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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,333 records · Page 74
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Crack mitigation and wear performance of high-strength steel coatings deposited by high-speed laser cladding

This article investigates the fabrication of defect-free Rockit® 606, a high‑carbon, vanadium- and chromium-enriched precipitation-hardening martensitic steel coating, using high-speed laser cladding (HSLC). Compared to conventional laser cladding, HSLC offers higher deposition efficiency, improved coating quality, minimal thermal distortion, and a reduced heat-affected zone. Various HSLC parameters—including laser power, travel speed, powder feed rate, and overlap distance—were optimized to achieve superior coating properties. Microstructural analysis revealed solidification cracks in coatings deposited on carburized steel, regardless of processing parameters. However, preheating the substrate to 250 °C effectively eliminated cracking by reducing thermal gradients. The coatings exhibited a columnar dendritic microstructure, with coarser dendrites near the substrate and finer dendrites towards the surface. Hardness measurements confirmed that all coatings significantly exceeded the industry-specified threshold of 60 HRC, with preheating having minimal effect on overall hardness distribution. Reciprocating sliding wear tests demonstrated a substantial improvement in wear resistance for the defect-free HSLC coatings compared to baseline carburized steel. These findings underscore the potential of HSLC for producing high-performance, wear-resistant coatings suitable for industrial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Environmental stability of additively manufactured siliconized silicon carbide for applications in hybrid energy systems

A key consideration for the successful operation of hybrid energy systems will be the environmental stability of materials used for their construction, particularly when experiencing service environments containing water vapor at high temperatures. Here, we report results from the characterization of siliconized silicon carbide (Si-SiC) prepared via binder jet additive manufacturing and reactive silicon melt infiltration after being exposed to environments representative of those in solid oxide fuel cell (SOFC) anodes, and to exhaust gases inside a microturbine operating on natural gas. In both cases, it was found that oxide scales formed on the surface and that these scales were dense, continuous, and well-bonded to the substrates, although there was evidence of transverse and longitudinal cracking most likely as a result of mismatches in the thermal expansion of the scale and the substrate. Measured values of the thickness of the oxide scale were compared to those predicted by parabolic oxidation kinetics of silicon, but the potential effects of silica volatilization induced by water vapor, and silica reduction when exposed to hydrogen are discussed. The overall results showed that the oxide scale is expected to be protective under the conditions of hybrid power generation systems.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Evaluation of nondestructive testing techniques for the space shuttle nonmetallic thermal protection system

A program was conducted to evaluate nondestructive analysis techniques for the detection of defects in rigidized surface insulation (a candidate material for the Space Shuttle thermal protection system). Uncoated, coated, and coated and bonded samples with internal defects (voids, cracks, delaminations, density variations, and moisture content), coating defects (holes, cracks, thickness variations, and loss of adhesion), and bondline defects (voids and unbonds) were inspected by X-ray radiography, acoustic, microwave, high-frequency ultrasonic, beta backscatter, thermal, holographic, and visual techniques. The detectability of each type of defect was determined for each technique (when applicable). A possible relationship between microwave reflection measurements (or X-ray-radiography density measurements) and the tensile strength was established. A possible approach for in-process inspection using a combination of X-ray radiography, acoustic, microwave, and holographic techniques was recommended.

Tiede, D. A.↗
NASA NTRS1972

Stress Corrosion Cracking and Fatigue Crack Growth Studies Pertinent to Spacecraft and Booster Pressure Vessels

This experimental program was divided into two parts. The first part evaluated stress corrosion cracking in 2219-T87 aluminum and 5Al-2.5Sn (ELI) titanium alloy plate and weld metal. Both uniform height double cantilever beam and surface flawed specimens were tested in environments normally encountered during the fabrication and operation of pressure vessels in spacecraft and booster systems. The second part studied compatibility of material-environment combinations suitable for high energy upper stage propulsion systems. Surface flawed specimens having thicknesses representative of minimum gage fuel and oxidizer tanks were tested. Titanium alloys 5Al-2.5Sn (ELI), 6Al-4V annealed, and 6Al-4V STA were tested in both liquid and gaseous methane. Aluminum alloy 2219 in the T87 and T6E46 condition was tested in fluorine, a fluorine-oxygen mixture, and methane. Results were evaluated using modified linear elastic fracture mechanics parameters.

