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Design of mechanical components for long-term performance
Review of the results of a NASA program designed to study advanced techniques for determining the long-term performance of rocket engine components. Aging and operational degradation mechanisms of metal valve seats are identified. Characterization of metal valve seat surfaces by optical signature analysis is described. The results of the development of a long-life 'zero leakage' metal valve seal designed to avoid failure by contamination, stress/strain, fatigue, and the deterioration of the surface by wear is reported. An analysis of a specific seat design showed that material strain prevention along all axes would prevent these failures. The design provided for refurbishment of the sealing surfaces during each valve cycle, thereby preventing cumulative surface damage.
Reliability study of the NiH2 strain gage
This paper summarizes a joint study by Gates Aerospace Batteries (GAB) and the Reliability Analysis Center (RAC). This study characterizes the reliability and robustness of the temperature compensated strain gages currently specified for sensing of internal pressure of NiH2 cells. These strain gages are characterized as fully encapsulated, metallic foil grids with known resistance that varies with deformation. The measurable deformation, when typically installed on the hemispherical portion of a NiH2 cell, is proportional to the material stresses as generated by internal cell pressures. The internal pressure sensed in this manner is calibrated to indicate the state-of-charge for the cell. This study analyzes and assesses both robustness and reliability for the basic design of the strain gage, the installation of the strain gage, and the circuitry involved.
Advanced oxide dispersion strengthened sheet alloys for improved combustor durability
Burner design modifications that will take advantage of the improved creep and cyclic oxidation resistance of oxide dispersion strengthened (ODS) alloys while accommodating the reduced fatigue properties of these materials were evaluated based on preliminary analysis and life predictions, on construction and repair feasibility, and on maintenance and direct operating costs. Two designs - the film cooled, segmented louver and the transpiration cooled, segmented twin Wall - were selected for low cycle fatigue (LCF) component testing. Detailed thermal and structural analysis of these designs established the strain range and temprature at critical locations resulting in predicted lives of 10,000 cycles for MA 956 alloy. The ODs alloys, MA 956 and HDA 8077, demonstrated a 167 C (300 F) temperature advantage over Hastelloy X alloy in creep strength and oxidation resistance. The MA 956 alloy was selected for mechanical property and component test evaluations. The MA 956 alloy was superior to Hastelloy X in LCF component testing of the film cooled, segmented louver design.
Modeling stiffness loss in boron/aluminum below the fatigue limit
Boron/aluminum can develop significant internal matrix cracking when fatigued. These matrix cracks can result in a 40 percent secant modulus loss in some laminates, even when fatigued below the fatigue limit. It is shown that the same amount of fatigue damage will develop during stress or strain-controlled tests. Stacking sequence has little influence on secant modulus loss. The secant modulus loss in unidirectional composites is small, whereas the losses are substantial in laminates containing off-axis plies. A simple analysis is presented that predicts unnotched laminate secant modulus loss due to fatigue. The analysis is based upon the elastic modulus and Poisson's ratio of the fiber and matrix, fiber volume fraction, fiber orientations, and the cyclic-hardened yield stress of the matrix material. Excellent agreement was achieved between model predictions and experimental results. With this model, designers can project the material stiffness loss for design load or strain levels and assess the feasibility of its use in stiffness-critical parts.
