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At least 1,117 records · Page 62
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Fitness-for-Service Analysis of Reactor Components under Flexible Load-Following Operating Conditions

Conventional power-generation plants, including nuclear plants, have been traditionally designed to provide a steady baseload energy capacity, optimizing output efficiency while minimizing variable costs. However, the growing adoption of large-scale renewable energy-generation systems, which rely on intermittent sources such as solar and wind, has introduced more variability into the energy supply in interconnected electricity grids. As a result, the next generation of power plants needs to operate in what is known as the load-following mode, requiring flexible adjustments in electricity production to align with the energy demand on the grid. This transition from the steady baseload operation to load-following operating conditions can significantly increase the number of times various plant components are exposed to transient stresses. This increased thermo-mechanical cycling can lead to accelerated material degradation, thereby elevating the risk of premature failure of a component. It becomes imperative to conduct a comprehensive analysis of fatigue, creep-fatigue, and stress corrosion cracking life, to assess the resilience of the various engineering components under these flexible load-following operating conditions. This study aims to develop a comprehensive numerical model of a light-water reactor pressure vessel (RPV) to investigate its degradation under various operating scenarios. This coupled thermo-mechanical finite element analysis evaluated the stress response of the RPV caused by considering fluctuations in thermal and mechanical loads caused by the varying pressure and temperature occurring during the load-following operation. Critical locations on the RPV are subsequently identified based on the stress response. The stress intensity factors for the postulated flaws at those locations are then calculated, followed by an evaluation of the reactor's life in accordance with the ASME Boiler and Pressure Vessel Code Section XI. This comprehensive life assessment covers a number of transients expected during the flexible load-following operation, providing invaluable insights into the RPV's structural integrity. Moreover, the development methodology can be adapted to other reactor components, as well as components of conventional power stations that are affected by varying operating conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Evaluations of Connectors, Inlets, and Adapters on Side-Load and Withstand Force

This report examines the mechanical forces that direct current fast charging (DCFC) electric vehicle supply equipment (EVSE) connectors and electric vehicle (EV) inlet ports experience during normal usage. As we witness the fast and growing variety of EVs, charge port locations, and bigger and more powerful EVSE configurations including the SAE J3400 North American Charging Standard (NACS), which has increased the use of adapters with J3400 and J1772 compatibility. These new conditions contribute to increased mechanical forces due to their size, weight and lever arm effect, which creates the need to study and compare these forces to the limits on UL2251 and IEC 62196-1 standards. This report focuses solely on high power DC charging EVSE connectors, EV inlets and adapters for the specific compatibility cases on J3400 with J1772. We first describe the details of the 100N and the 750N side-load evaluations as described in the standards, then present the data obtained by replicating these tests to finally go into more detail on the findings and our recommendations.

100N↗
NASA NTRS2023

Shock- and Corrosion-Resistant Bearings for Space Mechanisms

Nickel-titanium (NiTi) alloys are an emerging class of materials for rolling element bearing applications that require superior corrosion resistance and/or high load capability. Certain space mechanisms fall into one or both of those categories. Often, due to size and mass considerations, space mechanism systems are limited in torque margin and necessarily require small, precision-instrument bearings with very little frictional drag (i.e., low torque). In addition, space mechanism bearings must survive launch conditions without suffering raceway dents known as brinnelling, which would increase operating torque and reduce overall smoothness. Consequently, a bearing material or design that reduces or eliminates brinnelling under high contact stress conditions would represent a beneficial technology advancement. One specific alloy, nickel-titanium-hafnium (NiTi-Hf), under development for several years at the NASA Glenn Research Center as a bearing material, has the potential to mitigate concerns about brinnelling under extreme load conditions due to its unusually high elastic strain capability. In the present work, a sample of small precision bearings produced with three different ball materials (steel, ceramic, and NiTi-Hf) is subjected to a range of load conditions sufficient to dent the races. The dent depth as a function of load is compared and demonstrates that NiTi-Hf has the potential to increase bearing load capacity from the perspective of brinnelling under severe load conditions; additional testing of full NiTi-Hf bearings demonstrates corrosion resistance superior to that of 440C bearings.