Hall, L. R.↗
NASA NTRS1979

Environmental effects on space shuttle reusable surface insulation coated with reaction cured glass

Sample titles of the space shuttle reusable surface insulation was subjected alternately to simulated mission heating and either real or simulated environmental exposure for up to 34 cycles. The coating cracked as a result of exposure to high temperature and moisture conditions, and insulation with cracked coatings absorbed significant quantities of water in the launch-pad environment. Cracking was a complex function of time, temperature, and moisture exposure. Cracked coatings remained adherent to the insulation for up to 24 cycles past initial cracking.

Ransone, P. O.↗
NASA NTRS1982

Lacquer Reveals Impact Damage in Composites

Brittle lacquer unveils effects normally visible only by ultrasonic inspection. Laquer coating measures spread of cracking and delamination in graphite/epoxy panels subjected to cyclic compression loads after impact damage. Test specimen is coated with lacquer on side opposite surface at which projectile will be fired. Spalled area shows effect of impact without removing specimen from test fixture.

Rhodes, M. D.↗
NASA NTRS2000

Evaluation of Thermo-Mechanical Stability of COTS Dual-Axis MEMS Accelerometers for Space Applications

Microelectromechanical systems in MEMS is one of the fastest growing technologies in microelectronics, and is of great interest for military and aerospace applications. Accelerometers are the earliest and most developed representatives of MEMS. First demonstrated in 1979, micromachined accelerometers were used in automobile industry for air bag crash- sensing applications since 1990. In 1999, N4EMS accelerometers were used in NASA-JPL Mars Microprobe. The most developed accelerometers for airbag crash- sensing are rated for a full range of +/- 50 G. The range of sensitivity for accelerometers required for military or aerospace applications is much larger, varying from 20,000 G (to measure acceleration during gun and ballistic munition launches), and to 10(exp -6) G, when used as guidance sensors (to measure attitude and position of a spacecraft). The presence of moving parts on the surface of chip is specific to MEMS, and particularly, to accelerometers. This characteristic brings new reliability issues to micromachined accelerometers, including cyclic fatigue cracking of polysilicon cantilevers and springs, mechanical stresses that are caused by packaging and contamination in the internal cavity of the package. Studies of fatigue cracks initiation and growth in polysilicon showed that the fatigue damage may influence MEMS device performance, and the presence of water vapor significantly enhances crack initiation and growth. Environmentally induced failures, particularly, failures due to thermal cycling and mechanical shock are considered as one of major reliability concerns in MEMS. These environmental conditions are also critical for space applications of the parts. For example, the Mars pathfinder mission had experienced 80 mechanical shock events during the pyrotechnic separation processes.

Sharma, Ashok K.↗
NASA NTRS2008

Critical Initial Flaw Size Analysis

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The USS consists of several "tuna can" segments that are approximately 216 inches in diameter, 115 inches tall, and 0.5 inches thick. A 6 inch wide by 1 inch thick flange is welded to the skin and is used to fasten adjacent tuna cans. A schematic of a "tuna can" and the location of the flange-to-skin weld are shown in Figure 1. Gussets (shown in yellow in Figure 1) are welded to the skin and flange every 10 degrees around the circumference of the "tuna can". The flange-to-skin weld is a flux core butt weld with a fillet weld on the inside surface, as illustrated in Figure 2. The welding process may create loss of fusion defects in the weld that could develop into fatigue cracks and jeopardize the structural integrity of the Ares I-X vehicle. The CIFS analysis was conducted to determine the largest crack in the weld region that will not grow to failure within 4 lifetimes, as specified by NASA standard 5001 & 5019 [1].

