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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 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Flat H Redundant Frangible Joint Development

Orion and Commercial Crew Program (CCP) Partners have chosen to use frangible joints for certain separation events. The joints currently available are zero failure tolerant and will be used in mission safety applications. The goal is to further develop a NASA designed redundant frangible joint that will lower flight risk and increase reliability. FY16 testing revealed a successful design in subscale straight test specimens that gained efficiency and supports Orion load requirements. Approach / Innovation A design constraint is that the redundant joint must fit within the current Orion architecture, without the need for additional vehicle modification. This limitation required a design that changed the orientation of the expanding tube assemblies (XTAs), by rotating them 90deg from the standard joint configuration. The change is not trivial and affects the fracture mechanism and structural load paths. To address these changes, the design incorporates cantilevered arms on the break plate. The shock transmission and expansion of the XTA applies force to these arms and creates a prying motion to push the plate walls outward to the point of structural failure at the notched section. The 2014 test design revealed that parts could slip during functioning wasting valuable energy needed to separate the structure with only a single XTA functioning. Dual XTA functioning fully separated the assembly showing a discrepancy can be backed up with redundancy. Work on other fully redundant systems outside NASA is limited to a few patents that have not been subjected to functionality testing Design changes to prevent unwanted slippage (with ICA funding in 2015) showed success with a single XTA. The main goal for FY 2016 was to send the new Flat H RFJ to WSTF where single XTA test failures occurred back in 2014. The plan was to gain efficiency in this design by separating the Flat H RFJ with thicker ligaments with dimensions baselined in 2014. Other modifications included geometry changes to better disperse loads paths and to minimize air gaps. The design additionally added more structural strength to enhance the structural limits in static loads testing. The design also implemented a smoother load line through the assembly. Results / Knowledge Gained The new Flat H RFJ successfully fractured at WSTF with thicker ligaments and lower cord size. Where failure to separate occurred earlier, there is now excessive energy available for structural separation. The new challenge to provide some structural support to prevent secondary fracturing of the break plate remains to be completed. This future work is being funded by the JSC Engineering Directorate in 2017 to elevate the TRL on curved Flat H RFJs that configure with the Orion Service Panel Separation. Additional funding from JSC Engineering will provide new design testing to avoid secondary fracturing.

Brown, Chris↗
DOE OSTI2023

Mechanical properties of heterogeneous metallic glasses: Insights from brick-and-mortar designs

The brick-and-mortar architectural paradigm is commonly applied in structural design to achieve an exceptional combination of strength and plasticity due to its highly tunable mechanical attributes. This study applies molecular dynamics simulations of tensile loading to investigate the mechanical properties and failure mechanisms of brick-and-mortar metallic glasses (BMMGs). The focus is primarily on the implications of the aspect ratio of the bricks and interlayer thickness on the strength, plasticity, and deformation mechanisms. Results indicate that the failure mode is typified by multiple shear bands localized within the softer mortar regions, creating a staggered network under smaller aspect ratios that significantly enhances plastic deformation. However, a transition to a single dominant SB occurs when the aspect ratio exceeds 4.1. In addition, results indicate that a concurrent improvement in strength and plasticity can be achieved by modulating the distance between brick layers in BMMGs. This enhancement originates from the extensive generation and interaction of shear transformation zones. Furthermore, this study highlights that a desirable balance between strength and plasticity can be obtained in BMMGs with appropriate brick aspect ratios and interlayer thicknesses, providing a potential design strategy for the advancement of novel metallic glasses with superior properties.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quantification of electrochemical-mechanical coupling in lithium-ion batteries

Lithium-ion battery safety and durability by nature are dependent on electrochemical and mechanical coupling. Interdisciplinary efforts are required to understand and quantify coupling behaviors. Here we design and conduct mechanically constrained charge and discharge characterizations with efforts supported by multiphysics modeling to unravel the coupling mechanisms of solid-liquid electrode-electrolyte and solid-solid active materials in lithium-ion batteries. We demonstrate that a lithium-ion battery cell under mechanical constraint exhibits a higher voltage during charging and a shorter charging time because of increased electrolyte resistance and decreased diffusivity caused by decreased electrode porosity. The reaction force response of the cell is a combined result of the cell structural response mechanically and lithium-ion intercalation/de-intercalation-induced volume variation electrochemically. Under mechanical constraint, cell capacity is significantly reduced in fast-charge scenarios; however, it can be recovered by a constant-voltage charge protocol. The results highlight the promise of multiphysics approaches to unravel the electrochemical-mechanical coupling mechanisms to direct battery system design and management.

