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At least 1,081 records · Page 60
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Subscale and Full-Scale Testing of Buckling-Critical Launch Vehicle Shell Structures

New analysis-based shell buckling design factors (aka knockdown factors), along with associated design and analysis technologies, are being developed by NASA for the design of launch vehicle structures. Preliminary design studies indicate that implementation of these new knockdown factors can enable significant reductions in mass and mass-growth in these vehicles and can help mitigate some of NASA s launch vehicle development and performance risks by reducing the reliance on testing, providing high-fidelity estimates of structural performance, reliability, robustness, and enable increased payload capability. However, in order to validate any new analysis-based design data or methods, a series of carefully designed and executed structural tests are required at both the subscale and full-scale level. This paper describes recent buckling test efforts at NASA on two different orthogrid-stiffened metallic cylindrical shell test articles. One of the test articles was an 8-ft-diameter orthogrid-stiffened cylinder and was subjected to an axial compression load. The second test article was a 27.5-ft-diameter Space Shuttle External Tank-derived cylinder and was subjected to combined internal pressure and axial compression.

Hilburger, Mark W.↗
NASA NTRS1978

Development of a preprototype vapor compression distillation water recovery subsystem

The activities involved in the design, development, and test of a preprototype vapor compression distillation water recovery subsystem are described. This subsystem, part of a larger regenerative life support evaluation system, is designed to recover usable water from urine, urinal rinse water, and concentrated shower and laundry brine collected from three space vehicle crewmen for a period of 180 days without resupply. Details of preliminary design and testing as well as component developments are included. Trade studies, considerations leading to concept selections, problems encountered, and test data are also presented. The rework of existing hardware, subsystem development including computer programs, assembly verification, and comprehensive baseline test results are discussed.

Johnson, K. L.↗
DOE OSTI2022

Performance of Lithium-Ion Batteries with 3D Printed Anodes and Compressible Carbon Structures

Carbon scaffolds have been shown to improve the performance of Li metal anodes in Li-ion batteries by acting as conductive hosts for Li metal plating and stripping. The scaffolds provide a more uniform electric field, and their 3D geometry enables smaller diffusion paths for the Li ions. In this project, several different types of carbon lattices were 3D printed, mechanically tested, and analyzed in coin cells. Planar and 3D printed graphite coatings were evaluated as the baseline, since graphite is a common anode material. The results showed that implementing a 3D graphite lattice into a coin cell improved the Li plating and stripping efficiency compared to the planar coating. However, since graphite can intercalate Li ions, other carbon materials were also explored that should act as better hosts for Li plating/stripping. To improve the compressibility of these non-graphite carbon scaffolds, five different carbon ink formulations were 3D printed in lattice configurations. SEM imaging and compression testing showed that both the final dimensions and the compressibility of the carbon lattices depended on the type of carbon precursors used. The two most suitable compositions were found to be those made with graphene oxide-resorcinol formaldehyde and graphene oxide-ammonium hydroxide. In the future, these formulations will be further refined to increase their mechanical strength, and their performance as scaffold hosts for Li metal anodes will be evaluated in coin cells.