Dawicke, David S.↗
NASA NTRS2017

Kinetic Monte Carlo Simulations of Diffusion in Environmental Barrier Coating Materials

Ceramic Matrix Components (CMC) components for use in turbine engines offer a number of advantages compared with current practice. However, such components are subject to degradation through a variety of mechanisms. In particular, in the hot environment inside a turbine in operation a considerable amount of water vapor is present, and this can lead to corrosion and recession. Environmental Barrier Coating (EBC) systems that limit the amount of oxygen and water reaching the component are required to reduce this degradation and extend component life. A number of silicate-based materials are under consideration for use in such coating systems, including Yttterbium and Yttrium di- and monosilicates. In this work, we present results of kinetic Monte Carlo computer simulations of oxygen diffusion in Yttrium disilicate, and compare with previous work on Yttterbium disilicate. Coatings may also exhibit cracking, and the cracks can provide a direct path for oxygen to reach the component. There is typically a bond coat between the coating and component surface, but the bond coat material is generally chosen for properties other than low oxygen diffusivity. Nevertheless, the degree to which the bond coat can inhibit oxygen diffusion is of interest, as it may form the final defense against oxygen impingement on the component. We have therefore performed similar simulations of oxygen diffusion through HfSiO4, a proposed bond coat material.

Computer Simulation↗
NASA NTRS2018

Cryogenic Multilayer Insulation Theory and An Analysis of Seams Under a Variety of Assumptions

The theory of thermal radiation as applied to cryogenic surfaces is explored, andvalidation cases are solved in Thermal Desktop. Some results are compared topreviously published research, and new results are published regarding cracks inboth spherical and cylindrical cryogenic insulations with a cold boundary of 90Kto 220K for ten layer blankets under a variety of assumptions and scenarios.It was found that enabling directional emission{as well as specular, mirrorlikereflections have little impact on the results.

Elchert, J. P.↗
DOE OSTI2022

Effect of Applied Stress on the Selective Oxidation of Alloy 600 Exposed to PWR Primary Water and Rhines Pack Environments

A mechanistic understanding of corrosion and oxidation processes is crucial to ensure long-term resistance to stress corrosion cracking of Ni-base structural alloys in pressurized water reactor (PWR) primary and secondary systems. Aqueous corrosion of Ni-base alloys under PWR primary water conditions was previously compared to gaseous oxidation with comparable oxygen potentials. However, those studies considered only stress-free conditions, which removes a critical parameter for understanding stress corrosion behaviors. A significant knowledge gap exists for the role of applied stresses on selective internal oxidation in gaseous environments. A micro-4-point-bend jig was designed to facilitate stress in a Rhines Pack set-up. Selective oxidation at different stress and strain conditions was investigated in a series of Rhines Pack experiments for Alloy 600. Focused ion beam milling enabled the extraction of site-specific specimens containing selected high-energy grain boundaries from tensile and compressive stress regions. Analytical transmission electron microscopy was employed to analyze the microstructure and chemical composition of the resulting oxides. Protective surface oxide films and selective intergranular oxides were observed at different conditions. The implications of these fundamental differences are discussed relative to intergranular attack and stress corrosion cracking mechanisms in PWR primary water.

stress, 4-point-bend, selective oxidation, Alloy 6↗
NASA NTRS1992

The effects of uneven fiber spacing on thermal residual stresses in a unidirectional SCS-6Ti-15-3 laminate

High residual stresses develop in SCS-6/Ti-15-3 composites during cooldown from the fabrication temperature; these residual stresses can effect the mechanical and physical properties of the composite. Discrete fiber-matrix finite element models were used to study the residual stresses due to the temperature change during the fabrication process, including the effects of uneven fiber spacing, the free surface, and increased fiber volume fractions. To accurately model the effects of the free surface, it is only necessary to model one fiber through the thickness. Below the first ply, the analysis predicts stress distributions that are identical to the infinite array predictions. For uneven fiber space less then 0.042 mm in an interior ply, the maximum hoop stress was predicted to occur between fibers within a ply and to increase as the fiber spacing decreased. The maximum hoop stress correlated well with the observed radial cracking between fibers. For the case of touching fibers, the analysis predicted tensile radial stresses at the fiber-matrix debonding during the fabrication cooldown. Identical trends were predicted for uneven fiber spacing in surface plies with slightly greater values of maximum stresses. The analysis predicted matrix yielding to occur upon cooldown when the edge-to-edge fiber spacing was less than or equal to 0.022 mm. The stress distributions predicted for increasing fiber volume fractions were similar to those predicted for decreasing the fiber spacing for two adjacent fibers within a ply.

