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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Sensor Based Engine Life Calculation: A Probabilistic Perspective

It is generally known that an engine component will accumulate damage (life usage) during its lifetime of use in a harsh operating environment. The commonly used cycle count for engine component usage monitoring has an inherent range of uncertainty which can be overly costly or potentially less safe from an operational standpoint. With the advance of computer technology, engine operation modeling, and the understanding of damage accumulation physics, it is possible (and desirable) to use the available sensor information to make a more accurate assessment of engine component usage. This paper describes a probabilistic approach to quantify the effects of engine operating parameter uncertainties on the thermomechanical fatigue (TMF) life of a selected engine part. A closed-loop engine simulation with a TMF life model is used to calculate the life consumption of different mission cycles. A Monte Carlo simulation approach is used to generate the statistical life usage profile for different operating assumptions. The probabilities of failure of different operating conditions are compared to illustrate the importance of the engine component life calculation using sensor information. The results of this study clearly show that a sensor-based life cycle calculation can greatly reduce the risk of component failure as well as extend on-wing component life by avoiding unnecessary maintenance actions.

Guo, Ten-Huei↗
DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗
NASA NTRS2010

Evolving Material Porosity on an Additive Manufacturing Simulation with the Generalized Method of Cells

The effect of material porosity on final part distortion and residual stresses in a selective laser sintering manufacturing simulation is presented here. A time-dependent thermomechanical model is used with the open-source FEA software CalculiX. Effective homogenized material properties for Inconel 625 are precomputed using NASA’s Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC). The evolving porosity of the material is estimated with each pass of the laser beam during simulation runtime. A comparison with a homogenous model and the evolving model shows that the evolving porous model predicts larger distortions with greater residual stresses.

Silva, Luis F.↗
NASA NTRS1993

An analysis of isothermal, bithermal, and thermomechanical fatigue data of Haynes 188 and B1900+Hf by energy considerations

The low-cycle fatigue behavior of Haynes 188 and B1900+Hf under isothermal, bithermal, and thermomechanical loading conditions has been analyzed on the basis of the total hysteresis energy expended per cycle. It has been observed that in the case of isothermal fatigue the total hysteresis energy correlates well with the fatigue life. In the case of bithermal 'high rate' fatigue, for a given total hysteresis energy per cycle, the fatigue life is equal to or greater than the isothermal fatigue life at the maximum bithermal temperature. This observation could be used to establish a lower bound on life for design purposes. In one case of bithermal creep-fatigue and in thermomechanical fatigue, the life is shorter than that corresponding to the isothermal life at the maximum temperature. The energy supplied, per se, may not always give a systematic correlation with the fatigue life in the cases where time-dependent creep and environmental effects are encountered. Thus, in bithermal creep-fatigue and thermomechanical fatigue, the role of creep and environment and their dependence on the energy supplied have to be properly accounted for before the energy term can be used for life prediction.

Radhakrishnan, V. M.↗
DOE OSTI2021

Thermomechanical Microstructural Predictions of Fracture Nucleation of Zircaloy-4 Alloys With δ and ε Hydride Distributions

Abstract A crystalline dislocation-density formulation that was incorporated with a nonlinear finite-element (FE) method was utilized to understand and to predict the thermomechanical behavior of an hexagonal closest packed (h.c.p.) zircaloy system with hydrides with either face-centered cubic (f.c.c.) or body-centered cubic (b.c.c.) hydrides. This formulation was then used with a recently developed fracture methodology that is adapted for finite inelastic strains and multiphase crystalline systems to understand how different microstructurally based fracture modes nucleate and propagate. The interrelated microstructural characteristics of the different crystalline hydride and matrix phases with the necessary orientation relationships (ORs) have been represented, such that a detailed physical understanding of fracture nucleation and propagation can be predicted for the simultaneous thermomechanical failure modes of hydride populations and the matrix. The effects of volume fraction, morphology, crystalline structure, and orientation and distribution of the hydrides on simultaneous and multiple fracture modes were investigated for radial, circumferential, and mixed distributions. Another key aspect was accounting for temperatures changes due to the effects of thermal conduction and dissipated plastic work and their collective effects on fracture. For hydrided aggregates subjected to high temperatures, thermal softening resulted in higher ductility due to increased dislocation-density activity, which led to higher shear strain accumulation and inhibited crack nucleation and growth. The predictions provide validated insights into why circumferential hydrides are more fracture-resistant than radial hydrides for different volume fractions and thermomechanical loading conditions.