25 ENERGY STORAGE↗
NASA NTRS2007

Fabrication of Polyimide-Matrix/Carbon and Boron-Fiber Tape

The term HYCARB denotes a hybrid composite of polyimide matrices reinforced with carbon and boron fibers. HYCARB and an improved process for fabricating dry HYCARB tapes have been invented in a continuing effort to develop lightweight, strong composite materials for aerospace vehicles. Like other composite tapes in this line of development, HYCARB tapes are intended to be used to build up laminated structures having possibly complex shapes by means of automated tow placement (ATP) - a process in which a computer-controlled multiaxis machine lays down prepreg tape or tows. The special significance of the present process for making dry HYCARB for ATP is that it contributes to the reduction of the overall cost of manufacturing boron-reinforced composite-material structures while making it possible to realize increased compression strengths. The present process for making HYCARB tapes incorporates a "wet to dry" process developed previously at Langley Research Center. In the "wet to dry" process, a flattened bundle of carbon fiber tows, pulled along a continuous production line between pairs of rollers, is impregnated with a solution of a poly(amide acid) in N-methyl-2-pyrrolidinone (NMP), then most of the NMP is removed by evaporation in hot air. In the present case, the polyamide acid is, more specifically, that of LaRC. IAX (or equivalent) thermoplastic polyimide, and the fibers are, more specifically, Manganite IM7 (or equivalent) polyacrylonitrile- based carbon filaments that have a diameter of 5.2 m and are supplied in 12,000-filament tows. The present process stands in contrast to a prior process in which HYCARB tape was made by pressing boron fibers into the face of a wet carbon-fiber/ poly(amide acid) prepreg tape . that is, a prepreg tape from which the NMP solvent had not been removed. In the present process, one or more layer(s) of side-by-side boron fibers are pressed between dry prepreg tapes that have been prepared by the aforementioned gwet to dry h process. The multilayer tape is then heated to imidize the matrix material and remove most of the remaining solvent, and is pressed to consolidate the multiple layers into a dense tape. For tests, specimens of HYCARB tapes and laminated composite panels made from HYCARB tape were prepared as follows: HYCARB tapes were fabricated as described above. Each panel was made by laying down ten layers of tape, containing, variously, one, two, or three boron-fiber plies and the remainder carbon- fiber-only plies (see figure). Each panel was made by laying down ten layers of tape. Each panel was then cured by heating to a temperature of 225 C for 15 minutes, then pressing at 200 psi (A1.4 MPa) while heating to 371 C, holding at 371 C for 1 hour, then continuing to hold pressure during cooling. Control specimens that were otherwise identical except that they did not contain boron fibers also were prepared. In room-temperature flexural tests, the HYCARB specimens performed comparably to the control specimens; in room-temperature, open-hole compression tests, the HYCARB specimens performed slightly better, by amounts that increased with boron content.

