion units should also allow significant acquisition and operating cost reductions. Whether full-electric (relying solely on batteries) or hybrid-electric (relying on a combination of batteries, fuel-powered engines, and generators.), eVTOLs are also expected to generate less noise and air pollution than conventional aircraft with similar payloads. According to the 2019 Annual Review of IATA (International Air Transport Association) [ref.1], due to an expected increase in air transport traffic by 5% every year and a doubling of air transport passenger numbers to 8.2 billion by 2037 significant challenges are posed to the aviation industry. Furthermore, this report does not factor in the expected demand for short-range (intra-city) air transportation, which is in development and yet to be operational. The increased demand to fly creates a responsibility to expand in a sustainable manner and an endeavor to develop more environmentally-friendly aircraft. eVTOL aircraft, either piloted or autonomous, is gathering considerable interest worldwide. Modern and novel full-electric or hybrid-electric eVTOL configurations enable a new paradigm shift in air transportation as the aviation industry remains committed to its goals of carbon-neutral growth from 2020 onwards and cutting CO2 emissions to half 2005 levels by 2050. While electric power has been used for decades, recent developments in mobile electric/hybrid propulsion coupled with advanced materials and autonomous systems may create the possibility to transition into the next age of air mobility propelled by electric/hybrid VTOL aircraft technology. Although eVTOL aircraft might seem like an incremental improvement or even a counterintuitive regression with regard to past VTOL development, it has in fact the potential to transform air mobility across a wide range of government applications. Previous transformations in aviation generated dramatic leaps in performance, but the cost was commensurate with performance, limiting quantity produced. This next age appears to take a different approach. Performance may not increase, but at this moment technology is poised for future urban mobility that will spawn commercial passenger drone services, that is, autonomous (pilotless) air taxis and thereby add a new dimension to the urban transportation mix of the future [ref. 2]. Advances in electric propulsion, autonomous flight technology, and 5G communication networks will enable this fast new-growing market to become a reality. It is now time to envision the introduction of electric/hybrid eVTOL aircraft for Public Services2. We believe that in the next decades eVTOL aircraft will have the potential to become an essential tool to Public Service agencies around the world in applications such as firefighting, public safety, search and rescue, disaster relief and law enforcement. This is due to several major factors. • First, with the increasing popularity of small, unmanned aircraft vehicles (UAVs) or drones, many companies today are focusing on the development of passenger UAVs designed to accommodate up to five passengers or equivalent cargo payload. Many such configurations are electric or hybrid-electric designs with VTOL capabilities. Several of these projects have started a flight test program and many more are expected to be in the experimental and development phase in 2020. Such revolutionary vehicles could be in commercial operations by 2030. These eVTOL systems could be ready for selected Public Services missions even sooner. • Second, although these advanced eVTOL vehicles under development still need access to fuel (hybrid) and/or electric charging capability, they can take off and land from almost anywhere. Therefore, such vehicles, both manned and unmanned can be successfully integrated for the critical missions of the Public Services with extra deployment flexibilities. • Third, advancement in electric propulsion systems in the automotive industry together with NASA’s leading efforts in electrification of aircraft propulsion systems, FAA’s ongoing active eVTOL certification programs, and EASA’s proposed framework for the certification of electric/hybrid small category VTOL aircraft in Europe [ref. 3] will help accelerate industry electric propulsion system development and integration. • Finally, eVTOL vehicles could be deployed for Public Services sooner than air taxi or other commercial applications, since Public Services missions may be more easily approved based on specific mission criteria, localized airworthiness authority for public-use aircraft3, and are normally operating under centralized airspace management and control by the theater command. Moreover, public perception and acceptance are generally less of a concern when operations save lives and benefit the wider community. The prioritized introduction of eVTOL aircraft in Public Services is ambitious, but we believe it is achievable in the coming decades if fundamental enablers (people and technologies) are engaged in defining the objectives and needs of these missions. The revolution that is currently taking place in eVTOL aircraft represents an unprecedented opportunity to develop a safer, more affordable, more available and more environmentally friendly future of vertical flight. To ensure that these novel aircraft meet the future expectations of Public Services, it is essential to take a collaborative and multi-disciplinary approach to their development, across engineering disciplines, policy-making, program management, business case development, manufacturing, and flight demonstrations. It should be noted that the term eVTOL (in the near term) used throughout this publication implies aircraft capable of transporting up to 5 persons which may or may not include a pilot if operated fully autonomously, assuming an average of 200 pounds (91 kg) per person or equivalent payload and a range up to 60 miles plus a suitable reserve. Hybrid or hydrogen powered eVTOLs would have greater range. For example, a “3-seat” eVTOL aircraft may only be able to carry two fully equipped firemen, and payload capacity is more relevant when used for the supply mission. Moreover, this paper concentrates on the “last-mile” solutions with a deployment time of no more than 6 hours. Although not specifically discussed in this document, it is understood that the future of Transformative Vertical Flight in general and Public Services, in particular, will also involve smaller UAVs that will undoubtedly play a crucial role in future aerial operations. For example, smaller unmanned aircraft may be used to dispatch medical supplies, portable filtration systems or perform the Search task of future Search and Rescue (SAR) operations. Close collaboration between the aircraft industry, the Civil Aviation Authorities (CAA), e.g., Federal Aviation Administration (FAA), European Aviation Safety Agency (EASA), Transport Canada Civil Aviation (TCCA) and the Department of Defense (DoD) certifiers, will help identify Public Services requirements, define expectations and limit development cost and timescales. Take the US Air Force Agility Prime as an example, the majority of the eVTOL application opportunities and mission elements identified are in line with the NASA TVF WG-4 objectives and use cases. Together, it forms a strong partnership to accelerate the development, certification, and practical deployment for public service missions. The US Air Force Agility Prime has been a collaboration partner on this white paper, and provided valuable input and recommendations. Most of the eVTOL public service mission elements discussed in this paper and additional use cases envisioned by the NASA TVF WG-4 team are shared by the Agility Prime program. The focus and efforts of the Agility Prime in product and system development, industry and government partnership, accelerated certifications as well as early test and deployment are totally in sync with the path forward recommended by this white paper. This kind of collaboration and partnership will help enable the practical use of the eVTOL for public service missions, benefit the eVTOL public acceptance, and accelerate the eVTOL industry revolution.

