SEARCH · Engineering Papers
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.
Quality control and nondestructive testing of scientific satellite components stressing adequate standards and contractor responsibility
Free air simulations in conventional transonic wind tunnels require improvement which adaptive wall testing techniques can provide primarily by minimizing wall interferences. In addition, these techniques offer other substantial advantages such as increased Reynolds number capability and a reduction in tunnel drive power. The combination of an adaptive wall test section with a continuous flow cryogenic wind tunnel is unique. The test section has four solid walls with two flexible walls mounted between rigid sidewalls. This modification of an existing major facility stresses the practicalities of the testing technique. These practicalities were evaluated in terms of flexible wall test section design and operation. Increased hardware and operating complexity of the new test section is offset by a significant improvement in real-time data accuracy in two-dimensional testing. Validation testing has expanded the experience with flexible walled test sections into the realms of flight Reynolds numbers and high lift. Data accuracy has been assessed with regard to test section geometry and operating tolerances. The successful evaluation of the testing technique in two-dimensional testing has proved that a production type operation is possible, with suitable control system and test section design. The 0.3-m Transonic Cryogenic Tunnel with an adaptive wall test section currently represents the most advanced two-dimensional facility anywhere.
To support the development of new materials for the design of next generation supersonic transports, a research program is underway at NASA to assess the long term durability of advanced polymer matrix composites (PMC's). One of main objectives of the program was to explore the effects of elevated temperature (23 to 200 C) on the constitutive model's material parameters. To achieve this goal, test data on the observed nonlinear, stress-strain behavior of IM7/5260 and IM7/8320 composites under tension and compression loading were collected and correlated against temperature. These tests, conducted under isothermal conditions using variable strain rates, included such phenomena as stress relaxation and short term creep. The second major goal was the verification of the model by comparison of analytical predictions and test results for off axis and angle ply laminates. Correlation between test and predicted behavior was performed for specimens of both material systems over a range of temperatures. Results indicated that the model provided reasonable predictions of material behavior in load or strain controlled tests. Periods of loading, unloading, stress relaxation, and creep were accounted for.
The present investigation has focused on a computational methodology for the fundamental case of transition in channel flow, in which recently published experimental data are utilized both as a stimulus and as a measure of merit of the method. The research has proceeded along three avenues in parallel. The first task has consisted of the development and verification of a computer code which calculates the mean evolution of flow in a channel similar to the one employed experimentally by Blair and Anderson. An analytical test case was created for the dual purposes of code verification and of highlighting the interactions between the Reynolds stress and the mean velocity profile. This test case generated a Reynolds stress by the residue in the momentum equation which is produced by a typical analytical velocity profile. By a substitution of this Reynolds stress into the appropriate code module, the correctness of the code may be verified, along with the accuracy of the computational method. The second task pursued has involved the development of a triple layer model for the Reynolds stress profile, which was suggested and derived from experimental velocity profiles. It is demonstrated that the innermost length scale is based on the local friction velocity, the intermediate layer corresponds to the usual logarithmic law of the wall region in which the normalized Reynolds stress is approximately unity, and the outermost layer is represented by a closed mathematical form depending explicitly on the velocity profile in the wake region. The third task was comprised of scrutiny of the excellent databases developed by Blair and others, and the planning of its incorporation into the transition analysis. These extensive measurements indicate that turbulent statistics in the transition regime may be considered to alternate between laminar and fully turbulent types, the proportions of which are quantified by a measured intermittency function.
Efforts expended in testing, analyzing and the development of a meaningful definition of the mean number of peak pulses before failure (mp2bf) levels of a family of transient voltage suppressor devices were documented. Tests were done to determine the ability of the transient suppressor to effectively and reliably protect against severe short term, millisecond range, and transient voltages of the types resulting from inductive load switching and induced lightning. Existing pulse testing instrumentation was utilized, interfaced to an automatic sequencing test rack accommodating up to 50 devices. Tests were performed in step stress increments of 25% beginning at 25% and extending thru 100% rated I(pp) for each voltage category. The four voltage types test were the 6.8V, 33V, 91V, and 190V. Engineering efforts addressed the problem of improving the reliability of the 190V types.
A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.
A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30%PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.
Fatigue tests were made on some 1.375-inch-diameter and 0.300-inch diameter specimens of a 17S-T aluminum alloy rod. One test of a large specimen was run continuously to failure at a maximum stress of 22,000 pounds per square inch. In two other tests of large specimens, thin surface layers were removed periodically until failure occurred. The same nominal maximum stress of 22,000 pounds per square inch was used throughout the two tests and the load on the fatigue machine was lowered accordingly after the removal of each surface layer. As each test progressed the stress in the metal of the final surface area therefore was increased after the removal of each surface layer. Because of the stresses used, this metal was overstressed, that is, stressed above its endurance limit. All the remaining specimens were subjected to similar over- stressing conditions but no metal was removed and a low initial stress was increased periodically to a final maximum value of 22,000 pounds per square inch as each test progressed. It was found that the fatigue resistance of 17S-T aluminum alloy can be increased by moderate overstressing. Apparently the increase in fatigue lift obtained in the tests of specimens from which layers were removed was the result of overstressing rather than from the removal of damaged surface layers.