Belvin, Harry L.↗
DOE OSTI2021

IACMI Project 4.2: Thermoplastic Composite Development for Wind Turbine Blades

(Section 5.1) Composites made from Arkema’s Elium® thermoplastic resin and Johns Manville fiberglass were researched during this project for applications in wind blade manufacturing. A techno-economic model was developed to model this wind blade manufacturing process using these materials in place of traditional composites made with thermoset resin. This model was based on manufacturing a 61.5-meter wind blade, which showed a 4.7% reduction in wind blade cost as compared traditional thermoset materials. These cost savings were not from the thermoplastic material costing less than traditional thermoset materials, but rather from decreased capital costs, faster cycle times and reduced energy requirements and labor costs. (Section 5.2) An infusion and curing model was developed for thermoplastic composite wind blades using PAM-RTM. The primary goal was to demonstrate the infusion simulation for the Elium® resin system on a 13-meter wind blade. Additionally, the exotherm temperature was predicted and compared to measurements, which showed model results within 10% of actual measurements. (Section 5.3) Composite laminate panels and composite sandwich panels with a balsa core were produced; specimens were cut and characterized. Similar composite specimens were made with Elium® thermoplastic resin and Hexion thermoset epoxy (RIMR135/RIMH1366) to enable comparisons between these resin systems. The static test methods included: tensile, compression, in-plane shear, interlaminar shear, flexural, sandwich core shear flexure, and single cantilever beam tests for sandwich beams. Fatigue testing at room temperature was completed to composite laminate panels at a stress ratio of R=0.1 and R=10. In addition, fatigue testing to laminate panels was completed at -30°C, and at room temperature after conditioning specimens at 70°C and 90% relative humidity. Overall, mechanical test results from Elium® composites are similar to epoxy composites. (Section 5.4) Elium composite panels were produced with intentional defects such as voids and nonwetting of fibers to begin to understand performance sensitivity to defects. A thermal digital image correlation (TDIC) method provides high spatial resolution strain field at elevated temperatures and can be used to identify defective regions within composite panels. Flexural modulus differences of 21% were seen between defect and non-defect panels. Other Elium® composite panels were forced to be defective by boiling the resin after infusion, which created voids throughout the composite laminate. X-ray computed tomography scanning was used to view the internal structure of the defect panels. Defect panels had a significant reduction in fatigue life as compared to baseline panels produced without intentional defects. (Section 5.5) Lap shear specimens were fabricated to compare the lap shear strength of an off-the-shelf adhesive (Plexus MA590) and two new adhesives developed by Arkema (Bostik SAF30 90 and Bostik SAF30 120). ISO standard 4587:2003 was used to standardize the testing method and sample fabrication. Lap shear specimens were made at 1mm, 3mm, and 10mm thicknesses. The Bostik adhesive lap shear test results were similar to Plexus for all thicknesses. (Section 5.6) Fiber-reinforced polymer (FRP) composites are typically used in high-performance applications (e.g., aerospace), and their expansion into high-volume industries (e.g. consumer automotive and wind turbine blade manufacturer or similar) is hindered by their cost and a lack of efficient manufacturing techniques. Monitoring the curing process of these composites during manufacturing can improve the efficiency of the process, and therefore reduce the manufacturing cost. Cure monitoring techniques were developed that use probabilistic estimation methods and surface temperature measurements made using infrared cameras. These techniques enable real-time monitoring of the infusion process to locate manufacturing flaws, and they can, potentially, estimate residual stresses in the part. Their commercialization will help facilitate expansion of FRP composites in high-volume industries. (Section 5.7) A 13-meter composite wind blade was produced with Elium® resin and Johns Manville fiberglass; this blade was made with VARTM processing similar to how megawatt-scale wind blades are currently manufactured, but no post-mold heating was used for this thermoplastic composite blade. The wind blade underwent full-scale validation for static loading (4-different load orientations) and flapwise fatigue loading to simulate 20-years of operational loads. The thermoplastic composite wind blade withstood the loading without any noted issues and performed similar to results from a previous full-scale validation to an equivalent epoxy composite wind blade produced with the same blade molds. (Section 5.8) A study was conducted to determine the feasibility of recycling composite wind turbine blade components fabricated with glass fiber reinforced Elium® thermoplastic resin. Dissolution, which is a process unique to thermoplastic matrices, allows recovery of both the polymer matrix and full-length glass fibers, while maintaining their stiffness and strength throughout the recovery process. The economics of recycling is favorable if 50% of the glass fiber is recovered and resold for a process of $\$$ 0.28/kg, and 90% of the resin is recovered and resold at a price of $\$$ 2.50/kg.(Section 10) Recommendations are outlined for commercializing thermoplastic resin for composite wind blade production, in addition to recommended areas for future research.

17 WIND ENERGY↗
NASA NTRS2000

Modeling Step-Strain Relaxation and Cyclic Deformations of Elastomers

Data for step-strain relaxation and cyclic compressive deformations of highly viscous short elastomer cylinders are modeled using a large strain rubber viscoelastic constitutive theory with a rate-independent friction stress term added. In the tests, both small and large amplitude cyclic compressive strains, in the range of 1% to 10%, were superimposed on steady state compressed strains, in the range of 5% to 20%, for frequencies of 1 and 10 Hz. The elastomer cylinders were conditioned prior to each test to soften them. The constants in the viscoclastic-friction constitutive theory are determined by employing a nonlinear least-squares method to fit the analytical stresses for a Maxwell model, which includes friction, to measured relaxation stresses obtained from a 20% step-strain compression test. The simulation of the relaxation data with the nonlinear model is successful at compressive strains of 5%, 10%, 15%, and 20%. Simulations of hysteresis stresses for enforced cyclic compressive strains of 20% +/- 5% are made with the model calibrated by the relaxation data. The predicted hysteresis stresses are lower than the measured stresses.

Johnson, A.R.↗
DOE OSTI2016

Mechanical and electrical properties of low temperature phase MnBi

Low temperature phase (LTP) manganese bismuth (MnBi) is a promising rare-earth-free permanent magnet material due to its high intrinsic coercivity and large positive temperature coefficient. While scientists are making progress on fabricating bulk MnBi magnets, engineers have begun considering MnBi magnets for motor applications. Physical properties other than magnetic ones could significantly affect motor design. Here, we report results of our investigation on the mechanical and electrical properties of bulk LTP MnBi and their temperature dependence. A MnBi ingot was prepared using an arc melting technique and subsequently underwent grinding, sieving, heat treatment, and cryomilling. The resultant powders with a particle size of ∼5 μm were magnetically aligned, cold pressed, and sintered at a predefined temperature. Micro-hardness testing was performed on a part of original ingot and we found that the hardness of MnBi was 109 ± 15 HV. The sintered magnets were subjected to compressive testing at different temperatures and it was observed that a sintered MnBi magnet fractured when the compressive stress exceeded 193 MPa at room temperature. Impedance spectra were obtained using electrochemical impedance spectroscopy at various temperatures and we found that the electrical resistance of MnBi at room temperature was about 6.85 μΩ m.

