Inspection for Damage to Carbon/Epoxy Composite Overwrapped Pressure Vessels
Objective: To train aerospace flight hardware visual inspectors detect visible damage to the composite shell of Graphite/Epoxy COPVs.
Yoder, Tommy B.↗
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Research and Development of Automated Eddy Current Testing for Composite Overwrapped Pressure Vessels
Eddy current testing (ET) was used to scan bare metallic liners used in the fabrication of composite overwrapped pressure vessels (COPVs) for flaws which could result in premature failure of the vessel. The main goal of the project was to make improvements in the areas of scan signal to noise ratio, sensitivity of flaw detection, and estimation of flaw dimensions. Scan settings were optimized resulting in an increased signal to noise ratio. Previously undiscovered flaw indications were observed and investigated. Threshold criteria were determined for the system software's flaw report and estimation of flaw dimensions were brought to an acceptable level of accuracy. Computer algorithms were written to import data for filtering and a numerical derivative filtering algorithm was evaluated.
Carver, Kyle L.↗
NDT and SHM of Carbon Fiber Composites using Linear Drive MWM-Arrays
Carbon fiber composites are used in a wide range of structural applications due to their excellent specific strength and stiffness. However, the anisotropic mechanical and electrical properties associated with the fibers within each composite layer present challenges, and opportunities, for Nondestructive Testing (NDT) methods used to characterize and assess the structure condition. This includes composite condition after manufacture (such as fiber orientation and density, porosity, delamination, and bond strength) and during usage (such as damage from impact, fiber breakage, thermal exposure or applied stress). Ultrasonic and thermographic methods can address some of these challenges, but eddy current methods provide an alternative method for composite structures that contain a conducting material, such as carbon fibers or a metallic liner. This presentation reviews recent advances in the development of eddy current sensors and arrays for carbon fiber composite NDT and Structural Health Monitoring (SHM) applications. The focus is on eddy current sensor constructs with linear drive windings, such as MWM -Arrays, that induce currents primarily within the linear fibers of the composite. By combining this type of sensor construct with micromechanical models that relate composite constituent properties to measurable sensor responses, insight is obtained into the volumetric distribution of electrical properties within the composite and the associated manufacturing, damage, or strain conditions. With knowledge of the fiber layup, this MWM-Array technology is able to detect damage and strain/stress as a function of depth and fiber orientation. This work has been funded by NASA, NA V AIR and the Army for applications ranging from composite overwrapped pressure vessels (COPVs) to aircraft structures and rotorcraft blades. This presentation will specifically present background on the MWM-Array technology, results from the micromechanical modeling effort, and results from ongoing efforts for high resolution imaging and volumetric strain sensing.
Washabaugh, Andrew↗
Regolith Volatile Characterization (RVC) in RESOLVE
Resource investigation in the lunar poles is of importance to the potential impact of in-situ resource utilization (ISRU). The RESOLVE project developed a payload to investigate the permanently shadowed areas of the lunar poles and demonstrate ISRU technology. As a part of the RESOLVE project, the regolith volatile characterization (RVC) subsystem was designed to examine the release of volatiles from sample cores. The test sample was heated in the reactor to release the volatiles where they were analyzed with gas chromatography. Subsequently, the volatile sample was introduced into the lunar water resource demonstration (LWRD) subsystem where the released hydrogen and water were selectively captured. The objective of the Regolith Volatile Characterization (RVC) subsystem was to heat the crushed core sample and determine the desorption of volatile species of interest. The RVC subsystem encompasses the reactor and the system for volatile analysis. The system was designed to analyze H2, He, CO, CO2, N2, 02, CH4, H2S and H2O. The GC chosen for this work is a Siemens MicroSAM process GC with 3 columns and 8 TCD detectors. Neon was chosen as the carrier gas to enhance the analysis of hydrogen and helium.The limit of detection for the gases is approx.1000ppm for H2, CO. CO2 , N2, O2 and H2 S. The limit of detection for CH4 is approx.4000ppm and the water limit of detection is -10000 ppm with a sample analysis time of 2-3 minutes. These values (with the exception of water and H2S) were determined by dilution of a six gas mixture from Scott Gas (5% CO2, CO, O2, N2, 4% CH4 and H2) using mass flow controllers (MFC5). Water was calibrated at low levels using an in house relative humidity (RH) generator. H 2S and high concentrations of H2 were calibrated by diluting a pure stream of gas with MFCs. Higher concentrations of N2 and 02 were calibrated using Air again diluting with MFCs. There were three modification goals for the GC in EBU2 that would allow this process GC to be used in the field demo for RESOLVE. The first modification was to decrease the weight associated with the GC, this included eliminating the explosion proof case (Figure 1) and replacing it with a lightweight case as well as using an on board COPV tank for the neon carrier gas. The next goal was to add a second oven for the molecular sieve column to allow for dual temperature control during GC operation; the separation of hydrogen and helium is optimum at lower temperatures while the water analysis required higher temperatures creating a competing design requirement. The second oven also allows a lower limit of detection for water quantification and avoids the possibility of water condensing in the GC which could ruin the column characteristics. The final goal was to modify the column arrangement to optimize the system for our specific application. Figure 2 shows the internal details of the module optimized optimized for our field application. The modifications and performance of the gas analysis system will be discussed in detail.