Johnny T. Doo↗

Design and Materials of Reference Electrodes for Radioactive Waste Tank Service – A Literature Review

The Hanford site stores approximately 55 million gallons of radioactive and chemically hazardous wastes from the production of weapons materials. The wastes are stored in 177 underground, carbon steel storage tanks, 149 of these are single shell tanks (SSTs) and 28 of these are double shell tanks (DSTs). The DSTs provide critical retrieval and interim storage before the waste is vitrified in the Waste Treatment and Isolation Plant (WTP). The DSTs have been in service for 38 to 56 years and current plans indicate that WTP operations will be completed in 2075. Thus, the tanks will need to remain in service far beyond the initial 40-year life expectancy. For life extension of the tanks, effective corrosion control practices must remain in force. This effort includes direct measurements of the extent of corrosion (e.g., ultrasonic measurements and corrosion coupons) and electrochemical processes (e.g., linear polarization measurements).

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Experiment module concepts study. Volume 5 book 1, appendix A: Shuttle only task

Results of a preliminary investigation of the effect on the candidate experiment program implementation of experiment module operations in the absence of an orbiting space station and with the availability of the space shuttle orbiter vehicle only are presented. The fundamental hardware elements for shuttle-only operation of the program are: (1) integrated common experiment modules CM-1, CM-3, and CM-4, together with the propulsion slice; (2) support modules capable of supplying on-orbit crew life support, power, data management, and other services normally provided by a space station; (3) dormancy kits to enable normally attached modules to remain in orbit while shuttle returns to earth; and (4) shuttle orbiter. Preliminary cost estimates for 30 day on-orbit and 5 day on-orbit capabilities for a four year implementation period are $4.2 billion and $2.1 billion, respectively.