Jiang, Xiujuan↗
DOE OSTI2015

Microstructure and micro-texture evolution during large strain deformation of Inconel alloy IN718

The hot deformation behaviour of Inconel alloy IN718 was studied in the temperature range of 950–1100 °C and at strain rates of 0.01 and 1 s{sup −1} with a view to understand the microstructural evolution as a function of strain rate and temperature. For this purpose, a single hit, hot isothermal plane strain compression (PSC) technique was used. The flow curves obtained during PSC exhibited weak flow softening at higher temperatures. Electron backscattered diffraction analysis (EBSD) of the PSC tested samples at the location of maximum strain revealed dynamic recrystallisation occurring at higher temperatures. Based on detailed microstructure and microtexture analyses, it was concluded that single step, large strain deformation has a distinct advantage in the thermo-mechanical processing of Inconel alloy IN718. - Highlights: • Plane strain compression (PSC) on IN718 was conducted. • Evolution of microstructure during large strain deformation was studied. • Flow curves exhibited weak softening at higher temperatures and dipping of the flow curve at a strain rate of 1 s{sup −1}. • Optimization of microstructure and process parameter for hot rolling possible by plane strain compression testing • Dynamic recrystallisation occurs in specimens deformed at higher temperatures and lower strain rates.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Tensile and compressive plastic deformation behavior of medium-entropy Cr-Co-Ni single crystals from cryogenic to elevated temperatures

The equiatomic Cr-Co-Ni medium-entropy alloy has the face-centered cubic (FCC) structure. Bulk single crystals of this alloy were grown and tested in tension and compression between 14 K and 1373 K with the loading axis parallel to [23]. At room temperature, the critical resolved shear stress (CRSS) for {111}<10> slip is 65 ± 5 MPa and does not exhibit a tension-compression asymmetry. It does, however, increase significantly as the test temperature decreases. A dulling of this temperature dependence occurs below 50 K, which may be due to the inertia effect. When the measured values above 50 K are extrapolated to lower temperatures, a value of 225 MPa is estimated for the CRSS at 0 K. This is larger than that (168 MPa) previously determined for the equiatomic Cr-Mn-Fe-Co-Ni high-entropy alloy using a similar procedure. The stacking fault energy of the present Cr-Co-Ni is estimated to be about 14 mJm-2, which is sufficiently low to account for deformation twinning both at 77 K and room temperature. Twinning at 77 K occurs on conjugate (1) planes at an onset shear stress of 482 MPa after primary slip and propagates in the form of Lüders deformation. At room temperature, twinning occurs uniformly throughout the gauge section on primary (111) planes at an onset shear stress of 381 MPa after primary and subsequent conjugate slip. Thin layers with the hexagonal close-packed stacking are observed in association with twinning both at 77 K and room temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2021

LA-R43S6-L1 Postshot Report [Slides]