Captain, Janine↗
Material Usage in High Pressure Oxygen Systems for the International Space Station
The Nitrogen/Oxygen Recharge System (NORS) for the International Space Station (ISS) Program was required as part of the Space Shuttle retirement efforts to sustain the ISS life support systems. The system is designed around a 7000 psia Oxygen or Nitrogen Recharge Tank Assembly which is able to be utilized both internally and externally to the ISS. Material selection and usage were critical to ensure oxygen compatibility for the design, while taking into consideration toxicity, weldability, brazability and general fabrication and assembly techniques. The system uses unique hardware items such a composite overwrap pressure vessel (COPV), high pressure mechanical gauges, compact regulators and valves, quick disconnects, metal tubing and flexhoses. Numerous challenges and anomalies were encountered due to the exotic nature of this project which will be discussed in detail. The knowledge gained from these anomalies and failure resolutions can be applied to more than space applications, but can also be applicable to industry pressurized systems.
Kravchenko, Michael↗
Structural CNT Composites Part II: Assessment of CNT Yarns as Reinforcement for Composite Overwrapped Pressure Vessels
Carbon nanotubes (CNTs) are one-dimensional nanomaterials with outstanding electrical and thermal conductivities and mechanical properties. This combination of properties offers routes to enable lightweight structural aerospace components. Recent advances in the manufacturing of CNTs have made bulk forms such as yarns, tapes and sheets available in commercial quantities to permit the evaluation of these materials for aerospace use, where the superior tensile properties of CNT composites can be exploited in tension dominated applications such as composite overwrapped pressure vessels (COPVs). To investigate their utility in this application, aluminum rings were overwrapped with thermoset/CNT yarn composite and their mechanical properties measured. CNT composite overwrap characteristics such as processing method, CNT/resin ratio, and applied tension during CNT yarn winding were varied to determine their effects on the mechanical performance of the CNT composite overwrapped Al rings (CCOARs). Mechanical properties of the CCOARs were measured under static and cyclic loads at room, elevated, and cryogenic temperatures to evaluate their mechanical performance relative to bare Al rings. At room temperature, the breaking load of CCOARs with a 10.8% additional weight due to the CNT yarn/thermoset overwrap increased by over 200% compared to the bare Al ring. The quality of the wound CNT composites was also investigated using x-ray computed tomography.
Kim, Jae-Woo↗
Structural CNT Composites: Developing a Carbon Nanotube Filament Winder - Part I
Carbon nanotube (CNT) based materials promise advances in the production of high strength and multifunctional components for aerospace and other applications. Specifically, in tension dominated applications, the latest CNT based filaments are yielding composite properties comparable to or exceeding composites from more established fibers such as Kevlar and carbon fiber. However, for the properties of these materials to be fully realized at the component level, suitable manufacturing processes have to be developed. These materials handle differently from conventional fibers, with different wetting characteristics and behavior under load. The limited availability of bulk forms also requires that the equipment be scaled down accordingly to tailor the process development approach to material availability. Here, the development of hardware and software for filament winding of carbon nanotube based tapes and yarns is described. This hardware features precision guidance of the CNT material and control of the winding tension over a wide range in an open architecture that allows for effective process control and troubleshooting during winding. Use of the filament winder to develop CNT based Composite Overwrapped Pressure Vessels (COPVs) shall also be discussed.
