SEARCH · Engineering Papers

Results for “THERMAL STRESSES”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,369 records · Page 76

All sources NASA NTRS DOE OSTI

NASA NTRS1981

The application of probabilistic design theory to high temperature low cycle fatigue

Metal fatigue under stress and thermal cycling is a principal mode of failure in gas turbine engine hot section components such as turbine blades and disks and combustor liners. Designing for fatigue is subject to considerable uncertainty, e.g., scatter in cycles to failure, available fatigue test data and operating environment data, uncertainties in the models used to predict stresses, etc. Methods of analyzing fatigue test data for probabilistic design purposes are summarized. The general strain life as well as homo- and hetero-scedastic models are considered. Modern probabilistic design theory is reviewed and examples are presented which illustrate application to reliability analysis of gas turbine engine components.

Wirsching, P. H.↗

DOE OSTI2018

Initiation of Experimental Campaign to Address Knowledge Gaps Related to Simultaneous Thermal and Gamma Radiation Aging of Crosslinked Polyethylene and Ethylene-Propylene Rubber Cable Insulation

Key cable knowledge gaps identified in the Expanded Materials Degradation Assessment (EMDA) volume on Aging of Cables and Cable Systems (Volume 5) specifically relate to the combined effects of thermal and gamma irradiation stresses on cable insulation materials. These include dose rate effects (DRE), inverse temperature effects (ITE), and synergistic effects (S/E). Extent of radiation-induced polymer degradation is proportional to absorbed dose, but DRE describe the phenomenon in which degree of damage is based not only on total dose, but also on the dose rate experienced during dose accumulation. This can be particularly complicated in the presence of thermal stress as a material spends more time at elevated temperature to receive the same total dose at a lower dose rate. Rates of cable polymer degradation generally increases with temperature, but ITE describes the situation in which polymer material damage under irradiation is greater at lower temperatures than at higher temperatures. Finally, S/E describe the concept that the mechanism of polymer material degradation when exposed to thermal aging and radiation aging in succession may be different than when exposed to thermal and radiation aging concurrently. The experimental campaign at the Pacific Northwest National Laboratory (PNNL) described in this report seeks to address these knowledge gaps through investigation of the degradation of relevant cable insulation materials at select conditions using controlled temperatures, dose rates and total doses. Insulation materials considered were chosen to represent those most commonly found in U.S. nuclear power plants in terms of manufacturers and polymer systems. They include products from manufactures including The Rockbestos Company; The Okonite Company; Boston Insulated Wire & Cable Company; Kerite Company; Anaconda Company; Brand Rex, Inc.; and Samuel Moore Company. The products include the most ubiquitous cross-linked polyethylene (XLPE) and ethylene-propylene rubber (EPR) classes of insulation polymer. Circulating air ovens with remote temperature sensing and control are positioned within the gamma irradiation beam to enable controlled temperatures during radiation exposure. Dose rates are controlled through repeatable positioning of specimens at determined distances from the Cobalt-60 gamma source. Total absorbed doses for comparing temperature and dose rate effects are controlled by removing samples from exposure at pre-determined time points. The effects of gamma beam geometry, source decay and attenuation due to samples, ovens and racks are determined and controlled for using local point dosimetry. The temperature, dose and dose rates selected for the experimental campaign described in this report were determined following input from a range of stakeholders and intended to balance the constraints of the experimental capabilities, available material, project timeline and project funding with the value of the effort in narrowing EMDA-identified knowledge gaps. Results from this campaign are anticipated to reduce uncertainty in the understanding of cable material degradation behavior in nuclear power plant environments and thereby support cable aging management in long term operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1992

Contact thermal shock test of ceramics

A novel quantitative thermal shock test of ceramics is described. The technique employs contact between a metal-cooling rod and hot disk-shaped specimen. In contrast with traditional techniques, the well-defined thermal boundary condition allows for accurate analyses of heat transfer, stress, and fracture. Uniform equibiaxial tensile stresses are induced in the center of the test specimen. Transient specimen temperature and acoustic emission are monitored continuously during the thermal stress cycle. The technique is demonstrated with soda-lime glass specimens. Experimental results are compared with theoretical predictions based on a finite-element method thermal stress analysis combined with a statistical model of fracture. Material strength parameters are determined using concentric ring flexure tests. Good agreement is found between experimental results and theoretical predictions of failure probability as a function of time and initial specimen temperature.