The Ranchero LA-R43S6-L1 test (formerly referred to as LA-43S-L1. The R specifically designates it is a Ranchero device and the 6 indicates a 6” high explosive charge diameter in anticipation of using larger diameters in the future.) was conducted on 3/8/17 with good success. The experiment was the first test of a “Swooped” Ranchero flux compression generator (FCG), and the load for the test was an aluminum imploding liner. In addition to the swoop, the stator was anodized to provide an insulating layer instead of one or more layers of polyethylene as had been the case for all earlier Ranchero tests. Using the Firing point TA-39-88 capacitor bank, 3.5 MA was delivered to the FCG for the initial magnetic field, and 36.4 MA were delivered to the load having an initial inductance of 2.5 nH. Implosion speeds over 1.1 cm/us were recorded, which exceeds previous LANL solid liner experimental results. The test was diagnosed with 18 PDV channels, 12 of which recorded liner implosion data, and the other 6 of which tracked the FCG armature during flux compression. These armature expansion data recorded during flux compression are the first of their kind, and it was previously unknown, due to unknown effects of the SF 6 in the flux compression volume, whether or not the expansion could be recorded using the PDV technique. Post shot 2D MHD calculations employed a complete external circuit model, and an improved flux diffusion model not available prior to the test. Results from these simulations show very good agreement with the experimental result. Four PDV channels recorded the liner implosion viewed radially outward from the center of the liner. All four of these probes recorded implosion velocities greater that 1 cm/µs, with the cylindrical center displaced by ~2 mm from actual center. Four PDV channels looked at +10° angles from the CMU wall, and four looked at -10° angles. A glide plane interaction is shown moving toward the center of the liner in MHD calculations, and PDV probes provide confirmation. The high explosive (HE) in the LA-R43S6-L1 test was PBX 9501 which had to be glued together in many pieces, and the test was preceded by a camera test to verify that the PBX 9501 could be assembled with acceptable tolerance in glue joints to prevent severing the armature during expansion. The camera test verified an acceptable armature performance, and results are given in complete detail in a post shot report LA-UR-19-20124, and summarized here. This report provides complete detail of the considerable body of data obtained on the test and in the post shot calculations. It is prepared in Power Point for ease of preparation and future review. Shot documentation available in the LANL on-line library are included as references, and non-referenceable documents will be cited and stored in an LA- R43S6-L1 post shot folder stored on an M-6 shared drive. Fabrication drawings are also maintained in an M-6 shared drive and paper files are available from M-6 personnel. This report will be maintained as a PowerPoint document on the shared drive, as well, since included movies will play and graphs from Excel files retain information in the PowerPoint versions. PDF versions are required for clearance and are not to large to send by e-mail.

42 ENGINEERING↗
NASA NTRS1975

Effects of selected design variables on three ramp, external compression inlet performance

Two inlet performance tests and one inlet/airframe drag test were conducted in 1969 at the NASA-Ames Research Center. The basic inlet system was two-dimensional, three ramp (overhead), external compression, with variable capture area. The data from these tests were analyzed to show the effects of selected design variables on the performance of this type of inlet system. The inlet design variables investigated include inlet bleed, bypass, operating mass flow ratio, inlet geometry, and variable capture area.

Kamman, J. H.↗
DOE OSTI2021

Shock-ramp analysis test problem

Quasi-isentropic (ramp) compression is now a well-established experimental method and so are the analysis techniques to give Lagrangian sound speed, pressure, and density along the sample material's isentrope. A shock followed by ramp compression is a natural extension to investigate, for example, shock melt and refreeze on compression, or isentropes of states off the Hugoniot or principal isentrope. In practice, graded-density impactors produce initial shocks, compression by shaped laser pulses may be unable to produce a smooth pressure increase from zero, and incidental perturbations on the drive pulse may also give rise to shocks, so robust shock-ramp analysis methods will be needed. Appropriate analysis methods are needed for shock-ramp experiments, based on those for quasi-isentropic compression, and these require validation. This paper describes three different analyses of a shock-ramp test problem, including an assessment of their estimated errors. The methods tested were based on hydrodynamic characteristics or integration backward in space. All methods gave the known Lagrangian sound speed to within ~1%, and pressure and volume to within less than 2% and 1%, demonstrating that the analysis methods of isentropic compression experiments can be confidently extended to the analysis of shock and ramp compression.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Quasi-static and Dynamic Compression of Aluminum Foam at Different Temperatures