Source record↗

Health Monitoring of Composite Material Structures using a Vibrometry Technique

Large composite material structures such as aircraft and Reusable Launch Vehicles (RLVS) operate in severe environments comprised of vehicle dynamic loads, aerodynamic loads, engine vibration, foreign object impact, lightning strikes, corrosion, and moisture absorption. These structures are susceptible to damage such as delamination, fiber breaking/pullout, matrix cracking, and hygrothermal strain. To ensure human safety and load-bearing integrity, these structures must be inspected to detect and locate often invisible damage and faults before becoming catastrophic. Moreover, nearly all future structures will need some type of in-service inspection technique to increase their useful life and reduce maintenance and overall costs. Possible techniques for monitoring the health and indicating damage on composite structures include: c-scan, thermography, acoustic emissions using piezoceramic actuators or fiber-optic wires with gratings, laser ultrasound, shearography, holography, x-ray, and others. These techniques have limitations in detecting damage that is beneath the surface of the structure, far away from a sensor location, or during operation of the vehicle. The objective of this project is to develop a more global method for damage detection that is based on structural dynamics principles, and can inspect for damage when the structure is subjected to vibratory loads to expose faults that may not be evident by static inspection. A Transmittance Function Monitoring (TFM) method is being developed in this project for ground-based inspection and operational health monitoring of large composite structures as a RLV. A comparison of the features of existing health monitoring approaches and the proposed TFM method is given.

Schulz, Mark J.↗

In-Service Evaluation of HVOF Coated Main Landing Gear on Navy P-3 Aircraft

Due to the environmental and health concerns with Electroplated Hard Chrome (EHC), the Hard Chrome Alternatives Team (HCAT) has been working to provide an alternative wear coating for EHC. The US Navy selected Tungsten-Carbide Cobalt (WC- 17Co) High Velocity Oxy-Fuel (HVOF) thermal spray coating for this purpose and completed service evaluations on select aircraft components to support the HCAT charter in identifying an alternative wear coating for chrome plating. Other benefits of WC-Co thermal spray coatings over EHC are enhanced corrosion resistance, improved durability, and exceptional wear properties. As part of the HCAT charter and to evaluate HVOF coatings on operational Navy components, the P-3 aircraft was selected for a service evaluation to determine the coating durability as compared to chrome plating. In April 1999, a VP-30 P-3 aircraft was outfitted with a right-hand Main Landing Gear (MLG) shock strut coated with WCCo HYOF thermal spray applied to the piston barrel and four axle journals. The HVOF coating on the piston barrel and axle journals was applied by Southwest United Industries, Inc. This HVOF coated strut assembly has since completed 6,378 landings. Teardown analysis .for this WC-Co HVOF coated MLG asset is significant in assessing the durability of this wear coating in service relative to EHC and to substantiate Life Cycle Cost (LCC) data to support a retrograde transition from EHC to HVOF thermal spray coatings. Findings from this teardown analysis may also benefit future transitions to HVOF thermal spray coatings by identifying enhancements to finishing techniques, mating bearing and liner material improvements, improved seal materials, and improvements in HVOF coating selection.

