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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 1,081 records · Page 60
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

An overview of elevated temperature damage mechanisms and fatigue behavior of a unidirectional SCS-6/Ti-15-3 composite

The fatigue behavior of a unidirectionally reinforced titanium matrix composite (TMC), SiC/Ti-15-3, was thoroughly characterized to support life prediction modeling of advanced TMC disks designed for gas turbine engine applications. The results of this coupon-level experimental investigation are reviewed. On a stress basis, the isothermal fatigue behavior of the (0 deg) TMC revealed significant improvements over the unreinforced matrix. In contrast, the (90 deg) TMC exhibited degraded properties and lives for similar comparisons. This was attributed to the weak fiber/matrix interfacial bond. Encasing the (0 deg) TMC with a Ti-15-3 case did not affect isothermal fatigue lives at higher strain levels. However, at lower strain levels, rapid initiation and propagation of large fatigue cracks in the case degraded the fatigue lives. Thermomechanical fatigue (TMF) lives were significantly reduced for the (0 deg) TMC when compared to isothermal lives. At high strains, in-phase TMF produced extremely short lives. This degradation was attributed to fiber overload failures brought about by stress relaxation in the matrix. At low strains, out-of-phase TMF conditions became life limiting. Environment-assisted surface cracking was found to accelerate fatigue failure. This produced extensive matrix damage with minimal fiber damage. For the (90 deg) TMC, TMF conditions did not promote an additional degradation in cyclic life beyond that observed under isothermal conditions.

Castelli, Michael G.↗
DOE OSTI2012

Thermal creep model for CWSR zircaloy-4 cladding taking into account the annealing of the irradiation hardening

After irradiation and cooling in a pool, spent nuclear fuel assemblies are either transported for wet storage to a devoted site or loaded in casks for dry storage. During dry transportation or at the beginning of dry storage, the cladding is expected to be submitted to creep deformation under the hoop stress induced by the internal pressure of the fuel rod. The thermal creep is a potential mechanism that might lead to cladding failure. A new creep model was developed, based on a database of creep tests on as-received and irradiated cold-worked stress-relieved Zircaloy-4 cladding in a wide range of temperatures (310 degrees C to 470 degrees C) and hoop stress (80 to 260 MPa). Based on three laws-a flow law, a strain-hardening recovery law, and an annealing of irradiation hardening law this model allows the simulation of not only the transient creep and the steady-state creep, but also the early creep acceleration observed on irradiated samples tested in severe conditions, which was not taken into account in the previous models. The extrapolation of the creep model in the conditions of very long-term creep tests is reassuring, proving the robustness of the chosen formalism. The creep model has been assessed in progressively decreasing stress conditions, more representative of a transport. Set up to predict the cladding creep behavior under variable temperature and stress conditions, this model can easily be implemented into codes in order to simulate the thermomechanical behavior of spent fuel rods in various scenarios of postirradiation phases. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2009

Designing of a Fleet-Leader Program for Carbon Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPVs) are often used for storing pressurant gases on board spacecraft when mass saving is a prime requirement. Substantial weight savings can be achieved compared to all metallic pressure vessels. For example, on the space shuttle, replacement of all metallic pressure vessels with Kevlar COPVs resulted in a weight savings of about 30 percent. Mass critical space applications such as the Ares and Orion vehicles are currently being planned to use as many COPVs as possible in place of all-metallic pressure vessels to minimize the overall mass of the vehicle. Due to the fact that overwraps are subjected to sustained loads during long periods of a mission, stress rupture failure is a major concern. It is, therefore, important to ascertain the reliability of these vessels by analysis, since it is practically impossible to show by experimental testing the reliability of flight quality vessels. Also, it is a common practice to set aside flight quality vessels as "fleet leaders" in a test program where these vessels are subjected to slightly accelerated operating conditions so that they lead the actual flight vessels both in time and load. The intention of fleet leaders is to provide advanced warning if there is a serious design flaw in the vessels so that a major disaster in the flight vessels can be averted with advance warning. On the other hand, the accelerating conditions must be not so severe as to be prone to false alarms. The primary focus of the present paper is to provide an analytical basis for designing a viable fleet leader program for carbon COPVs. The analysis is based on a stress rupture behavior model incorporating Weibull statistics and power-law sensitivity of life to fiber stress level.