Over the past thirty years, laboratory experiments have been devised to develop fatigue crack growth rate data that is representative of the material response. The crack growth rate data generated in the laboratory is then used to predict the safe operating envelope of a structure. The ability to interrelate laboratory data and structural response is called similitude. In essence, a nondimensional term, called the stress intensity factor, was developed that includes the applied stresses, crack size and geometric configuration. The stress intensity factor is then directly related to the rate at which cracks propagate in a material, resulting in the material property of fatigue crack growth response. Standardized specimen configurations and experimental procedures have been developed for laboratory testing to generate crack growth rate data that supports similitude of the stress intensity factor solution. In this paper, the authors present laboratory fatigue crack growth rate test data and finite element analyses that show similitude between standard specimen configurations tested using the constant stress ratio test method is unobtainable.
The salient aspects of the theoretical modeling of a conventional triaxial test (CTC) of a cohesionless granular medium with stress and strain rate loading are described. Included are a controllable gravitational body force and provision for low confining pressure and/or very low intergranular stress. The modeling includes rational, analytic, and numerical phases, all in various stages of development. The numerical evolutions of theoretical models will be used in final design stages and in the analysis of the experimental data. In this the experimental design stage, it is of special interest to include in the candidate considerations every anomaly found in preliminary terrestrial experimentation. Most of the anomalies will be eliminated by design or enhanced for measurement as the project progresses. The main aspect of design being not the physical apparatus but the type and trajectories of loading elected. The major considerations that have been treated are: appearance and growth of local surface aberrations, stress-power coefficients, strain types, optical strain, radial bead migration, and measures of rotation for the proper stress flux.
An experimental program has been undertaken to better characterize the stress-strain characteristics of flexible material systems to support a NASA ground test program for inflatable decelerator material technology. A goal of the current study is to investigate experimental methods for the characterization of coated woven material stiffness. This type of experimental mechanics data would eventually be used to define the material inputs of fluid-structure interaction simulation models. The test methodologies chosen for this stress-strain characterization are presented along with the experimental results.
High dose rate irradiation with hydrogen stress is proposed as an accelerated total dose test method for bipolar linear circuits. The method is validated across process and circuit technologies with five parts that are commonly used in space: a comparator (LM193 from National Semi-conductor), a voltage regulator (HSYE-117 RH from Intersil), a voltage reference (LT1019 from Linear Technology), a JFET input op amp (OP42 from Analog Devices) and a temperature transducer (AD590 from Analog Devices). The testing technique could rapidly establish an upper bound to the low dose rate response of parts in space and help with the part selection process in the design phase of a mission. The technology dependence and the viability of this technique are qualitatively explored using a physical model describing the dose rate response and the effect of hydrogen in bipolar technologies. The model uses four core processes: 1) space charge effects, 2) free electron/hole pair recombination, hole-hydrogen defect reactions in the oxides and 4) proton depassivation of dangling bonds at the Si/SiO2 interface. Radiation hardness assurance implications are discussed.
Onset of creep stress measured for metallic materials subjected to constant loads at elevated temperatures - tension testing
The evaluation of three phenylquinoxaline polymers as high temperature structural adhesives is presented. These included an experimental crisskubjabke oiktner (X-PQ) and two experimental materials (PPQ-2501) and (PPQ-HC). Lap shear, crack extension, and climing drum peel specimens were fabricated from all three polymers, and tested after thermal, combined thermal/humidity, and stressed Skydrol exposure. All three polymers generally performed well as adhesives at initial test temperatures from 219K (-67 F) to 505K (450 F) and after humidity exposure. The 644K (700 F) cured test specimens exhibited superior Skydrol resistance and thermal stability at 505K (450 F) when compared to the 602K (625 F) cured test specimens.
NASA Glenn Research Center (GRC) has been supporting development of free-piston Stirling conversion technology for spaceflight electrical power generation since 1999. GRC has also been supporting the development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance data for the Advanced Stirling Convertor (ASC). The Thermal Energy Conversion branch at GRC is conducting extended operation of several free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) on multiple units to build a life and reliability database. Currently, GRC is operating 18 convertors. This hardware set includes Technology Demonstration Convertors (TDCs) from Infinia Corporation, of which one pair (TDCs #13 and #14) has accumulated over 60,000 hr (6.8 years) of operation. Also under test are various Sunpower, Inc. convertors that were fabricated during the ASC development activity, including ASC-0, ASC-E (including those in the ASRG engineering unit), and ASC-E2. The ASC-E2s also completed, or are in progress of completing workmanship vibration testing, performance mapping, and extended operation. Two ASC-E2 units will also be used for durability testing, during which components will be stressed to levels above nominal mission usage. Extended operation data analyses from these tests are covered in this paper.
A kinetic rate theory previously presented for describing non-Newtonian phenomena has been further modified to predict the flow behavior of viscoelastic materials under constant stress conditions. The thixotropic shear stress or shear rate is predicted by the kinetic theory, and the experimental stress or shear rate is obtained by modifying the thixotropic value by a stress or shear rate retardation term. The retardation term stems from a Maxwellian approach for stress retardation. In order to test the validity of this approach, transient and steady-state data were obtained for two solutions of polymethylmethacrylate in diethylphthalate. Both constant stress measurements and constant shear rate data were taken over a broad range.
Stress analysis of the Advanced Attack Helicopter (AAH) composite main rotor blade root end lug is described. The stress concentration factor determined from a finite element analysis is compared to an empirical value used in the lug design. The analysis and test data indicate that the stress concentration is primarily a function of configuration and independent of the range of material properties typical of Kevlar-49/epoxy and glass epoxy.
Testing and evaluation of acoustic spectrometer for nondestructive measurement of stress and location of flaws in materials