Engineering↗
DOE OSTI2024

Designing a Dynamic Material via Interlocking Kraft Lignin with Ultrahigh Molecular Weight Poly(ethylene oxide)

The environmental issues stemming from plastic waste and the excessive use of petroleum-based chemicals are both concerning and urgent. To effectively address this problem, we need to adopt a comprehensive approach involving developing more sustainable and renewable materials. These materials should be capable of demonstrating similar or even better performance than functional polymers synthesized from petroleum-based chemicals. Our research aims to develop more sustainable materials by leveraging the intrinsic characteristics of a natural polymer, lignin, a byproduct of the biorefinery industries. We utilized the three-dimensional branching structure of lignin as a material framework. We employed an approach to co-reactive melt processing of kraft lignin with aliphatic flexible chains of soft cross-linkers through the reaction of the cross-linker epoxy chain ends with lignin functional groups. Our study demonstrates that the interlocked structure formed from the co-blending of kraft lignin with ultrahigh molecular weight poly(ethylene oxide) and the cross-linking of lignin chains through a solvent-free process can manipulate the macromolecular interactions and relaxation. This manipulation results in materials that exhibit a wide range of thermomechanical properties and self-healing and shape memory effects, with drastically improved stiffness in a single material. We have explored the fundamental understanding of the macromolecular chain relaxation dynamics originating from the interlocking structure formation. In conclusion, this investigation utilized various techniques, including thermal, mechanical, rheology, and quasi-elastic neutron scattering.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Atomistic modeling of interface strengthening in Al-Si eutectic alloys

Al-Si cast alloys are usually composed of α-Al and Al-Si eutectic. Si flakes and Al matrix generally hold cube-on-cube orientation relationship with the primary interface (111) Al ∥(111) Si . Extensive experimental studies demonstrated that Si flakes cannot significantly improve mechanical properties of Al-Si cast alloys. We hypothesize that the weak strengthening effect associated with Si flakes might be attributed to thermomechanical properties of Al-Si interfaces besides their morphologies. To characterize Al-Si interfaces with a large lattice mismatch (> 30%), we proposed the quasi-coincident site lattice (Q-CSL) as reference lattice, and demonstrated that the Q-CSL Al-Si coherent interface has three characteristic coherent structures, one stable and low energy structure and two metastable and high energy structures. The translation vectors for the same type of coherent Q-CSL structures are consistent with three displacement shift complete (DSC) vectors. The two metastable structures can be obtained by shifting the low energy structure with three partial DSC vectors. Semi-coherent interface is composed of the low energy Q-CSL patches and three sets of interface misfit dislocations with Burgers vectors same as the DSC vectors. Atomistic simulations revealed that Al-Si interface exhibits low shear resistance. Ideal shear strength of the Q-CSL coherent interface is 110 MPa and semi-coherent interface is 20 MPa. The low shear resistance is attributed to the glide of interface misfit dislocations. Al-Si interface also exhibits low formation and migration energies of point defects. Owing to low shear strength and low formation and migration energies of point defects, interface sliding or shear readily happen under mechanical loading or during dislocation-interface interactions. Lattice dislocations can cross slip onto or climb along Al-Si interfaces. These reactions decrease the number of accumulated dislocation loops around Si flakes and promote nucleation and emission of lattice dislocations from Al-Si interfaces to matrix, consequently reduce the repulsive force on approaching dislocations and weaken Si flakes strengthening effect. In situ tension and compression tests in a scanning electron microscope reveal relatively weak strengthening effect due to Si flakes, consistent with the computed dislocation interaction with interfaces and shear behavior of interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermomechanical Separation of Biogenic and Non-biogenic Carbon from Non-Recyclable MSW

The effective separation of biogenic and non-biogenic carbon from non-recyclable municipal solid waste (n-MSW) presents a significant challenge in the United States. Currently, there are no efficient methods available to address this issue, hindering the potential for maximizing waste utilization and reducing landfilling rates. This project aims to develop and implement a combine thermomechanical separation techniques to separate biogenic and non-biogenic carbon within n-MSW, ultimately facilitating greater resource recovery and enhancing the efficiency and environmental impact of waste management practices.