Murthy, Pappu L.N.↗
DOE OSTI2014

Early detection of critical material degradation by means of electromagnetic multi-parametric NDE

With an increasing number of power plants operated in excess of their original design service life an early recognition of critical material degradation in components will gain importance. Many years of reactor safety research allowed for the identification and development of electromagnetic NDE methods which detect precursors of imminent damage with high sensitivity, at elevated temperatures and in a radiation environment. Regarding low-alloy heat-resistant steel grade WB 36 (1.6368, 15NiCuMoNb5), effects of thermal and thermo-mechanical aging on mechanical-technological properties and several micromagnetic parameters have been thoroughly studied. In particular knowledge regarding the process of copper precipitation and its acceleration under thermo-mechanical load has been enhanced. Whilst the Cu-rich WB 36 steel is an excellent model material to study and understand aging effects related to neutron radiation without the challenge of handling radioactive specimens in a hot cell, actually neutron-irradiated reactor pressure vessel materials were investigated as well. The neutron fluence experienced and the resulting shift of the ductile-brittle transition temperature were determined electromagnetically, and it was shown that weld and base material can be distinguished from the cladded side of the RPV wall. Low-cycle fatigue of the austenitic stainless steel AISI 347 (1.4550, X6CrNiNb18-10) has been characterized with electromagnetic acoustic transducers (EMATs) at temperatures of up to 300 °C. Time-of-flight and amplitude of the transmitted ultrasound signal were evaluated against the number of load cycles applied and observed as an indication of the imminent material failure significantly earlier than monitoring stresses or strains.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Accelerated characterization of graphite/epoxy composites

A method to predict the long term compliance of unidirectional off-axis laminates from short term laboratory tests is presented. The method uses an orthotropic transformation equation and the time-stress-temperature superposition principle. Short term tests are used to construct master curves for two off-axis unidirectional laminates with fiber angles of 10 and 90 degrees. Analytical predictions of long term compliance for 30 and 60 degrees laminates are made. Comparisons with experimental data are also given.

Griffith, W. I.↗
DOE OSTI2020

Transient solute drag and strain aging of dislocations

The transient drag force exerted by mobile solutes on a moving dislocation is computed using continuum theory. These mobile solutes form so-called Cottrell atmospheres around dislocations during static and dynamic strain aging. We evaluate the evolution of the drag force exerted by the atmosphere under two velocity time-histories: impulsive acceleration to a chosen velocity and a constant acceleration rate. A particular focus is on the conditions under which the stationary limit assumed by theories of dynamic strain aging is obeyed. According to our results, two conditions—one on the dislocation velocity and one on the acceleration rate—must be satisfied for the stationary limit to hold. Using the Orowan relation and a line tension model, we obtain estimates for the temperature, stress, strain rate, and dislocation density regimes where the stationary limit is valid, and compare these results with experiments for a few material systems.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Development of a high power electron beam welding gun with replaceable high voltage feed-through insulators

Ceramic to metal sealed feed-through insulators are commonly used in electron beam welding gun. The above feed-through insulators are susceptible to failure, as the brazing joints in them are not always very strong. Failure in one of these feed-through could render the complete gun unusable. This problem has already been faced in BARC, which led to the development of the electron gun with replaceable feed through insulators. A 24 kW Electron Beam Welding (EBW) gun with indigenous designed replaceable insulators is fabricated in BARC. Emphasis during the design of the gun had been to reduce the use of imported components to zero. This paper describes the design and fabrication of this gun and reports various simulations and tests performed. Beam trajectory of the gun is numerically computed and presented. Weld passes were carried out on stainless steel plates show satisfactory penetrations. (author)

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Magnetic and Mechanical Analysis of a Large Aperture 15 T Cable Test Facility Dipole Magnet