Bearings↗
NASA NTRS2002

Analyses of Failure Mechanisms and Residual Stresses in Graphite/Polyimide Composites Subjected to Shear Dominated Biaxial Loads

This research contributes to the understanding of macro- and micro-failure mechanisms in woven fabric polyimide matrix composites based on medium and high modulus graphite fibers tested under biaxial, shear dominated stress conditions over a temperature range of -50 C to 315 C. The goal of this research is also to provide a testing methodology for determining residual stress distributions in unidirectional, cross/ply and fabric graphite/polyimide composites using the concept of embedded metallic inclusions and X-ray diffraction (XRD) measurements.

Kumosa, M.↗
DOE OSTI2022

High-fidelity micromechanical modeling of the effects of defects on damage and creep behavior in single tow ceramic matrix composite

Despite the superior properties of ceramic matrix composites (CMCs), their fabrication process generates inevitable defects with high density that significantly influence material integrity and residual useful life. Recent efforts have focused on CMC property prediction and investigation of their different inelastic mechanisms, but very limited work exists on understanding the influence of defects on inelastic responses of CMCs. Here, we introduce a three-dimensional micromechanics computational framework that includes experimentally informed material microstructure and architectural variabilities to investigate CMC response in the presence of manufacturing-induced defects. A developed microstructure generation algorithm is used to generate the representative volume elements in the micromechanics models from complex material morphology information obtained from extensive characterization studies of C/SiNC and SiC/SiNC CMCs. A fracture mechanics-informed matrix damage model is reformulated, in which the model considers the growth of porosity and microcracks in the as-received material. A progressive fiber damage model as well as Orthotropic viscoplasticity creep formulation are also utilized for the study. This methodology is implemented within the micromechanics framework to investigate the complex temperature- and time-dependent load transfer and damage mechanisms of CMCs under operation loading conditions. The developed framework explores the influence of as-received defects on the damage and creep behavior in service conditions. It also provides new insights into the effect of size, shape, distribution, and location of these defects on material response. The framework is then calibrated with unidirectional CMC minicomposite results available in the literature.

36 MATERIALS SCIENCE↗
NASA NTRS1997

Space flight and the skeleton: lessons for the earthbound

Loss of bone during extended space flight has long been a concern that could limit the ability of humans to explore the universe. Surprisingly, the available data do not support the concept that weightlessness leads inexorably to a depleted skeleton unable to withstand the stress of a return to a 1-g environment. Nevertheless, some bone loss does occur, especially in those bones most stressed by gravity prior to flight, which provides confirmation of the proposal formulated over a century ago by Julius Wolff that mechanical stress determines the form and function of bone. Although the phenomenon of bone loss with skeletal unloading, whether by space flight or immobilization or just taking a load off your feet (literally) is well established, the mechanisms by which bone senses load and adjusts to it are not so clear. What actually is the stimulus, and what are the sensors? What are the target cells? How do the sensors communicate the message into the cells, and by what pathways do the cells respond? What is the role of endocrine, factors vs. paracrine or autocrine factors in mediating or modulating the response? None of these questions has been answered with certainty, but, as will become apparent in this review, we have some clues directing us to the answers. Although the focus of this review concerns space flight, it seems highly likely that the mechanisms mediating the transmission of mechanical load to changes in bone formation and resorption apply equally well to all forms of disuse osteoporosis and are likely to be the same mechanisms affected by other etiologies of osteoporosis.

unmanned↗
NASA NTRS1997

Spaceflight and the skeleton: lessons for the earthbound

Loss of bone during extended space flight has long been a concern that could limit the ability of humans to explore the universe. Surprisingly the available data do not support the concept that weightlessness leads inexorably to a depleted skeleton unable to withstand the stress of a return to a 1g environment. Nevertheless, some bone loss does occur especially in those bones most stressed by gravity prior to flight, providing confirmation of the proposal formulated over a century ago by Julius Wolff that mechanical stress determines the form and function of bone. Although the phenomenon of bone loss with skeletal unloading, whether by space flight or immobilization or just taking a load off your feet (literally) is well established, the mechanisms by which bone senses load and adjusts to it are not so clear. What actually is the stimulus and what are the sensors? What are the target cells? How do the sensors communicate the message into the cells, and by what pathways do the cells respond? What is the role of endocrine factors versus paracrine or autocrine factors in mediating or modulating the response? None of these questions has been answered with certainty, but as will become apparent in this review, we have some clues directing us to the answers. Although the focus of this review concerns space flight, it seems highly likely that the mechanisms mediating the transmission of mechanical load to changes in bone formation and resorption apply equally well to all forms of disuse osteoporosis, and are likely to be the same mechanisms affected by other etiologies of osteoporosis.