25 ENERGY STORAGE↗
NASA NTRS1981

A drive unit for the instrument pointing system

The requirements, capabilities, and unique design features of the instrument pointing system drive units (DU) are presented. The DU's are identical for all three gimbal axes (elevation, cross elevation, and azimuth) and provide alternating rotation of shaft versus the housing of + or - 180 deg. The design features include: two ball bearing cartridges using cemented carbide balls coated with TiC a layer; redundant brushless torque motors and resolvers; a load by-pass mechanism driven by a dc torque motor to off-load the bearings during ascent/descent, ground transportation, and to provide an emergency breaking capability; and cabling over each gimbal axis by means of cable follow-up consisting of 13 signal and 15 power flat band cable loops. Test results of disturbance torque characteristics are presented.

Birner, R.↗
NASA NTRS1971

An experimental study of the mechanism of failure of rocks under borehole jack loading

Laboratory and field tests with an experimental jack and an NX-borehole jack are reported. The following conclusions were made: Under borehole jack loading, a circular opening in a brittle solid fails by tensile fracturing when the bearing plate width is not too small. Two proposed contact stress distributions can explain the mechanism of tensile fracturing. The contact stress distribution factor is a material property which can be determined experimentally. The borehole tensile strength is larger than the rupture flexural strength. Knowing the magnitude and orientation of the in situ stress field, borehole jack test results can be used to determine the borehole tensile strength. Knowing the orientation of the in situ stress field and the flexural strength of the rock substance, the magnitude of the in situ stress components can be calculated. The detection of very small cracks is essential for the accurate determination of the failure loads which are used in the calculation of strengths and stress components.

Van, T. K.↗
DOE OSTI2021

Constructing high-performance radiation-resistant ternary YSZ-MgO-CNT nanocomposites via tailored nanostructures

Developing long-lifetime bulk-form ceramic-based materials with high irradiation resistance is crucial for advanced nuclear systems. Here, we incorporated carbon nanotubes (CNTs) into yttria-stabilized zirconia (YSZ) and magnesia (MgO) nanocrystals to fabricate bulk YSZ-MgO-CNT nanocomposites with abundant ternary nanostructures by spark plasma sintering. To understand the role of tailored ternary nanostructure on irradiation, we investigated the microstructure and mechanical properties evolutions of the YSZ-MgO-CNT nanocomposites irradiated by multi-energy He + ions at high temperature to different fluences. Compared with the single-phase YSZ and ultrafine-grained YSZ-MgO composites, the YSZ-MgO-CNT nanocomposites possessed higher ability to manage irradiation-induced He bubbles/defects via the defect-interface interactions of proposed “loading-unloading” and “loading-transporting-unloading” mechanisms for controlling the dynamical behaviors of He atoms/defects in the CNT-doped ternary nanostructures, thereby presenting more stable microstructure and better performance in resisting irradiation hardening. In conclusion, this work provides insight into the design of advanced inert matrix nuclear fuel and new nuclear waste management materials.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Experimental and theoretical studies of subsonic fan noise

The noise generated by inlet turbulence impinging on a subsonic axial flow fan was studied as a function of tip speed, flow coefficient, and intensity and scale of turbulence was carried out. Both turbulence and far field acoustic measurements were made. The new elements introduced in the theoretical analysis were accounting for blade loading dependent noise mechanisms and consideration of anisotropic turbulence impinging on the rotor because of inlet flow contraction effects. Experimentally an unexplained increase of noise at about 1/2 and 1 1/2 times blade passsing frequency was observed at low flow coefficients even though there was no evidence of compressor surge. In the final version the theory does a fair job of predicting variations of noise with blade loading and tip speed. Alteration of inlet turbulence length scales produced some but not very pronounced changes in the far field PWL spectra. Some degree of eddy contraction and resulting anisotropy were essential to explain the concentration of energy around blade passing frequencies.