The US Department of Energy (DOE) Office of Science (SC), is funding a large bore “Cable Test Facility Magnet” for testing advanced cables and inserts in high transverse field. This is a joint effort between the Office of High Energy Physics (HEP) and the Office of Fusion Energy Sciences (FES). The background field magnet for this facility is being developed at Lawrence Berkeley National Laboratory (LBNL) while the cryostat and test facility will be located and operated by Fermi National Accelerator Laboratory (FNAL). The Nb 3 Sn dipole magnet, which will provide the transverse background field, is designed to generate a field of 15 T in a 100 × 150 mm bore at 1.9 K. The conceptual design of a block-type dipole with flared ends and a structure based on key-and-bladder technology will be introduced. The results of the magnetic and mechanical analysis will be presented.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Independence of Environmental and Mechanical Damages on Silicone Adhesive Stored in a Thermo-Oxidative Environment

Abstract Elastomeric polymer materials hold a special place in today’s industrial sectors with respect to structural application needs. Low quality materials are detrimental to industries like aerospace, and automotive engineering. Assessment of the durability of elastomers for structural applications has been of much interest among the literary circles for decades and new materials keep outperforming the existing ones. Polymeric adhesives are one of the most abundantly used materials in these industries. All polymeric materials get damaged when in contact with aggressive environments in presence of high temperature and oxygen. Commonly referred to as thermo-oxidation, this environment exposes the material to heat and oxidation reactions in presence of oxygen. Resultantly, during service life, the damage to the polymer matrix is primarily caused by two factors: mechanical damage and environmental aging. Environmental aging is an irreversible phenomenon caused by changes in the molecular structure while mechanical damage maintains the shape of the polymer matrix, and the deterioration is mostly due to polymer chain mobility. Environmental aging can be caused by a single environmental agent or by a synergized impact of several environmental elements. Increasing temperature is found to be proportional to decreasing tensile strength and toughness of material. The rate and extent of degradation can be accessed by scrutinizing the changes in constitutive behavior of material through mechanical and chemical properties. Accelerated thermal aging is among the most common modes of process related degradation, leading generally to chain scission, and crosslinking phenomena and reduced resistance to fracture stress, and strain. In this experimental study, our goal is to separate the environmental degradation from mechanical damage. A silicone-based adhesive was aged in thermo-oxidative at (0%RH) aging environment. The damage and decay mechanisms have been used to draw a distinction between environmental degradation and mechanical damage. Material characterization included uniaxial tensile test (failure and cyclic) and scanning electron microscopy (SEM) tests on as-received and aged samples. Aging was conducted at three different temperatures (60°C, 80°C and 95°C) and six different exposure durations (1, 3, 10, 30, 90 and 200 days). This work confirms that environmental damage is superposed on top of the mechanical damage, and thus, they are separable. The total mechanical and environmental damage is a synergized effect of all exposure conditions and parameters involved i.e., aging time, temperature, and oxygen. The chemistry and mechanics of the polymer degradation were found to be in good agreement with each other.

Alazhary, Sharif↗
DOE OSTI2016

Workshop Report on Additive Manufacturing for Large-Scale Metal Components - Development and Deployment of Metal Big-Area-Additive-Manufacturing (Large-Scale Metals AM) System

Additive manufacturing (AM) is considered an emerging technology that is expected to transform the way industry can make low-volume, high value complex structures. This disruptive technology promises to replace legacy manufacturing methods for the fabrication of existing components in addition to bringing new innovation for new components with increased functional and mechanical properties. This report outlines the outcome of a workshop on large-scale metal additive manufacturing held at Oak Ridge National Laboratory (ORNL) on March 11, 2016. The charter for the workshop was outlined by the Department of Energy (DOE) Advanced Manufacturing Office program manager. The status and impact of the Big Area Additive Manufacturing (BAAM) for polymer matrix composites was presented as the background motivation for the workshop. Following, the extension of underlying technology to low-cost metals was proposed with the following goals: (i) High deposition rates (approaching 100 lbs/h); (ii) Low cost (<$10/lbs) for steel, iron, aluminum, nickel, as well as, higher cost titanium, (iii) large components (major axis greater than 6 ft) and (iv) compliance of property requirements. The above concept was discussed in depth by representatives from different industrial sectors including welding, metal fabrication machinery, energy, construction, aerospace and heavy manufacturing. In addition, DOE’s newly launched High Performance Computing for Manufacturing (HPC4MFG) program was reviewed. This program will apply thermo-mechanical models to elucidate deeper understanding of the interactions between design, process, and materials during additive manufacturing. Following these presentations, all the attendees took part in a brainstorming session where everyone identified the top 10 challenges in large-scale metal AM from their own perspective. The feedback was analyzed and grouped in different categories including, (i) CAD to PART software, (ii) selection of energy source, (iii) systems development, (iv) material feedstock, (v) process planning, (vi) residual stress & distortion, (vii) post-processing, (viii) qualification of parts, (ix) supply chain and (x) business case. Furthermore, an open innovation network methodology was proposed to accelerate the development and deployment of new large-scale metal additive manufacturing technology with the goal of creating a new generation of high deposition rate equipment, affordable feed stocks, and large metallic components to enhance America’s economic competitiveness.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Understanding and Overcoming Water-induced Interfacial Degradation in Si Modules (Final Technical Report)