Sauti, Godfrey↗
Some Observations on Damage Tolerance Analyses in Pressure Vessels
AIAA standards S080 and S081 are applicable for certification of metallic pressure vessels (PV) and composite overwrap pressure vessels (COPV), respectively. These standards require damage tolerance analyses with a minimum reliable detectible flaw/crack and demonstration of safe life four times the service life with these cracks at the worst-case location in the PVs and oriented perpendicular to the maximum principal tensile stress. The standards require consideration of semi-elliptical surface cracks in the range of aspect ratios (crack depth a to half of the surface length c, i.e., (a/c) of 0.2 to 1). NASA-STD-5009 provides the minimum reliably detectible standard crack sizes (90/95 probability of detection (POD) for several non-destructive evaluation (NDE) methods (eddy current (ET), penetrant (PT), radiography (RT) and ultrasonic (UT)) for the two limits of the aspect ratio range required by the AIAA standards. This paper tries to answer the questions: can the safe life analysis consider only the life for the crack sizes at the two required limits, or endpoints, of the (a/c) range for the NDE method used or does the analysis need to consider values within that range? What would be an appropriate method to interpolate 90/95 POD crack sizes at intermediate (a/c) values? Several procedures to develop combinations of a and c within the specified range are explored. A simple linear relationship between a and c is chosen to compare the effects of seven different approaches to determine combinations of aj and cj that are between the (a/c) endpoints. Two of the seven are selected for evaluation: Approach I, the simple linear relationship, and a more conservative option, Approach III. For each of these two Approaches, the lives are computed for initial semi-elliptic crack configurations in a plate subjected to remote tensile fatigue loading with an R-ratio of 0.1, for an assumed material evaluated using NASGRO (registered 4) version 8.1. These calculations demonstrate that for this loading, using Approach I and the initial detectable crack sizes at the (a/c) endpoints in 5009 specified for the ET and UT NDE methods, the smallest life is not at the two required limits of the (a/c) range, but rather is at an intermediate configuration in the range (a/c) of 0.4 to 0.6. Similar analyses using both Approach I and III with the initial detectable crack size at the (a/c) endpoints in 5009 for PT NDE showed the smallest life may be at an (a/c) endpoint or an intermediate (a/c), depending upon which Approach is used. As such, analyses that interrogate only the two (a/c) values of 0.2 and 1 may result in unconservative life predictions. The standard practice may need to be revised based on these results.
Raju, Ivatury S.↗
Pressure-Fed LOX/LCH4 Reaction Control System for Spacecraft: Transient Modeling and Thermal Vacuum Hotfire Test Results
An integrated cryogenic liquid oxygen, liquid methane (LOX/LCH4) reaction control system (RCS) was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. The RCS is a subsystem of the Integrated Cryogenic Propulsion Test Article (ICPTA), a pressure-fed LOX/LCH4 propulsion system composed of a single 2,800 lbf main engine, two 28 lbf RCS engines, and two 7 lbf RCS engines. Propellants are stored in four 48 inch diameter 5083 aluminum tanks that feed both the main engine and RCS engines in parallel. Helium stored cryogenically in a composite overwrapped pressure vessel (COPV) flows through a heat exchanger on the main engine before being used to pressurize the propellant tanks to a design operating pressure of 325 psi. The ICPTA is capable of simultaneous main engine and RCS operation. The RCS engines utilize a coil-on-plug (COP) ignition system designed for operation in a vacuum environment, eliminating corona discharge issues associated with a high voltage lead. There are two RCS pods on the ICPTA, with two engines on each pod. One of these two engines is a heritage flight engine from Project Morpheus. Its sea level nozzle was removed and replaced by an 85:1 nozzle machined using Inconel 718, resulting in a maximum thrust of 28 lbf under altitude conditions. The other engine is a scaled down version of the 28 lbf engine, designed to match the core and overall mixture ratios as well as other injector characteristics. This engine can produce a maximum thrust of 7 lbf with an 85:1 nozzle that was additively manufactured using Inconel 718. Both engines are film-cooled and capable of limited duration gas-gas and gas-liquid operation, as well as steady-state liquid-liquid operation. Each pod contains one of each version, such that two engines of the same thrust level can be fired as a couple on opposite pods. The RCS feed system is composed