Bigelow, C. A.↗
NASA NTRS1992

The effects of uneven fiber spacing on thermal residual stresses in a unidirectional SCS-6/Ti-15-3 laminate

High residual stresses develop in SCS-6/Ti-15-3 composites during cooldown from the fabrication temperature; these residual stresses can effect the mechanical and physical properties of the composite. Discrete fiber-matrix finite element models were used to study the residual stresses due to the temperature change during the fabrication process, including the effects of uneven fiber spacing, the free surface, and increased fiber volume fractions. To accurately model the effects of the free surface, it is only necessary to model one fiber through the thickness. Below the first ply, the analysis predicts stress distributions that are identical to the infinite array predictions. For uneven fiber space less than 0.042 mm in an interior ply, the maximum hoop stress was predicted to occur between fibers within a ply and to increase as the fiber spacing decreased. The maximum hoop stress correlated well with the observed radial cracking between fibers. For the case of touching fibers, the analysis predicted tensile radial stresses at the fiber-matrix debonding during the fabrication cooldown. Identical trends were predicted for uneven fiber spacing in surface plies with slightly greater values of maximum stresses. The analysis predicted matrix yielding to occur upon cooldown when the edge-to-edge fiber spacing was less than or equal to 0.022 mm. The stress distributions preidcted for increasing fiber volume fractions were similar to those predicted for decreasing the fiber spacing for two adjacent fibers within a ply.

Bigelow, Catherine A.↗
NASA NTRS1992

Determination of cleavage planes and fracture characterization of Ni-based single crystal superalloys

The room temperature fracture behavior of the Ge Rene N-4, CMSX-2, and CMSX-4C single crystal Ni-based superalloys was studied. All crystals were grown along the (001) direction and tensile tested in both helium and hydrogen atmospheres. A stereoscopic technique developed for use with a scanning electron microscope was applied to determine cleavage planes. Planar gamma(') morphologies also were examined to help determine cleavage planes. Helium charged specimens failed on a number of planes including the (111), (110), and (320). In most cases planes of the (111)-type initiated at the notch region and became smaller and smaller as they moved in radially. Tensile strengths in helium averaged 1000 MPa higher than that of the hydrogen charged specimens. Specimens tested in hydrogen generally failed on (100)-type planes originating from the notch region. This (100) region comprised 60 to 80 percent of the total fracture surface on most samples and appeared as large flat planes perpendicular to the growth direction of the crystal. The interior regions contained (100)-type planes as well as (321), (320), (210), and (111)-types. Hydrogen charged specimens also showed a high percentage of large cracks oriented at 90 deg to one another, indicative of the (100)-type fracture. The Ge Rene N4 and the CMSX-4C samples contained 3-5 percent gamma/gamma(') eutectic, while the CMSX-2 samples had little or no gamma/gamma(') eutectic. The relationship between gamma/gamma(') eutectic and the fracture surface has not been fully determined, but it is thought that the gamma/gamma(') eutectic may serve as a possible trapping site for hydrogen.

Merrill, John M.↗
NASA NTRS2003

Statistical Distribution of Inflation on Lava Flows: Analysis of Flow Surfaces on Earth and Mars