Rogers, W. P.↗

DOE OSTI2015

An Investigation into the Effects of Interface Stress and Interfacial Arrangement on Temperature Dependent Thermal Properties of a Biological and a Biomimetic Material

A significant effort in the biomimetic materials research is on developing materials that can mimic and function in the same way as biological tissues, on bio-inspired electronic circuits, on bio-inspired flight structures, on bio-mimetic materials processing, and on structural biomimetic materials, etc. Most structural biological and biomimetic material properties are affected by two primary factors: (1) interfacial interactions between an organic and an inorganic phase usually in the form of interactions between an inorganic mineral phase and organic protein network; and (2) structural arrangement of the constituents. Examples are exoskeleton structures such as spicule, nacre, and crustacean exoskeletons. A significant effort is being directed towards making synthetic biomimetic materials based on a manipulation of the above two primary factors. The proposed research is based on a hypothesis that in synthetic materials with biomimetic morphology thermal conductivity, k, (how fast heat is carried away) and thermal diffusivity, D, (how fast a material’s temperature rises: proportional to the ratio of k and heat capacity) can be engineered to be either significantly low or significantly high based on a combination of chosen interface orientation and interfacial arrangement in comparison to conventional material microstructures with the same phases and phase volume fractions. METHOD DEVELOPMENT 1. We have established a combined Raman spectroscopy and nanomechanical loading based experimental framework to perform environment (liquid vs. air vs. vacuum) dependent and temperature dependent (~1000 degree-C) in-situ thermal diffusivity measurements in biomaterials at nanoscale to micron scale along with the corresponding analytical theoretic calculations. (Zhang and Tomar, 2013) 2. We have also established a new classical molecular simulation based framework to measure thermal diffusivity in biomolecular interfaces. We are writing a publication currently (Qu and Tomar, 2013) to report the framework and findings in tropocollagen-hydroxyapatite based idealized biomaterial interfaces. PHYSICAL FINDINGS 1. Analyses using experiments have revealed that in the case of bone thermal conductivity and thermal diffusivity at micron scale shows significant dependence on compressive stress and temperature. Overall, there is a decrease with respect to increase in temperature and increase with respect to increase in compressive stress. Bio-molecular simulations on idealized tropocollagen-hydroxyapatite interfaces confirm such findings. However, simulations also reveal that thermal diffusivity and thermal conductivity can be significantly tailored by interfacial orientation. More importantly, in inorganic materials, interfaces contribute to reduce thermal conductivity and diffusivity. However, analyses here reveal that both can be increased despite presence of a lot of interfaces. 2. Based on significant role played by interfaces in affecting bone thermal properties, a crustacean-exoskeleton system is examined for thermal diffusivity using the newly developed setup. Special emphasis here is on this system since such arrangement is found to be common in fresh water shrimp as well as in some deep water organisms surviving in environment extremes. Experiments reveal that in such system thermal diffusivity is highly tailorable. 3. Overall, experiments and models have established that in biomaterial interfaces a counterintuitive role of interfaces in mediating thermal conduction as a function of stress and temperature is possible in contrast to inorganic materials where interfaces almost always lead to reduction of thermal conductivity as a function of such factors. More investigations are underway to reveal physical origins of such counter-physical characteristics. Such principles can be significantly useful in developing new and innovative bioenergy and inorganic energy systems where heat dissipation significantly affects system performance.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1978

Thermally stable polyimide components for space and commercial applications

The properties and applications of the thermally stable polyimide foams are discussed, together with an investigation of the methods for producing these materials. The qualities of the polyimide foams such as resistance to fire, not emitting smoke below 204 C, not producing incapacitating toxic by-products below 204 C, and resiliency and flexibility from minus 184 C to 315 C are stressed. The thermal, dielectric, induction, and microwave heating methods are discussed, particularly in relation to producing flexible resilient foams, thermal acoustical polyimide foams, and polyimide foam structural materials. It is concluded that the microwave approach shows to be a viable concept for generating flexible, low density cellular materials possessing a homogeneous structure and applicable to the aerospace industry and for commercial uses.