of symmetrical 3/8 inch lines that tap off of the main propellant manifold to send LOX and LCH4 outboard to the RCS pods. A Thermodynamic Vent System (TVS) is used to condition propellants at each pod by venting through an orifice and then routing the cold expansion products back through tubing that is welded along a large portion of the main RCS feed lines. Prior to final installation on the ICPTA, the RCS engines were tested in a small vacuum chamber at the Johnson Space Center (JSC) Energy Systems Test Area (ESTA) to verify functionality of the new COP ignition system and check out operation of the vacuum nozzles. After engine-level testing, the RCS engines were installed on the vehicle and a series of integrated hot-fire tests were performed at JSC consisting of various pulsing and steady-state firings as well as integrated main engine/RCS operation. The ICPTA was then integrated into the Plum Brook B-2 facility for vacuum and thermal/vacuum testing. Testing in the B-2 facility was composed of multiple thermal and pressure environments. The first set of tests were performed under ambient temperature and altitude pressure conditions. These tests consisted of a range of minimum impulse bit (MIB) pulsing sequences with low duty cycle, analogous to a coast phase in which the RCS is primarily used for station keeping. The primary goal of this sequence is to understand how propellant conditions were effected without an active TVS. In this scenario, consistent gas-gas operation is desirable since it results in a smaller MIB and more efficient propellant consumption. Multiple skin thermocouples are mounted on the feedlines, in addition to a submerged thermocouple on each commodity, in order to gather thermal data on the system. Higher duty cycle pulsing tests were then performed, analogous to an ascent or landing mission phase. The primary goal of this sequence was to examine how well the engines self-conditioned without active TVS when starting from a quiescent state. The TVS was then activated during some tests to demonstrate the capability to quickly condition the engines for higher pulsing demand scenarios. A thermocouple at the TVS outlet allows for the calculation of energy absorbed by the vented propellant. Lastly, tests with longer pulses and multiple engines firing either in sequence or simultaneously were run in order to gather transient system response data on waterhammer. Six total high-speed pressure transducers are installed on the RCS system, one sensor at the end of each propellant manifold line on the pods, and one at the tap-off location for each commodity. This will allow for the accurate characterization of waterhammer in the system under various propellant conditions and firing sequences. Other instrumentation for this test series includes nozzle throat thermocouples, chamber pressure measurement, heat soakback measurement, and tank wall plume impingement temperature measurement. The next set of tests were performed to demonstrate simultaneous main engine and RCS operation. Data from this test will be used to examine if there is any change to nominal operation of the RCS as a result of feed system interaction or other phenomenon. Some of these tests began under high vacuum conditions (target ambient pressure less than 1x10(exp -3) torr) and others began at altitude conditions. The last set of tests were performed with the B-2 cold wall active. Under these tests, many of the same low duty cycle MIB tests were repeated in order to characterize how propellant conditions changed with the lower heat leak. In this scenario the RCS manifold experiences much less heat leak, resulting in a change to how well the engines self-condition. As a result, an increase in maximum waterhammer pressures and a change in natural frequency of the system was expected due to higher density propellants. The lower heat leak should also result in a change to the MIB pulse profile, and data will be examined to understand how MIB repeatability is affected in the different operating environments. Parallel to the test efforts, a set of transient model development efforts were made to predict RCS performance. The primary effort was aimed at producing a SINDA/FLUINT model to predict propellant conditioning up to the engine inlet as a function of different environmental and operating parameters, with the goal of predicting chamber pressure, TVS performance, and propellant consumption over time. Preliminary results for this effort will be presented in comparison with test data. Additional modeling efforts were made using SINDA/FLUINT to predict waterhammer in the system since the software is capable of handling multiphase transient fluid dynamics. These results will be compared with the high-speed pressure transducer test data for validation purposes.