Mani, R.↗
NASA NTRS1996

Structural Evaluation of a Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump Turbine Blade

Thermal and structural finite-element analyses were performed on the first high pressure fuel turbopump turbine blade of the space shuttle main engine (SSME). A two-dimensional (2-D) finite-element model of the blade and firtree disk attachment was analyzed using the general purpose MARC (finite-element) code. The loading history applied is a typical test stand engine cycle mission, which consists of a startup condition with two thermal spikes, a steady state and a shutdown transient. The blade material is a directionally solidified (DS) Mar-M 246 alloy, the blade rotor is forged with waspalloy material. Thermal responses under steady-state and transient conditions were calculated. The stresses and strains under the influence of mechanical and thermal loadings were also determined. The critical regions that exhibited high stresses and severe localized plastic deformation were the blade-rotor gaps.

Abdul-Aziz, Ali↗
NASA NTRS2005

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.

Hilburger, Mark W.↗
NASA NTRS2006

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.

Hilburger, Mark W.↗
NASA NTRS1980

Mechanisms of lubrication and wear of a bonded solid lubricant film

To obtain a better understanding of how bonded solid lubricant films lubricate and wear (in general), the tribological properties of polyimide-bonded graphite fluoride films were studied (in specific). A pin-on-disk type of testing apparatus was used; but in addition to sliding a hemispherically tipped rider, a rider with a 0.95 mm diameter flat area was slid against the film. This was done so that a lower, less variable contact stress could be achieved. Two stages of lubrication occurred. In the first, the film supported the load. The lubricating mechanism consisted of the shear of a thin surface layer (of the film) between the rider and the bulk of the film. The second occurred after the bonded film had worn to the substrate, and consisted of the shear of very thin lubricant films between the rider and flat plateaus generated on the metallic substrate asperities. The film wear mechanism was strongly dependent on contact stress.

Fusaro, R. L.↗
DOE OSTI2020

Involute Working Group – Development and Validation of the Finite Element Models of the Cheverton-Kelley Experiments

In an involute-plate reactor, the fuel plates and side-plates are subjected to a non-uniform distribution of loads. Temperature variation derives from a variation in power distribution throughout the core. Due to small imperfections in the channel thickness, the coolant flowing in between the plates produces pressure differentials with a non-uniform distribution on the plate surface. The main goal of the analysis presented in this technical report is to investigate the ability of the commercial software STAR-CCM+ to model deformation of involute plates subjected to mechanical and thermal loads, representative of involute reactor operation conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Nonlinear Interface Reduction for Time-Domain Analysis of Hurty/Craig-Bampton Superelements with Frictional Contact

Virtual prototyping in engineering design relies today on modern numerical models of contacting structures with accurate resolution of interface mechanics, which strongly affect the system-level stiffness and energy dissipation due to frictional losses. High-fidelity modeling within the localized interfaces is required to resolve local quantities of interest that may drive design decisions. The high-resolution finite element meshes necessary to resolve inter-component stresses tend to be computationally expensive, particularly when the analyst is interested in response time histories. The Hurty/Craig-Bampton (HCB) transformation is a widely used method in structural dynamics for reducing the interior portion of a finite element model while having the ability to retain all nonlinear contact degrees of freedom (DOF) in physical coordinates. These models may still require many DOF to adequately resolve the kinematics of the interface, leading to inadequate reduction and computational savings. This study proposes a novel interface reduction method to overcome these challenges by means of system-level characteristic constraint (SCC) modes and properly orthogonal interface modal derivatives (POIMDs) for transient dynamic analyses. Both SCC modes and POIMDs are computed using the reduced HCB mass and stiffness matrices, which can be directly computed from many commercial finite element analysis software. Comparison of time history responses to an impulse-type load in a mechanical beam assembly indicate that the interface-reduced model correlates well with the HCB truth model. Localized features like slip and contact area are well-represented in the time domain when the beam assembly is loaded with a broadband excitation. The proposed method also yields reduced-order models with greater critical timestep lengths for explicit integration schemes.