NASA Discipline Musculoskeletal↗
NASA NTRSDate not supplied

The Effect of Fiber-Angle Fidelity on the Linear Response of Tow-steered Composite Plates

Composite laminate tailoring is traditionally performed by uniformly changing the in-plane ply orientation to obtain the desired mechanical performance. The emergence of tow-steered plies, where the fibers follow a prescribed curvilinear path, have increased the tailorability of composite laminates. However, characterizing the behavior of tow-steered laminates using finite element analysis is challenging because additional, and often numerous, orientation definitions may be required. The additional orientation definitions detrimentally increase the computational cost and hinder the use of advanced analysis techniques, such as Monte Carlo or uncertainty quantification, in the design process. To reduce computational cost without adversely affecting mechanics-based performance, the results of a parametric study that was used to investigate the effects of fiber-angle fidelity, element size, and tow-steered radius-of-curvature on various loading scenarios for tow-steered composite plates are presented. The three loading scenarios that were analyzed using finite element analysis included an axial tension load, an applied constant through-thickness-direction pressure load, and an axial compression load. Results for mechanics-based metrics of interest are presented and discussed for each loading scenario. Little sensitivity (less than one percent difference) to the effect of fiber-angle fidelity is observed in the mechanics-based metrics until the coarse-end of the considered range. Sensitivity to element size generally dominates the observed results for the mechanics-based metrics. Notable reductions in the preprocessing time are observed for increasingly coarse element size and fiber-rounding parameters. The preprocessing times decreased up to three orders of magnitude from a few thousand seconds to a few seconds without loss of accuracy in the mechanics-based metrics. Such increased computational performance is of particular interest to the structural design and analysis communities that may be conducting large counts of finite-element analyses, such as in other parametric studies, Monte-Carlo analyses, uncertainty quantification, or tow-steered optimization.

tow-steered composites↗
DOE OSTI2024

Bayesian blacksmithing: discovering thermomechanical properties and deformation mechanisms in high-entropy refractory alloys

Finding alloys with specific design properties is challenging due to the large number of possible compositions and the complex interactions between elements. This study introduces a multi-objective Bayesian optimization approach guiding molecular dynamics simulations for discovering high-performance refractory alloys with both targeted intrinsic static thermomechanical properties and also deformation mechanisms occurring during dynamic loading. The objective functions are aiming for excellent thermomechanical stability via a high bulk modulus, a low thermal expansion, a high heat capacity, and for a resilient deformation mechanism maximizing the retention of the BCC phase after shock loading. Contrasting two optimization procedures, we show that the Pareto-optimal solutions are confined to a small performance space when the property objectives display a cooperative relationship. Conversely, the Pareto front is much broader in the performance space when these properties have antagonistic relationships. Density functional theory simulations validate these findings and unveil underlying atomic-bond changes driving property improvements.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Effects of state recovery on creep buckling under variable loading

Structural alloys embody internal mechanisms that allow recovery of state with varying stress and elevated temperature, i.e., they can return to a softer state following periods of hardening. Such material behavior is known to strongly influence structural response under some important thermomechanical loadings, for example, that involving thermal ratchetting. The influence of dynamic and thermal recovery on the creep buckling of a column under variable loading is investigated. The column is taken as the idealized (Shanley) sandwich column. The constitutive model, unlike the commonly employed Norton creep model, incorporates a representation of both dynamic and thermal (state) recovery. The material parameters of the constitutive model are chosen to characterize Narloy Z, a representative copper alloy used in thrust nozzle liners of reusable rocket engines. Variable loading histories include rapid cyclic unloading/reloading sequences and intermittent reductions of load for extended periods of time; these are superimposed on a constant load. The calculated results show that state recovery significantly affects creep buckling under variable loading.