Modeling stiffness loss in boron/aluminum laminates below the fatigue limit
Boron/aluminum can develop significant internal matrix cracking when fatigued. These matrix cracks can result in a 40 percent secant modulus loss in some laminates, even when fatigued below the fatigue limit. It is shown that the same amount of fatigue damage will develop during stress or strain-controlled tests. Stacking sequence has little influence on secant modulus loss. The secant modulus loss in unidirectional composites is small, whereas the losses are substantial in laminates containing off-axis plies. A simple analysis is presented that predicts unnotched laminate secant modulus loss due to fatigue. The analysis is based upon the elastic modulus and Poisson's ratio of the fiber and matrix, fiber volume fraction, fiber orientations, and the cyclic-hardened yield stress of the matrix material. Excellent agreement was achieved between model predictions and experimental results. With this model, designers can project the material stiffness loss for design load or strain levels and assess the feasibility of its use in stiffness-critical parts. Previously announced in STAR as N82-24298
Materials for Advanced Turbine Engines (MATE): Project 3: Design, fabrication and evaluation of an oxide dispersion strengthened sheet alloy combustor liner, volume 1
The suitability of wrought oxide dispersion strengthened (ODS) superalloy sheet for gas turbine engine combustor applications was evaluated. Incoloy MA 956 (FeCrAl base) and Haynes Developmental Alloy (HDA) 8077 (NiCrAl base) were evaluated. Preliminary tests showed both alloys to be potentially viable combustor materials, with neither alloy exhibiting a significant advantage over the other. Both alloys demonstrated a +167C (300 F) advantage of creep and oxidation resistance with no improvement in thermal fatigue capability compared to a current generation combustor alloy (Hastelloy X). MA956 alloy was selected for further demonstration because it exhibited better manufacturing reproducibility than HDA8077. Additional property tests were conducted on MA956. To accommodate the limited thermal fatigue capability of ODS alloys, two segmented, mechanically attached, low strain ODS combustor design concepts having predicted fatigue lives or = 10,000 engine cycles were identified. One of these was a relatively conventional louvered geometry, while the other involved a transpiration cooled configuration. A series of 10,000 cycle combustor rig tests on subscale MA956 and Hastelloy X combustor components showed no cracking, thereby confirming the beneficial effect of the segmented design on thermal fatigue capability. These tests also confirmed the superior oxidation and thermal distortion resistance of the ODS alloy. A hybrid PW2037 inner burner liner containing MA956 and Hastelloy X components was designed and constructed.
Thermal Disorder‐Induced Strain and Carrier Localization Activate Reverse Halide Segregation
The reversal of halide ions is studied under various conditions. However, the underlying mechanism of heat-induced reversal remains unclear. This work finds that dynamic disorder-induced localization of self-trapped polarons and thermal disorder-induced strain (TDIS) can be co-acting drivers of reverse segregation. Localization of polarons results in an order of magnitude decrease in excess carrier density (polaron population), causing a reduced impact of the light-induced strain (LIS – responsible for segregation) on the perovskite framework. Meanwhile, exposing the lattice to TDIS exceeding the LIS can eliminate the photoexcitation-induced strain gradient, as thermal fluctuations of the lattice can mask the LIS strain. Under continuous 0.1 W cm -2 illumination (upon segregation), the strain disorder is estimated to be 0.14%, while at 80 °C under dark conditions, the strain is 0.23%. However, in situ heating of the segregated film to 80 °C under continuous illumination (upon reversal) increases the total strain disorder to 0.25%, where TDIS is likely to have a dominant contribution. Therefore, the contribution of entropy to the system's free energy is likely to dominate, respectively. Various temperature-dependent in situ measurements and simulations further support the results. These findings highlight the importance of strain homogenization for designing stable perovskites under real-world operating conditions.
Multi-parameter optimization tool for low-cost commercial fuselage crown designs
The work in progress for developing a methodology and software tool to aid in the optimal design of composite structures is discussed. The methodology is being developed to take advantage of the ability to tailor the composite material in conjunction with the design of the structure. The composites optimization design software UWCODA was found to be very successful in preliminary testing and early experience. UWCODA is a composites design code that uses a number of plies and fiber angles as design variables, employs maximum strain failure criteria for objective function and additional constraints, includes Boeing design tools for stiffened panels, and includes stiffener geometry in the design variables.
Aerodynamic measurements and thermal tests of a strain-gage balance in a cryogenic wind tunnel
An internal strain-gage balance designed and constructed in Europe for use in cryogenic wind tunnels has been tested in the Langley 0.3-Meter Transonic Cryogenic Tunnel. Part of the evaluation was made at equilibrium balance temperatures and it consisted of comparing the data taken at a tunnel stagnation temperature of 300 K with the data taken at 200 K and 110 K while maintaining either the Reynolds number or the stagnation pressure. A sharp-leading-edge delta-wing model was used to provide the aerodynamic loading for these tests. Results obtained with the balance during the force tests were found to be accurate and repeatable both with and without the use of a convection shield on the balance. An additional part of this investigation involved obtaining data on the transient temperature response of the balance during both normal and rapid changes in the tunnel stagnation temperature. The variation of the temperature with time was measured at three locations on the balance near the physical locations of the strain gages. The use of a convection shield significantly increased the time required for the balance to stabilize at a new temperature during the temperature response tests.