This paper focused on the quasi-static (strain rate of ~ 10{sup −3} s{sup −1}) and dynamic compression (strain rate of ~ 10{sup 2} s{sup −1}) behavior of closed-cell AlSi alloy foam at 25, 300, 420 and 560 °C. Quasi-static and dynamic stress–strain relations as well as deformation modes of the foam at different test temperatures were investigated. The results showed that as the test temperature increased, the compressive strength decreased both under quasi-static and dynamic loading. Compressive strength of the foam showed strong strain-rate sensitivity, exhibiting a maximum increase from 20.60 MPa at ~ 10{sup −3} s{sup −1} to 37.27 MPa at ~ 500 s{sup −1} at 25 °C, from 2.99 MPa at ~ 10{sup −3} s{sup −1} to 10.49 MPa at ~ 500 s{sup −1} at 560 °C. At similar strain rate of ~ 500 s{sup −1} as an example, DIF (dynamic increase factor) showed a maximum increase from 1.81 at 25 °C to 3.50 at 560 °C, indicating that the strain-rate sensitivity of compressive strength increased with increase in temperature. Deformation modes of the foam under quasi-static compression revealed a variation from brittle to ductile as temperature increased, cell wall/edges showed brittle fracture at 25 and 300 °C and a combination of brittle fracture and plastic bending at 420 and 560 °C. The foam under dynamic compression showed evident wedge-shaped shear failure at all the temperatures tested.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Buckling Testing of a Subscale Composite Cylinder

A subscale solid laminate composite cylinder with a 31.5-in. diameter, a 48.2-in. length, and a [23/0/-23]4S layup was designated NDL-1 and was designed to fail in buckling after a series of subcritical tests. NDL-1 was experimentally loaded in axial compression until buckling at 466.3 kips. Visual inspection of the test article after the test revealed that a shallow area of delamination occurred near the buckling initiation site. After a successful first buckling test, there was an opportunity to test NDL-1 in axial compression to failure a second time despite that the test article was not designed or analyzed for multiple buckling tests. During the second test to failure, NDL-1 reached a peak load of 390.4 kips, 16.3% lower than the first test. Buckling did not initiate in the same location during the second test to failure as the first test to failure. The second buckling event caused a large V-shaped crack that penetrated through the thickness of the barrel. Though buckling initiated at different locations, a similar radial deformation pattern was present just prior to buckling during the both tests. In the end, NDL-1 maintained a significant amount of its structural integrity and a similar prebuckling radial displacement pattern, even after the first buckling test.

Test↗
NASA NTRS1993

An experimental study of the effects of bodyside compression on forward swept sidewall compression inlets ingesting a turbulent boundary layer

Forward swept sidewall compression inlets have been tested in the Mach 4 Blowdown Facility at the NASA Langley Research Center to study the effects of bodyside compression surfaces on inlet performance in the presence of an incoming turbulent boundary layer. The measurements include mass flow capture and mean surface pressure distributions obtained during simulated combustion pressure increases downstream of the inlet. The kerosene-lampblack surface tracer technique has been used to obtain patterns of the local wall shear stress direction. Inlet performance is evaluated using starting and unstarting characteristics, mass capture, mean surface pressure distributions and permissible back pressure limits. The results indicate that inlet performance can be improved with selected bodyside compression surfaces placed between the inlet sidewalls.

Rodi, Patrick E.↗
NASA NTRS2009

Lossless Astronomical Image Compression and the Effects of Random Noise

In this paper we compare a variety of modern image compression methods on a large sample of astronomical images. We begin by demonstrating from first principles how the amount of noise in the image pixel values sets a theoretical upper limit on the lossless compression ratio of the image. We derive simple procedures for measuring the amount of noise in an image and for quantitatively predicting how much compression will be possible. We then compare the traditional technique of using the GZIP utility to externally compress the image, with a newer technique of dividing the image into tiles, and then compressing and storing each tile in a FITS binary table structure. This tiled-image compression technique offers a choice of other compression algorithms besides GZIP, some of which are much better suited to compressing astronomical images. Our tests on a large sample of images show that the Rice algorithm provides the best combination of speed and compression efficiency. In particular, Rice typically produces 1.5 times greater compression and provides much faster compression speed than GZIP. Floating point images generally contain too much noise to be effectively compressed with any lossless algorithm. We have developed a compression technique which discards some of the useless noise bits by quantizing the pixel values as scaled integers. The integer images can then be compressed by a factor of 4 or more. Our image compression and uncompression utilities (called fpack and funpack) that were used in this study are publicly available from the HEASARC web site.Users may run these stand-alone programs to compress and uncompress their own images.

Pence, William↗