Robinson, D. N.↗
NASA NTRS1990

Effects of state recovery on creep buckling under variable loading

Structural alloys embody internal mechanisms that allow recovery of state with varying stress and elevated temperature, i.e., they can return to a softer state following periods of hardening. Such material behavior is known to strongly influence structural response under some important thermomechanical loadings, for example, that involving thermal ratchetting. The influence of dynamic and thermal recovery on the creep buckling of a column under variable loading is investigated. The column is taken as the idealized (Shanley) sandwich column. The constitutive model, unlike the commonly employed Norton creep model, incorporates a representation of both dynamic and thermal (state) recovery. The material parameters of the constitutive model are chosen to characterize Narloy Z, a representative copper alloy used in thrust nozzle liners of reusable rocket engines. Variable loading histories include rapid cyclic unloading/reloading sequences and intermittent reductions of load for extended periods of time; these are superimposed on a constant load. The calculated results show that state recovery significantly affects creep buckling under variable loading.

Robinson, D. N.↗
NASA NTRS1986

Case histories involving fatigue and fracture mechanics; Proceedings of the Symposium, Charleston, SC, Mar. 21, 22, 1985

Papers are presented on cracking at nozzle corners in the nuclear pressure vessel industry, applied fracture mechanics for assessing defect significance in a crude oil pipeline, failure analysis of a large wind-tunnel compressor blade, analysis of a compressor-wheel failure, and preventing fracture by inspection and analysis. Consideration is also given to the fatigue crack growth predictions of welded aircraft structures containing flaws in the residual stress field, the fatigue and fracture mechanics analysis of a compression loaded aircraft structure, fracture of an aircraft horizontal stabilizer, fatigue life analysis of fuel tank skins under combined loads, and aircraft structural maintenance recommendations based on fracture mechanics analysis. Additional papers discuss an analysis of two metal-forming die failures, an analysis of a failed saw arbor, and the role of fracture mechanics in assessing the effect on fatigue life of design changes in welded fabrications.

Hudson, C. Michael↗
NASA NTRSDate not supplied

Methodology and Development of SLS Ascent Loads

The methodology and development of the Space Launch System (SLS) Block 1 Boost and Core phase Ascent loads will be presented in this paper. As is common practice, a series of fixed time/mass Finite Element Models of the vehicle were developed for the purpose of evaluating the structural loads and accelerations for particular Mach or time ranges associated with the Boost and Core phases of flight. Load contributors, which vary between bins, include the flight mechanic induced portion of the loads (e.g., Static-Elastic (STEL) or Vehicle Load Indicator (VLI) tool results), gust loads, buffet loads, Solid Rocket Booster thrust oscillations, Core Stage Engine thrust oscillations, maneuvering loads, thrust vector-related dispersions, and Programmed Test Input induced loads. Each of these load contributors will be examined in this paper, as well as the Loads Combination Equations used to generate the final loads. In addition to the typical coupled loads analysis, an Ascent loads evaluation is included in the SLS Artemis 1 Day of Launch process; a summary of this evaluation will also be presented in this paper.

SLS↗
DOE OSTI2022

Influence of weave architecture on mechanical response of SiC f -SiC m tubular composites

Due to their high resistance to radiation damage and elevated temperature, silicon carbide fiber-reinforced, silicon carbide matrix composites (SiC f -SiC m ) are identified as potential cladding structures for use in nuclear reactors. In this study, four composite architectures with varying ply numbers along the thickness direction and different biaxial or triaxial plain weave orientations at either 45° or 60°, were systematically evaluated under various stress states to assess the influence of weave architecture on mechanical performance. Experiments were conducted on SiC f -SiC m composite tubes under tensile hoop, axial compression, and rotating flexural loading to evaluate the mechanical response and investigate the failure modes using high-speed imaging and digital image correlation (DIC) techniques. It was found that for tensile hoop burst and flexural loading, the braiding angle had the most significant influence on the strength of the composite, whereas the effect of fiber angle was more limited for compression testing. Under axial compression a unique failure mode where a microcrack nucleates and grows only to a length equal to the thickness of a single yarn was identified. This crack growth behavior is reflected as periodic oscillations in the load-displacement response. For both axial and hoop loading, regardless of weave angle and number of plies, failure always initiated parallel to the tube axis in a single yarn and the cumulative interaction of these microcracks lead to either axial burst or fracture at an angle to the tube axis along a yarn. Furthermore, these results point to the importance of customizing the design of tube architecture for enhanced performance in specified nuclear applications.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Mechanoregulation of Proliferation, Differentiation, Senescence and Survival of Bone Marrow Primary Osteoprecursor Cells