Gagliani, J.↗

NASA NTRS2024

Stress Control of Multilayer Suspended MEMS Structures In High Contrast Microshutters

The microshutter array (MSA) is a programmable field mask (Fig. 1) that enables large-format multi-object spectroscopy at extremely high contrast ratios of over 105 in space [1]. Assessment of the first generation MSAs used on the James Webb Space Telescope (JWST) revealed light leakage and stuck shutters due to warping (Fig. 2) [2]. Such leakage is partially reduced with appropriate light shields and mitigation strategies. Anticipation of stricter performance requirements for the upcoming Habitable Worlds Observatory Flagship [3] motivates the study. In this paper, we present the systematic study of film stress effects using finite element modeling (FEM) and analysis of newly fabricated MSAs. We present structural designs to mitigate stress effects and improve flatness of suspended structures in micro-electromechanical systems (MEMS). Our study aims to provide a comprehensive view of film-to-film interaction, mechanical, and structural considerations in design and process definition that goes beyond NGMSA devices. The presented findings can be of value to the stress and morphology control in any suspended MEMS membranes.

Microshutters↗

DOE OSTI2026

Sculpting 2D Crystals via Membrane Contractions before and during Solidification

When phospholipids crystallize within the otherwise fluid membranes of giant unilamellar vesicles, the resulting molecularly thin “2D” solids exhibit great variety in their morphology evolution. For example, within membranes containing moderate amounts of the crystallizing component, crystals grow with a fixed morphology depending on vesicle size. Conversely for membranes containing large amounts of the crystallizing species, we find small compact crystals on vesicles of all sizes. However, on large vesicles, growing crystals sprout flower petals that lengthen progressively. These behaviors result from two combined mechanisms: first, like other 2D solids, the shear rigidity of phospholipid crystals renders them intolerant to morphologies with nonzero Gaussian curvature. As a result and especially at elevated membrane tension, the cost of bending elasticity is reduced at the expense of line energy by the formation of flowers as opposed to compact crystals. Second, the composition-dependent tension rise during cooling relaxes via water permeation of the membrane with a time constant scaling as R2. The amount of crystal formed for a small decrease in temperature determines this composition-dependent increase in stress from thermal contractions versus solidification. Surface Evolver computations were motivated using the predicted tension evolution to develop a processing space that maps to experimental observations for initial and growing crystal morphology. Important variable groups are identified, including a scaled ratio of bending to line energy, a vesicle-size-independent group for membrane contractions, and a time constant for stress relaxation. Though processing stresses ultimately relax, the crystal morphology persists well beyond the processing window.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1982

Design and development of a ceramic radial turbine for the AGT101

An acceptable and feasible ceramic turbine wheel design has been achieved, and the relevant temperature, stress, and success probability analyses are discussed. The design is described, the materials selection presented, and the engine cycle conditions analysis parameters shown. Measured MOR four-point strengths are indicated for room and elevated temperatures, and engine conditions are analyzed for various cycle states, materials, power states, turbine inlet temperatures, and speeds. An advanced gas turbine ceramic turbine rotor thermal and stress model is developed, and cumulative probability of survival is shown for first and third-year properties of SiC and Si3N4 rotors under different operating conditions, computed for both blade and hub regions. Temperature and stress distributions for steady-state and worst-case shutdown transients are depicted.

Finger, D. G.↗

DOE OSTI2014

Shutdown-induced tensile stress in monolithic miniplates as a possible cause of plate pillowing at very high burnup

Post-irradiation examination of Reduced Enrichment for Research and Test Reactors (RERTR)-12 miniplates showed that in-reactor pillowing occurred in at least 4 plates, rendering performance of these plates unacceptable. To address in-reactor failures, efforts are underway to define the mechanisms responsible for in-reactor pillowing, and to suggest improvements to the fuel plate design and operational conditions. To achieve these objectives, the mechanical response of monolithic fuel to fission and thermally-induced stresses was modeled using a commercial finite element analysis code. Calculations of stresses and deformations in monolithic miniplates during irradiation and after the shutdown revealed that the tensile stress generated in the fuel increased from 2 MPa to 100 MPa at shutdown. The increase in tensile stress at shutdown possibly explains in-reactor pillowing of several RERTR-12 miniplates irradiated to the peak local burnup of up to 1.11x1022 fissions/cm3 . This paper presents the modeling approach and calculation results, and compares results with post-irradiation examinations and mechanical testing of irradiated fuel. The implications for the safe use of the monolithic fuel in research reactors are discussed, including the influence of fuel burnup and power on the magnitude of the shutdown-induced tensile stress.

rertr↗

NASA NTRS2008

Influence of Test Procedures on the Thermomechanical Properties of a 55NiTi Shape Memory Alloy