Atwell, Matthew J.↗
Nanotechnology
Present an overview of the Nanotechnology Project at NASA's Game Changing Technology Industry Day. Mature and demonstrate flight readiness of CNT reinforced composites for future NASA mission applicationsSounding rocket test in a multiexperiment payloadIntegrate into cold gas thruster system as propellant storageThe technology would provide the means for reduced COPV mass and improved damage tolerance and flight qualify CNT reinforced composites. PROBLEM/NEED BEING ADDRESSED:Reduce weight and enhance the performance and damage tolerance of aerospace structuresGAME-CHANGING SOLUTION:Improve mechanical properties of CNTs to eventually replace CFRP –lighter and strongerFirst flight-testing of a CNT reinforced composite structural component as part of an operational flight systemUNIQUENESS:CNT manufacturing methods developedFlight qualify CNT reinforced composites
Nanotechnology↗
Analysis of a Radioisotope Thermal Rocket Engine
The Triton Hopper is a concept for a global hopper vehicle which uses a radioisotope rocket engine and In-situ propellant acquisition to explore the surface of Neptune's moon, Triton. The current Triton Hopper concept stores heated Nitrogen in a spherical tank to be used as the propellant. The aim of the research was to investigate the benefits of storing propellant at ambient temperature and heating it through the use of a thermal block during engine operation, as opposed to storing gas at a high temperature. Lithium, Lithium Fluoride and Beryllium were considered as possible materials for the thermal block. A heat energy analysis indicated that a lithium thermal mass would provide the highest heat energy for a temperature change from 900 Celsius to -100 Celsius. A heat transfer analysis was performed for Nitrogen at -100 Celsius flowing through 1000 passages inside a 1kg lithium thermal block at a temperature of 900 Celsius. The system was analyzed as turbulent flow through a tube with constant surface temperature. The analysis indicated that the propellant reached a maximum temperature of 877 Celsius before entering the nozzle. At this exit temperature, the average specific impulse [I(sub sp)] of the engine was determined to be 157s. Previous studies for the stored heated gas concept suggest that the engine would have an average I(sub sp) of approximately 52s. Thus, the use of a thermal block concept results in a 200 percent engine performance increase. In addition, a tank sizing study was performed to determine if the concept is feasible in terms of mass requirements. The mass for a spherical carbon fiber COPV storing 35kg of nitrogen at an initial temperature of -100 Celsius and a pressure of 1000psia, was determined to be 7.2kg. The specific impulse analysis indicated that the maximum engine performance is obtained for a mass ratio of 5kg of Nitrogen per every 1kg of lithium thermal mass. Thus for 35kg of Nitrogen the total thermal mass would be 7kg. This brings the total mass of the system to 49.2.kg which is less than the 56kg landing payload capacity of the Triton Hopper. Finally, an insulation analysis using 10mm of MLI insulation indicated that a total of 22 watts of heat are lost to the environment. With the heat loss known, the power required to heat the thermal mass to 900 Celsius in 24 days was determined to be 2.15 watts. The study's results allowed us to conclude that the thermal mass concept is the better option due to the performance increase provided, the low power requirement and its compliance with the landing mass requirement of the Triton Hopper.
Radioisotope↗
Demisability of GFRP and CFRP Components of Reentering Orbital Debris: Phase I Test Results
Observations of surviving reentry debris on the ground and research performed by Hyperschall Technologie Göttingen (HTG) [1] indicated that significantly more glass fiber-reinforced polymer (GFRP) and carbon fiber-reinforced polymer (CFRP) components survive reentry than current models predict. NASA’s Orbital Debris Program Office conducted a series of tests to evaluate the accuracy of material demise models for reentering orbital debris used in NASA’s Object Reentry Survival Analysis Tool (ORSAT) and Debris Assessment Software (DAS). Testing is planned in a multi-phase series to allow for quick quantification of results as well as refinement of methods resulting from lessons learned during early phases. The Phase 1 tests discussed here validated ORSAT models for homogeneous metals, provided an efficient quantification of composite material demisability properties like mass loss rate and overall time to demise, and identified potential failure modes, which are currently not well understood. Phase 2 tests will be used to further understand mass loss rates and modes of both thermal and mechanical failure in composite materials. The authors exposed 95 samples of aluminum, CFRP, Kevlar fiber-reinforced polymer, GFRP, and sheets of G10 fiberglass to conditions approximating the reentry environment using an inductively coupled plasma (ICP) torch facility. The cylindrical CFRP samples were exposed to the atmospheric pressure plasma, at both the end and the midpoint, to investigate the difference in demisability between parts with exposed edges, like panels, and parts with no edges, such as carbonoverwrapped pressure vessels (COPVs). In a non-oxidative environment, no composite materials demised within the 5-minute test time. In the oxidative, elevated heat flux environment, CFRP samples demised between 210 s and 270 s. For the first 100 s of insertion time, most of the mass loss was due to pyrolysis of resin, creating an approximately bi-linear mass-loss rate curve with time. In a non-oxidative environment, carbon filaments were observed to unravel from some of the CFRP end-burned samples; however, this effect did not seem to affect the overall time to demise for the samples significantly. These results indicate that both GFRP and CFRP components survive reentry with significantly more remaining mass than current models predict.