The surface morphology of a lava flow results from processes that take place during the emplacement of the flow. Certain types of features, such as tumuli, lava rises and lava rise pits, are indicators of flow inflation or endogenous growth of a lava flow. Tumuli in particular have been identified as possible indicators of tube location, indicating that their distribution on the surface of a lava flow is a junction of the internal pathways of lava present during flow emplacement. However, the distribution of tumuli on lava flows has not been examined in a statistically thorough manner. In order to more rigorously examine the distribution of tumuli on a lava flow, we examined a discrete flow lobe with numerous lava rises and tumuli on the 1969 - 1974 Mauna Ulu flow at Kilauea, Hawaii. The lobe is located in the distal portion of the flow below Holei Pali, which is characterized by hummocky pahoehoe flows emplaced from tubes. We chose this flow due to its discrete nature allowing complete mapping of surface morphologies, well-defined boundaries, well-constrained emplacement parameters, and known flow thicknesses. In addition, tube locations for this Mauna Ulu flow were mapped by Holcomb (1976) during flow emplacement. We also examine the distribution of tumuli on the distal portion of the hummocky Thrainsskjoldur flow field provided by Rossi and Gudmundsson (1996). Analysis of the Mauna Ulu and Thrainsskjoldur flow lobes and the availability of high-resolution MOC images motivated us to look for possible tumuli-dominated flow lobes on the surface of Mars. We identified a MOC image of a lava flow south of Elysium Mons with features morphologically similar to tumuli. The flow is characterized by raised elliptical to circular mounds, some with axial cracks, that are similar in size to the tumuli measured on Earth. One potential avenue of determining whether they are tumuli is to look at the spatial distribution to see if any patterns similar to those of tumuli-dominated terrestrial flows can be identified. Since tumuli form by the injection of lava beneath a crust, the distribution of tumuli on a flow should represent the distribution of thermally preferred pathways beneath the surface of the crust. That distribution of thermally preferred pathways may be a function of the evolution of a basaltic lava flow. As a longer-lived flow evolves, initially broad thermally preferred pathways would evolve to narrower, more well-defined tube-like pathways. The final flow morphology clearly preserves the growth of the flow over time, with inflation features indicating pathways that were not necessarily contemporaneously active. Here, we test using statistical analysis whether this final flow morphology produces distinct distributions that can be used to readily determine the distribution of thermally preferred pathways beneath the surface of the crust.

Glazel, L. S.↗
DOE OSTI2021

Water vapor oxidation of SiC layer in surrogate TRISO fuel particles

Under accidental conditions for high temperature gas-cooled reactors (HTGR), the SiC layer in tri-structural-isotropic (TRISO) fuel particles can be exposed to water vapor. In this study, oxidation behaviors of surrogate TRISO fuel particles were investigated in a He-20 vol% water vapor mixed atmosphere at temperatures up to 1600 °C. The growth of the crystalline oxide passivation layer with cracks and pores followed a parabolic law with time, where the maximum was 2.3 μm at 1600 °C. The oxide layer and the SiC surface under the oxide became flattened with increasing temperature, as a function of the silica viscosity and the diffusion path of water vapor. Volatilization of the oxide layer was analyzed using a mechanistic model that an inert gas in oxidizing atmospheres could influence the magnitude of volatilization. The fracture load and strength of the oxidized and thinned SiC layer were numerically estimated to decrease from 2.27 to 1.69 N and from 317 to 299 MPa, respectively, with the SiC thickness decrease from 35 to 32 μm. This prediction indicates that the oxidized SiC layer should retain fission products. Additionally, the mechanical integrity of each layer in the TRISO fuel particle after oxidation was evaluated. The results in this work provide important data for the safety analysis of accidental scenarios in HTGRs.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Preliminary Deposition Modeling: For Determining the Deposition of Corrosive Contaminants on SNF Canisters

This report fulfills the M3 milestone M3SF-20PN010207045. During fiscal year (FY) 2019, Pacific Northwest National Laboratory (PNNL) worked to develop initial deposition and particle tracking models which could be used to better understand how corrosive contaminants deposit on the surfaces of spent nuclear fuel (SNF) canisters during dry storage. These models may be useful in understanding the likelihood of chloride induced stress corrosion cracking (CISCC) on SNF canisters

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1977

Semiconductor ohmic contact

Contact formed on p-type surface of semiconductor laser has several advantages: highly conductive degenerate region and narrow band gap provides surface for good metal-to-semiconductor contact; lattice parameter of GaAs is 5.6533 A; improved lattice match eases interface strain which reduces interface cracking of semiconductor material.

Hawrylo, F. Z.↗