Devereaux, jon L.↗

Structural Health Management of Damaged Aircraft Structures Using the Digital Twin Concept

The development of multidisciplinary integrated Structural Health Management (SHM) tools will enable accurate detection, and prognosis of damaged aircraft under normal and adverse conditions during flight. As part of the digital twin concept, methodologies are developed by using integrated multiphysics models, sensor information and input data from an in-service vehicle to mirror and predict the life of its corresponding physical twin. SHM tools are necessary for both damage diagnostics and prognostics for continued safe operation of damaged aircraft structures. The adverse conditions include loss of control caused by environmental factors, actuator and sensor faults or failures, and structural damage conditions. A major concern in these structures is the growth of undetected damage/cracks due to fatigue and low velocity foreign object impact that can reach a critical size during flight, resulting in loss of control of the aircraft. To avoid unstable, catastrophic propagation of damage during a flight, load levels must be maintained that are below a reduced load-carrying capacity for continued safe operation of an aircraft. Hence, a capability is needed for accurate real-time predictions of damage size and safe load carrying capacity for structures with complex damage configurations. In the present work, a procedure is developed that uses guided wave responses to interrogate damage. As the guided wave interacts with damage, the signal attenuates in some directions and reflects in others. This results in a difference in signal magnitude as well as phase shifts between signal responses for damaged and undamaged structures. Accurate estimation of damage size, location, and orientation is made by evaluating the cumulative signal responses at various pre-selected sensor locations using a genetic algorithm (GA) based optimization procedure. The damage size, location, and orientation is obtained by minimizing the difference between the reference responses and the responses obtained by wave propagation finite element analysis of different representative cracks, geometries, and sizes.

Seshadri, Banavara R.↗

Space Station crew workload - Station operations and customer accommodations

The features of the Space Station which permit crew members to utilize work time for payload operations are discussed. The user orientation, modular design, nonstressful flight regime, in space construction, on board control, automation and robotics, and maintenance and servicing of the Space Station are examined. The proposed crew size, skills, and functions as station operator and mission specialists are described. Mission objectives and crew functions, which include performing material processing, life science and astronomy experiments, satellite and payload equipment servicing, systems monitoring and control, maintenance and repair, Orbital Maneuvering Vehicle and Mobile Remote Manipulator System operations, on board planning, housekeeping, and health maintenance and recreation, are studied.

Shinkle, G. L.↗

Life prediction and constitutive behavior: Overview

The evolution of programs to investigate high temperature consititutive behavior and develop cyclic life prediction methods is reviewed. Contracts granted for developing and verifying workable engineering methods for the calculation, in advance of service, of the local stress-strain response at the critical life governing location in typical hot section components as well as the resultant cyclic crack initiation and crack growth lifetimes are listed. The Langley fatigue facility is being upgraded to include: (1) a servocontrolled testing machine for high temperature crack growth; (2) three servocontrolled tension/torsion machines for biaxial studies; (3) a HOST/satellite computer for data acquisition, processing, storage, and retrieval; and (4) HCV/LCF machines for cumulative damage studies.

Halford, G. R.↗

Los Alamos National Laboratory SAVY-4000 Field Surveillance Plan Update for 2020

The Packaging Surveillance Program section of the Department of Energy (DOE) Manual 441.1-1, Nuclear Material Packaging Manual (DOE 2008), requires DOE contractors to “ensure that a surveillance program is established and implemented to ensure the nuclear material storage package continues to meet its design criteria.” The Los Alamos National Laboratory (LANL) SAVY-4000 Field Surveillance Plan was first issued in fiscal year (FY) 2013. The surveillance plan is reviewed annually and updated as necessary based on SAVY-4000 surveillance findings, as well as results of the lifetime extension studies. Five surveillance plan updates have been issued, one in 2014, one in 2016, one in 2017, one in 2018, and one in 2019. This 2020 update documents what was actually done in 2019 and what is planned for 2020. Deviations from the 2019 surveillance plan were necessary because some of the planned surveillance containers were not available for examination. The goal of the surveillance program is to provide data to: evaluate container component performance over time against the initial baseline qualification; validate the current SAVY container design life; provide data for future design life extensions of components as indicated; identify indications of container degradation early and identify similar containers and/or contents that may need remediation; maintain and continuously improve the surveillance information system that documents the complete life cycle of the containers including the initial production baseline, usage history, surveillance, and disposition; identify container issues related to wear and tear that could indicate the need for a maintenance program for in-service containers prior to the end of the design life.

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