Evaluation, Analysis, and Application of Internal Strain-Gage Balance Data
Experimental processes, analytical methods, and numerical algorithms are described that may be used to predict the forces and moments of an internal strain–gage balance during a wind tunnel test. First, the control volume model of a strain–gage balance and the concepts of load state, load space, and output space are introduced. These important abstractions provide a better understanding of fundamental characteristics of different balance load prediction approaches. Then, the description of strain–gage balance data and the definition of the primary bridge sensitivity are discussed. Afterwards, basic elements of the calibration of a typical six–component balance are reviewed. Two fundamentally different balance load prediction methods, the processing of check loads, and related topics are also discussed. Three real–world balance data examples are reviewed in great detail to illustrate typical analysis results for a variety of strain–gage balance designs. Finally, important observations are summarized and recommendations are provided. – Additional information and detailed mathematical derivations can be found in the appendices of the document. They include the following topics: balance terminology, definitions of important statistical metrics, balance axis system conventions, balance load transformations, the combined load diagram, electrical output format options, bi–directional output characteristics, determination of the natural zeros, derivation of two balance load prediction methods, description of two tare load iteration algorithms, modeling of balance temperature effects, basics of three–component moment balances, definition of the percent contribution, detection of linear and near–linear dependencies in balance calibration data, a regression model search algorithm, balance interactions, and other related information.
Evaluation, Analysis, and Application of Internal Strain-Gage Balance Data
Experimental processes, analytical methods, and numerical algorithms are described that may be used to predict the forces and moments of an internal strain-gage balance during a wind tunnel test. First, the control volume model of a strain-gage balance and the concepts of load state, load space, and output space are introduced. These important abstractions provide a better understanding of fundamental characteristics of different balance load prediction approaches. Then, the description of strain-gage balance data and the definition of the primary gage sensitivity is discussed. Afterwards, basic elements of the calibration of a typical six-component balance are reviewed. Two fundamentally different balance load prediction methods, the processing of check loads, and related topics are also discussed. Three real-world balance data examples are reviewed in great detail to illustrate typical analysis results for a variety of strain-gage balance designs. Finally, important observations are summarized and recommendations are provided. Additional information and detailed mathematical derivations can be found in the appendices of the document. They include the following topics: balance terminology, definitions of important statistical metrics, balance axis system conventions, balance load transformations, the combined load diagram, electrical output format options, bi-directional gage output characteristics, determination of the natural zeros, derivation of two balance load prediction methods, description of two tare load iteration algorithms, modeling of balance temperature effects, basics of three-component moment balances, definition of the percent contribution, detection of linear and near-linear dependencies in balance calibration data, a regression model term selection algorithm, and other related topics.
Discrete shaped strain sensors for intelligent structures
Design of discrete, highly distributed sensor systems for intelligent structures has been studied. Data obtained indicate that discrete strain-averaging sensors satisfy the functional requirements for distributed sensing of intelligent structures. Bartlett and Gauss-Hanning sensors, in particular, provide good wavenumber characteristics while meeting the functional requirements. They are characterized by good rolloff rates and positive Fourier transforms for all wavenumbers. For the numerical integration schemes, Simpson's rule is considered to be very simple to implement and consistently provides accurate results for five sensors or more. It is shown that a sensor system that satisfies the functional requirements can be applied to a structure that supports mode shapes with purely sinusoidal curvature.
PCP consensus protein/peptide alphavirus antigens stimulate broad spectrum neutralizing antibodies
Vaccines based on proteins and peptides may be safer and if calculated based on many sequences, more broad-spectrum than those designed based on single strains. Physicochemical Property Consensus (PCP con ) alphavirus (AV) antigens from the B-domain of the E2 envelope protein were designed, synthesized recombinantly and shown to be immunogenic (i.e. sera after inoculation detected the antigen in dotspots and ELISA). Antibodies in sera after inoculation with B-region antigens based on individual AV species (eastern or Venezuelan equine encephalitis (EEEV con , VEEV con ), or chikungunya (CHIKV con ) bound only their cognate protein, while those designed against multiple species (Mosaik con and EVC con ) recognized all three serotype specific antigens. The VEEV con and EEEV con sera only showed antiviral activity against their related strains (in plaque reduction neutralization assays (PRNT 50/80 ). Peptides designed to surface exposed areas of the E2-A-domain of CHIKV con were added to CHIKV con inocula to provide anti-CHIKV antibodies. EVC con , based on three different alphavirus species, combined with E2-A-domain peptides from AllAV con , a PCPcon of 24 diverse AV, generated broad spectrum, antiviral antibodies against VEEV, EEEV and CHIKV, AV with less than 35% amino acid identity to each other (>65% diversity). This is a promising start to a molecularly defined vaccine against all AV. A further study with these antigens can illuminate what areas are most important for a robust immune response, resistant to mutations in rapidly evolving viruses. The validated computational methods can also be used to design broad spectrum antigens against many other pathogen families.