Moisture ingress is an established issue for photovoltaic module durability. Durability studies probing moisture effects typically evaluate performance losses at the module level, attributing global power losses to the overall humidity condition of the test environment while leaving local module behavior unknown. This project successfully develops an in situ short-wave infrared probe of moisture content in PV modules with demonstrated detection limits better than 100 ppm in EVA-encapsulated Al-BSF and PERC architectures (66 µg/cm3) and applicability across the range of terrestrial conditions. Combining this optical moisture quantification method (water reflectometry detection, WaRD) with peel testing of interfaces, biased photoluminescence imaging of performance, and first principles computation, we correlate module moisture content and cell performance over the course of accelerated damp heat tests. By performing multi-level humidity and thermal accelerated testing over thousands of hours (0, 65 and 85% RH and 25, 65, and 85°C), we are able to attribute effects of individual environmental stresses and the dependence on module architecture. Using first-principles computational chemistry, we find that the decomposition of EVA to acetic acid (Norrish II) is thermodynamically preferred over a pathway to acetaldehyde (Norrish I), elucidating the underlying chemistry of encapsulant degradation. We also find it is likely that water segregates to the stable interfaces of the cell, especially the SiNx/EVA interface. We find that moisture is strongly correlated with reduction in adhesion at the interfaces of the cells, particularly at Ag fingers. We show uniquely that the peel strength required to delaminate the encapsulant from the front of the cell depends not only on the exposure to a high heat and humid environment, but also to the moisture content during the mechanical testing, indicating an important interaction between when mechanical stresses are faced in terms of the moisture content of the module and its durability. We find that the background sheet resistance (that is, the sheet resistance rise not attributable to finger interruptions or cracks) is substantially higher in the backsheet mini-modules vs glass-glass packages when humidity and temperature are faced. This increase in power loss due to the background resistance increase over time in damp heat in glass-backsheet modules resulted in ~3-4% larger decrease in relative PCE compared to glass-glass modules. In glass-backsheet modules, the effect of the moisture dose alone is comparable or greater than that of the combined temperature and water term, suggesting that glass-backsheet modules are overall more susceptible to moisture induced performance loss. Finally, we show that thin film PV modules are amenable to WaRD measurement, based on the ability to detect moisture in POE encapsulants or in the cell stack itself. The ease of WaRD measurement and its few requirements on the bill of materials should enable broad applicability of this technique for studying the effects of moisture in PV.

14 SOLAR ENERGY↗
NASA NTRS1973

Accelerated testing of space batteries

An accelerated life test program for space batteries is presented that fully satisfies empirical, statistical, and physical criteria for validity. The program includes thermal and other nonmechanical stress analyses as well as mechanical stress, strain, and rate of strain measurements.

Mccallum, J.↗
NASA NTRS1981

Accelerated life testing and reliability of high K multilayer ceramic capacitors

The reliability of one lot of high K multilayer ceramic capacitors was evaluated using accelerated life testing. The degradation in insulation resistance was characterized as a function of voltage and temperature. The times to failure at a voltage-temperature stress conformed to a lognormal distribution with a standard deviation approximately 0.5.