42 ENGINEERING↗
NASA NTRS1998

Thermal and Mechanical Buckling and Postbuckling Responses of Selected Curved Composite Panels

The results of an experimental and numerical study of the buckling and postbuckling responses of selected unstiffened curved composite panels subjected to mechanical end shortening and a uniform temperature increase are presented. The uniform temperature increase induces thermal stresses in the panel when the axial displacement is constrained. An apparatus for testing curved panels at elevated temperature is described, numerical results generated by using a geometrically nonlinear finite element analysis code are presented. Several analytical modeling refinements that provide more accurate representation of the actual experimental conditions, and the relative contribution of each refinement, are discussed. Experimental results and numerical predictions are presented and compared for three loading conditions including mechanical end shortening alone, heating the panels to 250 F followed by mechanical end shortening, and heating the panels to 400 F. Changes in the coefficients of thermal expansion were observed as temperature was increased above 330 F. The effects of these changes on the experimental results are discussed for temperatures up to 400 F.

Breivik, Nicole L.↗
NASA NTRS1999

An overview of vertebrate mineralization with emphasis on collagen-mineral interaction

The nucleation, growth, and development of mineral crystals through their interaction principally with collagen in normal bone and calcifying tendon have been elaborated by applying a number of different techniques for analysis of the inorganic and organic constituents of these tissues. The methods have included conventional and high voltage electron microscopy, electron diffraction, microscopic tomography and 3D image reconstruction, and atomic force microscopy. This summary presents results of these studies that have now characterized the size, shape, and aspects of the chemical nature of the crystals as well as their orientation, alignment, location, and distribution with respect to collagen. These data have provided the means for understanding more completely the formation and strength of the collagen-mineral composite present in most vertebrate calcifying tissues and, from that information, a basis for the adaptation of such tissues under mechanical constraints. In the context of the latter point, other data are given showing effects on collagen in bone cell cultures subjected to the unloading parameters of spaceflight. Implications of these results may be particularly relevant to explaining loss of bone by humans and other vertebrate animals during missions in space, during situations of extended fracture healing, long-term bedrest, physical immobilization, and related conditions. In a broader sense, the data speak to the response of bone and mineralized vertebrate tissues to changes in gravitational loading and applied mechanical forces in general.

Non-NASA Center↗
NASA NTRS2000

Effect of Discontinuities and Uncertainties on the Response and Failure of Composite Structures

The overall goal of this research was to assess the effect of discontinuities and uncertainties on the nonlinear response and failure of composite structures subjected to combined mechanical and thermal loads. The four key elements of the study were: (1) development of simple and efficient procedures for the accurate determination of transverse shear and transverse normal stresses in structural sandwiches as well as in unstiffened and stiffened composite panels and shells; (2) study the effects of transverse stresses on the response, damage initiation and propagation in composite and sandwich structures; (3) use of hierarchical sensitivity coefficients to identify the major parameters that affect the response and damage in each of the different levels in the hierarchy (micro-mechanical, layer, panel, subcomponent and component levels); and (4) application of fuzzy set techniques to identify the range and variation of possible responses. The computational models developed were used in conjunction with experiments, to understand the physical phenomena associated with the nonlinear response and failure of composite and sandwich structures. A toolkit was developed for use in conjunction with deterministic analysis programs to help the designer in assessing the effect of uncertainties in the different computational model parameters on the variability of the response quantities.

Noor, Ahmed K.↗
NASA NTRS1992

Failure mechanisms of uni-ply composite plates with a circular hole under static compressive loading

The objective of the study was to identify and study the failure mechanisms associated with compressive-loaded uniply graphite/epoxy square plates with a central circular hole. It is found that the type of compressive failure depends on the hole size. For large holes with the diameter/width ratio exceeding 0.062, fiber buckling/kinking initiated at the hole is found to be the dominant failure mechanism. In plates with smaller hole sizes, failure initiates away from the hole edge or complete global failure occurs. Critical buckle wavelengths at failure are presented as a function of the normalized hole diameter.

Khamseh, A. R.↗