Over the past few decades, binary NiTi shape memory alloys have received attention due to their unique mechanical characteristics, leading to their potential use in low-temperature, solid-state actuator applications. However, prior to using these materials for such applications, the physical response of these systems to mechanical and thermal stimuli must be thoroughly understood and modeled to aid designers in developing SMA-enabled systems. Even though shape memory alloys have been around for almost five decades, very little effort has been made to standardize testing procedures. Although some standards for measuring the transformation temperatures of SMA s are available, no real standards exist for determining the various mechanical and thermomechanical properties that govern the usefulness of these unique materials. Consequently, this study involved testing a 55NiTi alloy using a variety of different test methodologies. All samples tested were taken from the same heat and batch to remove the influence of sample pedigree on the observed results. When the material was tested under constant-stress, thermal-cycle conditions, variations in the characteristic material responses were observed, depending on test methodology. The transformation strain and irreversible strain were impacted more than the transformation temperatures, which only showed an affect with regard to applied external stress. In some cases, test methodology altered the transformation strain by 0.005-0.01mm/mm, which translates into a difference in work output capability of approximately 2 J/cu cm (290 in!lbf/cu in). These results indicate the need for the development of testing standards so that meaningful data can be generated and successfully incorporated into viable models and hardware. The use of consistent testing procedures is also important when comparing results from one research organization to another. To this end, differences in the observed responses will be presented, contrasted and rationalized, in hopes of eventually developing standardized testing procedures for shape memory alloys.

Padula, Santo A., II↗

DOE OSTI2021

Effects of cyclic plasma heating on surface damage of micro-porous tungsten

The operating temperature window of solid tungsten (W) is dictated by its Ductile to Brittle Transition Temperature (DBTT) and re-crystallization temperature; roughly between 300-1300 °C. The brittleness of W at lower temperatures is exasperated when it undergoes recrystallization. We investigate here the thermal shock resistance of micro-porous W as a meta-material fabricated in a 3D open-cell network structure. We present experimental results for the effects of cyclic high-enthalpy arc-jet plasma on surface damage in three testing categories. Observed damage includes surface ablation of asperities, melting and solidification of W-fuzz on samples that have been exposed to a prior helium plasma, and micro-cracks at ligament triple junctions. Scanning electron microscope (SEM) observations show more micro-cracking on 54% and 23% foams compared to the 43% ones. In all tested samples, thermal expansion/contraction displacements were accommodated by ligament rotation and a network of micro-cracks. Furthermore, no large through-thickness crack were observed.

36 MATERIALS SCIENCE↗

NASA NTRS2025

Engineered Edge Effect Stress Redistribution in Suspended Thin Film Stacks for Flatness Control

This paper presents the systematic study of edge effect stresses and interaction between thin film stacks to achieve flat suspended thin film structures. Finite element modeling (FEM) was used for rapid analysis of support structures on microshutter array (MSA) shutter blades. The design application aims to flatten the blades to provide ultra-high contrast to optical detectors using MSAs as field masks. This is the first comprehensive study of microscopic surface feature edge effect and film-to-film stress interaction in micro electromechanical systems (MEMS). This study demonstrates flattening of thin film stacks by stress redistribution by induced shear force at the edge of strategically designed reinforcement structures.

Thin Film MEMS↗

DOE OSTI2013

Changes of O/M, dimension and microstructure of MOX pellet during heat treatment

The oxidation and reduction behaviors of sintered (Pu{sub 0.3}U{sub 0.7})O{sub 2-x} pellets have been studied at 1873 K under a controlled oxygen partial pressure. From the results of oxygen-to-metal (O/M) ratio changes, dimensional and structural changes, it was concluded that the crack nucleation-propagation and the local density change of pores were caused by the tensile and compressive stresses due to the O/M ratio distribution in the direction of the pellet radius. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Thermo-mechanical characterization of silicone foams

Cellular solids such as elastomeric foams are used in many structural applications to absorb and dissipate energy, due to their light weight (low density) and high energy absorption capability. In this paper we will discuss foams derived from S5370, a silicone foam formulation developed by Dow Corning. In the application presented, the foam is consolidated into a cushion component of constant thickness but variable density. A mechanical material model developed by Lewis (2013), predicts material response, in part, as a function of relative density. To determine the required parameters for this model we have obtained the mechanical response in compression for ambient, cold and hot temperatures. The variable density cushion provided samples sufficient samples so that the effect of sample initial density on the mechanical response could be studied. The mechanical response data showed extreme sensitivity to relative density. We also observed at strains corresponding to 1 MPa a linear relationship between strain and initial density for all temperatures. Samples taken from parts with a history of thermal cycling demonstrated a stiffening response that was a function of temperature, with the trend of more stiffness as temperature increased above ambient. This observation is in agreement with the entropic effects on the thermo-mechanical behavior of silicone polymers. In this study, we present the experimental methods necessary for the development of a material model, the testing protocol, analysis of test data, and a discussion of load (stress) and gap (strain) as a function of sample initial densities and temperatures