Cell and animal studies conducted onboard the International Space Station and during the Shuttle program have provided extensive data illustrating bone degenerative responses to mechanical unloading in microgravity. Specifically CDKN1a/p21, an inhibitory modulator of cell cycle progression, is upregulated in osteoprecursor cells of the femur during 15-day spaceflight, suggesting that microgravity can block stem cell-based tissue regenerative process at the level of progenitor proliferation and differentiation. To study a potential role for CDKN1a/p21 in regulating osteogenic mechanosensitivity, we cultured primary bone marrow osteoprogenitor cells from CDKN1a/p21-null (p21-null) and wildtype mice with and without mechanical stimulation, and compared their morphological, proliferative, and in-vitro mineralization responses. Structural cell alterations due to mechanical stimulation were assessed by florescence labeling of f-actin cytoskeleton and focal adhesions. Mechanical stimulation of p21-null cells resulted in more pronounced cytoskeletal alignment with the axis of stretch than for wildtype cells. In addition, p21-null cells subjected to stretch loading also formed significantly more focal adhesions than wildtype cells. Combined these findings suggest that p21-null cells are structurally more responsive to stretch stimulation than the wildtype cells. Because osteoprogenitor cells are well known to respond to mechanical stimulation with increased proliferation, we also tested this response in p21-null cells. Results from those experiments show the proliferative capacity of mechanically stimulated p21-null cells far exceeded that of wildtype controls. Specifically, cell counts from 14, and 21 days post mechanical stimulation, show that p21- null cells to have a 4-fold increase in proliferation compared to wildtype. When the p21-null cell differentiation response to mechanical stimulation was evaluated, the p21-null cultuers elicited more extensive mineralization at earlier assessed timepoints than control cultures. Specifically, Von Kossa staining for mineralized matrix showed that the p21-null cells produced more than twice the mineralized surface area of wildtype cells, and at an earlier 7-day time point in culture. Taken together these results suggest that CDKN1a/p21 normally plays a role in negatively regulating osteoprogenitor proliferation and differentiation responses to mechanostimulation in bone. Findings of CDKN1a/p21's increased expression during spaceflight in microgravity also suggest not only a potential molecular mechanism for arresting regenerative bone growth in space, but potentially also a reduced impact for bone-formation-promoting exercise mechanostimulation. The findings described here constitute a novel role for p21 as a regulator of tissue regeneration in response to mechanical load stimulation, and also suggest a new promising molecular target to promote regenerative health in disuse conditions.

gravity↗
DOE OSTI2024

Agrivoltaic Racking Design Optimization Based on Wind and Snow Loading Finite Element Analysis

The racking structure of photovoltaic (PV) systems plays a critical role in ensuring the PV panels generate power properly as it provides integral structural support and sometimes even solar tracking ability. Distinct applications of PV systems require variations of racking structure designs, which yield different mechanical performances under external loading conditions from the environment, such as heavy wind and snow. Past works, such as Reddy et al. [1], have analyzed the pressure effects of wind and snow loading on the racking structure of conventional rooftop and utility PV systems, but there is little knowledge of how various agrivoltaic racking systems perform, in terms of stress and strain, under the same loading conditions. There is also a knowledge gap in the industry on a set of optimized agrivoltaic racking design standards. This study investigates the mechanical performance of various existing racking systems and proposes novel designs that are optimized for agrivoltaics applications under wind and snow loading.

Liao, Quanhuan↗