Minford, W. J.↗
NASA NTRS1992

Environmental fatigue of an Al-Li-Cu alloy. Part 2: Microscopic hydrogen cracking processes

Based on a fractographic analysis of fatigue crack propagation (FCP) in Al-Li-Cu alloy 2090 stressed in a variety of inert and embrittling environments, microscopic crack paths are identified and correlated with intrinsic da/dN-delta K kinetics. FCP rates in 2090 are accelerated by hydrogen producing environments (pure water vapor, moist air, and aqueous NaCl), as defined in Part 1. For these cases, subgrain boundary fatigue cracking (SGC) dominates for delta K values where the crack tip process zone, a significant fraction of the cyclic plastic zone, is sufficiently large to envelop 5 micron subgrains in the unrecrystallized microstructure. SGC may be due to strong hydrogen trapping at T1 precipitates concentrated at sub-boundaries. At low delta K, the plastic zone diameter is smaller than the subgrain size and FCP progresses along (100) planes due to either local lattice decohesion or aluminum-lithium hydride cracking. For inert environments (vacuum, helium, and oxygen), or at high delta K where the hydrogen effect on da/dN is small, FCP is along (111) slip planes; this mode does not transition with increasing delta K and plastic zone size. The SGC and (100) crystallographic cracking modes, and the governing influence of the crack tip process zone volume (delta K), support hydrogen embrittlement rather than a surface film rupture and anodic dissolution mechanism for environmental FCP. Multi-sloped log da/dN-log delta K behavior is produced by changes in process zone hydrogen-microstructure interactions, and not by purely micromechanical-microstructure interactions, in contradiction to microstructural distance-based fatigue models.

Robert S Piascik↗
NASA NTRS1993

Advanced collapsible tank for liquid containment

Tanks for bulk liquid containment will be required to support advanced planetary exploration programs. Potential applications include storage of potable, process, and waste water, and fuels and process chemicals. The launch mass and volume penalties inherent in rigid tanks suggest that collapsible tanks may be more efficient. Collapsible tanks are made of lightweight flexible material and can be folded compactly for storage and transport. Although collapsible tanks for terrestrial use are widely available, a new design was developed that has significantly less mass and bulk than existing models. Modelled after the shape of a sessible drop, this design features a dual membrane with a nearly uniform stress distribution and a low surface-to-volume ratio. It can be adapted to store a variety of liquids in nearly any environment with constant acceleration field. Three models of 10L, 50L, and 378L capacity have been constructed and tested. The 378L (100 gallon) model weighed less than 10 percent of a commercially available collapsible tank of equivalent capacity, and required less than 20 percent of the storage space when folded for transport.

Flanagan, David T.↗
NASA NTRS1992

The maintenance of the sun's differential rotation and its temporal variations

We use the horizontal momentum balance equation to infer the strength of the meridional circulation (MC) and Reynolds stresses (RS) at the sun's surface from the observed properties of the differential rotation (DR). Both MC and RS are important for maintaining the equatorial acceleration. The results indicate that the average value of MC is about 1.1 m/s, with circulation directed towards the poles in both the hemispheres, and the average value of RS is 3.6 10 exp 7 sq cm2/s, with transport of angular momentum directed towards the equator in both hemispheres, this latter in good agreement with observations. With the above values of MC and RS, we integrate the momentum equation in time, starting from a state of rigid rotation, to investigate the competitive role of MC and RS in producing the presently observed average DR. Our results show that DR is consistent with observations only if both MC and RS have opposite effects, with the strengths given above, in order to balance the viscous torque.

Chiu, H.-Y.↗
NASA NTRS2004

Neutron Star Structure in the Presence of Scalar Fields

Motivated by the possible presence of scalar fields on astrophysical scales, suggested by the apparent acceleration of the universe implied by the supernovae surveys, we present models of neutron star structure including the contribution of a (massless) scalar field to the stress energy momentum tensor, in addition to that made by the normal matter. To that end we solve the coupled Einstein -- scalar field -- hydrostatic balance equations to compute the effect of the presence of the scalar field on the neutron star structure. We find that the presence of the scalar field does change the structure of the neutron star, especially in cases of strong coupling between the scalar field and the matter density. We present the neutron star radius as a function of the matter--scalar field coupling constant for different values of the neutron star central density. The presence of the scalar field affects both the maximum neutron star mass and Its radius, the latter increasing with the value of the above coupling constant. We also compute particle and photon geodesics in the geometry of these neutron stars as well as to the geometry of black holes with different values of the scalar field. Our results may be testable with timing observations of accreting neutron stars.

Kazanas, Demosthenes↗