36 MATERIALS SCIENCE↗

NASA NTRS2019

Development of a Maxwell X-57 High Lift Motor Reference Design

NASA's all-electric X-57 airplane will utilize 14 electric motors, of which 12 are exclusively for lift augmentation during takeoff and landing. This report covers the design and development process taken to create an open reference model representative of the 12 lift augmenting motors. A combined worst case scenario was used as the design point, which represents the simultaneously occurring worst case aspects of thermal, static stress, electromagnetic, and rotor dynamic conditions. This work also highlights the tightly coupled nature of aerospace electric motor design, requiring constant iteration between all disciplines involved. Further adding to the uniqueness is the cooling method, which is limited to nacelle skin forced convection cooling only, no internal air flow is permitted. The stator outer diameter limit of 156.45 mm greatly impacts the degree of coupling between the electromagnetic design with the thermal analysis. The permanent magnet synchronous motor developed here operates between 385 V and 538 V, at a peak current of 50 A. Detailed electromagnetic, thermal, static load, and rotordynamic analysis was completed for this electric motor; all of which are required for a full design. The rotordynamic analysis took into consideration the motor housing which is designed specifically for this motor. The final electric motor has a mass of 2.34 kg, produces 24.1 Nm of torque with a specific power of 5.56 kW/kg, and has an efficiency of 96.61% at the combined worst case design point.

Electric Aircraft↗

DOE OSTI2018

High-Temperature Mechanical Properties of the P/M Extruded Mg-SiC{sub p} Composites

In the present study, pure magnesium reinforced with 0, 5, 10 and 15 vol.% SiC particulates was successfully prepared by powder metallurgy technique before being hot extruded. The average 14 μm grain size of the composite specimens remained almost unchanged after addition of SiC particles, while their dimensional stability was improved because of the reduction in the coefficient of thermal expansion (CTE) from 28.6 × 10{sup −6} K{sup −1} in pure Mg to 27.3, 25.3 and 23.4 × 10{sup −6} K{sup −1} in the Mg-5% SiC, Mg-10% SiC and Mg-15% SiC composites, respectively. Mechanical properties of the specimens were investigated in the temperature range of 298-498 K, implementing shear punch testing and hot hardness techniques. Depending on the test temperature, addition of SiC particles to the pure Mg matrix increased shear yield stress and ultimate shear strength of the materials by 5-25 and 6-23 MPa, respectively. The shear strength improvement was mainly attributed to the CTE mismatch strengthening mechanism (9.5-25.5 MPa), and to a lesser extent (1-4.5 MPa), to the load transfer mechanism. Finally, using the modified Clyne model, the contribution of different strengthening mechanisms to the total shear strength improvement in the composites was evaluated.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗

DOE OSTI2018

Trends in SiC MOSFET Threshold Voltage and ON-Resistance Measurements from Thermal Cycling and Electrical Switching Stresses: Preprint

Integrating SiC power MOSFETs is very attractive for advancing power electronic systems, yet the system reliability with new devices remains in question. This work presents two accelerated test experiments to further investigate the packaging and semiconductor failures of a TO-247 SiC MOSFET. First, a variation on power cycling experiments -- switching cycling -- is introduced. Traditional power cycling experiments utilize conduction losses to self-heat the device where a large temperature swing causes degradation at the packaging level. However, by decreasing the on-time such that the device only turns on and immediately turns off, the temperature swing is decreased and the semiconductor itself is degraded. This work shows experimental device degradation caused by continuous switching events - switching cycling, at 90% of the device's breakdown voltage. Second, thermal cycling experiments were conducted between -40 degrees C and 175 degrees C to observe degradation in the mechanical packaging of the device. Experimentally-measured changes in threshold voltage and ON-resistance are recorded in both experiments and compared. These results also illustrate the spectrum between device and package degradation from accelerated test methods.

33 ADVANCED PROPULSION SYSTEMS↗