Operando Tailoring of Defects and Strains in Corrugated β-Ni(OH) 2 Nanosheets for Stable and High-Rate Energy Storage
Nickel hydroxide represents a technologically important material for energy storage, such as hybrid supercapacitors. It has two different crystallographic polymorphs, α- and β-Ni(OH) 2 , showing advantages in either theoretical capacity or cycling/rate performance, manifesting a trade-off trend that needs to be optimized for practical applications. In this work, the synergistic superiorities in both activity and stability of corrugated β-Ni(OH) 2 nanosheets are demonstrated through an electrochemical abuse approach. With ≈91% capacity retention after 10 000 cycles, the corrugated β-Ni(OH) 2 nanosheets can deliver a gravimetric capacity of 457 C g -1 at a high current density of 30 A g -1 , which is nearly two and four times that of the regular α- and β-Ni(OH) 2 , respectively. Operando spectroscopy and finite element analysis reveal that greatly enhanced chemical activity and structural robustness can be attributed to the in situ tailored lattice defects and the strain-induced highly curved micromorphology. This work demonstrates a multi-scale defect-and-strain co-design strategy, which is helpful for rational design and tuned fabrication of next-generation electrode materials for stable and high-rate energy storage.
Homogeneous Gold Redox Chemistry: Organometallics, Catalysis, and Beyond
Gold redox chemistry holds the promise of unique reactivities and selectivities that are different to other transition metals. Recent studies have utilized strain release, ligand design, and photochemistry to promote the otherwise sluggish oxidative addition to Au(I) complexes. More details on the reductive elimination from Au(III) complexes have also been revealed. These discoveries have facilitated the development of gold redox catalysis and will continue to offer mechanistic insight and inspiration for other transition metals. Furthermore, this review highlights how research in organometallic chemistry has led to gold redox catalysis, as well as applications in materials science, bioconjugation, and radiochemical synthesis.
Kirigami Photopiezo Catalysts for Self-Sustainable Environment Remediation
Photo(electro)-piezo catalysis has emerged as one of the most effective strategies for sustainable environmental remediation. While various (nano)materials have been investigated for enhancing the intrinsic properties related to the interfacial band structure, increasing the efficiency by integration of materials with rational design for stress–strain applications has not yet been considered. Herein, we introduce kirigami strain engineering to photopiezo catalysts for enhancing efficiency by increasing the magnitude of applied strain and density of bends. Macroscale stretching motion is converted into localized bending by a pliable kirigami structure using similar or even lower input energy, which can be easily modulated by natural waves. The kirigami structure leads to a significant enhancement (~250%) in the degradation of dyes, and we discovered the significant contribution of the oxygen reduction pathway in the charge-transfer mechanism, which corresponds to the observed enhancement. In conclusion, the photopiezo catalytic effects of kirigami were further highlighted by the small water reservoir test, showing its feasibility in nature for self-sustainable environmental remediation that can be modulated using motions of winds, waves, and life vibrations.
Measuring nonlinearities of a cantilever beam using a low-cost efficient wireless intelligent sensor for strain (LEWIS-S)
In the context of experimental vibration data, strain gauges can obtain linear and nonlinear dynamic measurements. However, measuring strain can be disincentivizing and expensive due to the complexity of data acquisition systems, lack of portability, and high costs. This research introduces the use of a low-cost efficient wireless intelligent sensor for strain (LEWIS-S) that is based on a portable-sensor-design platform that streamlines strain sensing. Additionally, the softening behavior of a cantilever beam with geometric and inertial nonlinearities is characterized by the LEWIS-S based on high force level inputs. Two experiments were performed on a nonlinear cantilever beam with measurements obtained by the LEWIS-S sensor and an accelerometer. First, a sine sweep test was performed through the fundamental resonance of the system, then a ring-down test was performed from a large initial static deformation. Good agreement was revealed in quantities of interest such as frequency response functions, the continuous wavelet transforms, and softening behavior in the backbone curves.