Greene, Benton R.↗
Composite Technologies for Science Missions
ASTROLAB, Lunar Geophysical Network, Mars Icebreaker and Mars PLACER Net missions propose use of various types of vehicles – such as rovers, landers and flying probes - to accomplish their scientific objectives. Although designs for such vehicles are myriad, many structural components can be made using composite manufacturing technologies. Composite materials are also myriad, by nature, but carbon fiber reinforced polymers (CFRP) in particular are sought after for their high specific strength and specific stiffness. CFRP components could be especially beneficial in vehicle designs for Moon or Mars missions due to their nearly negligible coefficient of thermal expansion (CTE). CTE is a critical design characteristics in environments where significant thermal swings are prevalent, such as those of atmosphere-less Moon and Mars.MSFC/EM42 houses several relevant composites technologies. Strong and rigid struts can be filament-wound. Shells and platforms can be laid-up using automated fiber placement (for repeatability) or by hand (for small features). Monolithic structures can even be designed to reduce part count and therefore reduce the risk of joint failures. Composites are also tailorable, allowing the incorporation of different material types or formats through the thickness of a part. This includes materials which shield from radiation or electrostatic discharge. Finally, the rigidity of composite parts minimizes overall vibration and compliance within a design.Additionally, missions such as Triton Ocean World Surveyor anticipate use of traditional, metallic fuel tanks. Composite overwrapped pressure vessels (COPVs) are suitable for use in this application as well. The Triton mission even cites a concern for heat retention, for which CFRP also offers improved characteristics over traditional metallic tanks.
Lightweight↗
Developing a Pyrolysis Gas Thermal Blocking Model for Reentry Demise
In NASA’s Object Reentry Survival Analysis Tool (ORSAT), aerodynamic drag and aerothermal heating coefficients are computed for each of the free-molecular, continuum, and transitional flow regimes using analytical and semi-analytical methods. These heating coefficients were derived for typical metallic materials that melt and do not have a strong gas-phase contribution to the flow in the boundary layer. Modern satellites typically feature fiber-reinforced polymer (FRP) components, such as solar array booms, facesheets of sandwich panels, or overwraps for composite-overwrapped pressure vessels (COPV). These FRP materials do not behave the same as metals in the reentry environment, but instead will pyrolyze and develop significant volumes of gas into the boundary layer. Accurately predicting the reentry demise of FRP components is critical to assessing the reentry casualty risk for modern spacecraft. Research in recent years has shown that this demisability can depend heavily on how the expulsion of gaseous pyrolysis products through the outer surface of the material affects the heat flux at the surface. The ODPO has been developing a reduced-order model of the effect of pyrolysis gas blowing on the heat flux based on correlations between a blowing factor and a non-dimensional heat flux to be incorporated in the upcoming version 7.3 of the Object Reentry Survivability Analysis Tool (ORSAT). This presentation discusses the progress of this development project and the challenges remaining for generalizing the model across families of FRP materials.
Benton Greene↗
Using PZT Sensors for Tank Health Monitoring and Propellant Mass Gauging
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cryogenics↗
NASA Engineering and Safety Center Technical Bulletins 2007-2023
An NESC Technical Bulletin captures critical knowledge in the form of new engineering information or best practices in a one-page format that have resulted from NESC independent testing, analysis, and assessments. This document contains all NESC Technical Bulletins from 2007 through 2023.
additive manufacturing, battery, braycote, capacit↗
Experimental Design for Composite Overwrapped Pressure Vessel Life Prediction
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COPV↗
Measurements of the Failure of Composite Overwrapped Pressure Vessels by Direct Impact
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COPV↗