09 - BIOMASS FUELS↗
DOE OSTI2025

Relationship Between Filler Type, Thermomechanical Properties, and Aging of RTV Silicone Foams

Room-temperature vulcanizing (RTV) silicone foams are used in many industrial applications that require the material to perform over long time periods. However, mechanical properties tend to deteriorate when these foams age under a compressive load. The chemical aging is attributed to the presence of unreacted functional groups of the prepolymers, residues from acid, and catalytically active tin (II) species. Here, an optimized thermal treatment of an RTV foam that achieves completion of curing reactions and deactivation of reactive species is proposed. Foams that were thermally aged for three months under compressive load showed no signs of compression set, indicative of the effectiveness of the implemented post-curing approach. In addition, the effects of fillers (diatomaceous earth, fumed silica, and carbon nanofibers) on thermomechanical properties were investigated. Tensile strength, tear strength, and thermal conductivity increased when these fillers were added to the unfilled RTV formulation, with carbon nanofibers (CNFs) being the most effective filler. Rheological studies of RTV formulations indicated that 2.5 wt.% of CNFs is the upper limit that can be added to the RTV formulation.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Additive Manufacturing of Poly(phenylene Sulfide) Aerogels via Simultaneous Material Extrusion and Thermally Induced Phase Separation

Abstract Additive manufacturing (AM) of aerogels increases the achievable geometric complexity, and affords fabrication of hierarchically porous structures. In this work, a custom heated material extrusion (MEX) device prints aerogels of poly(phenylene sulfide) (PPS), an engineering thermoplastic, via in situ thermally induced phase separation (TIPS). First, pre‐prepared solid gel inks are dissolved at high temperatures in the heated extruder barrel to form a homogeneous polymer solution. Solutions are then extruded onto a room‐temperature substrate, where printed roads maintain their bead shape and rapidly solidify via TIPS, thus enabling layer‐wise MEX AM. Printed gels are converted to aerogels via postprocessing solvent exchange and freeze‐drying. This work explores the effect of ink composition on printed aerogel morphology and thermomechanical properties. Scanning electron microscopy micrographs reveal complex hierarchical microstructures that are compositionally dependent. Printed aerogels demonstrate tailorable porosities (50.0–74.8%) and densities (0.345–0.684 g cm −3 ), which align well with cast aerogel analogs. Differential scanning calorimetry thermograms indicate printed aerogels are highly crystalline (≈43%), suggesting that printing does not inhibit the solidification process occurring during TIPS (polymer crystallization). Uniaxial compression testing reveals that compositionally dependent microstructure governs aerogel mechanical behavior, with compressive moduli ranging from 33.0 to 106.5 MPa.

Chemistry↗
NASA NTRS1973

Liquid oxygen-compatible filament-winding matrix resin

Polyurethanes derived from hydroxy terminated polyperfluoro propylene oxide prepolymers were evaluated as matrix resins for filament wound composites which would be exposed to liquid (and 100% gaseous) oxygen environments. A number of structural modifications were brought about by variations in prepolymer molecular weight, and alternative curing agents which allowed retention of the oxygen compatibility. Although satisfactory performance was achieved at sub-ambient temperatures, the derived composites suffered considerable property loss at ambient or slightly elevated temperatures. To attain overall effectiveness of the composite system, upgrading of the polymer thermomechanical properties must first be achieved.

Harrison, E. S.↗
NASA NTRS1984

The B2 aluminides as alternative materials

The potential of the B2 aluminides as structural material alternatives for the strategic element containing superalloys currently used in gas turbine engines is being explored with emphasis on the equiatomic Fe and Ni aluminides. Although Co is a strategic material, the equiatomic Co aluminide is also being studied to gain a more complete understanding of these fourth period intermetallics. Research focuses on initial processing techniques such as ingot melting, power metallurgy, and rapid solidification with and without additional thermomechanical processing; high temperature deformation - primarily compressive creep; compositional effects within the binary B2 aluminides; third-element alloying addition effects on high temperature strength and oxidation resistance, and near room temperature ductility as influenced by processing, alloying, and grain size. Various programs now underway are reviewed and some highlights of research results are presented.

Stephens, J. R.↗
NASA NTRS1985

The B2 aluminides as alternative materials

The potential of the B2 aluminides as structural material alternatives for the strategic element containing superalloys currently used in gas turbine engines is being explored with emphasis on the equiatomic Fe and Ni aluminides. Although Co is a strategic material, the equiatomic Co aluminide is also being studied to gain a more complete understanding of these fourth period intermetallics. Research focuses on initial processing techniques such as ingot melting, power metallurgy, and rapid solidification with and without additional thermomechanical processing; high temperature deformation primarily compressive creep; compositional effects within the binary B2 aluminides; third-element alloying addition effects on high temperature strength and oxidation resistance, and near room temperature ductility as influenced by processing, alloying, and grain size. Various programs now underway are reviewed and some highlights of research results are presented.

Stephens, J. R.↗
NASA NTRS1985

Creep fatigue life prediction for engine hot section materials (isotropic): Third year progress review

This program is designed to investigate fundamental damage processes, identify modeling strategies, and develop practical models which can be used to guide the early design and development of new engines and to increase the durability of existing engines. A review is given of the base program, completed in 1984, which included the comparison and evaluation of several popular high-temperature life prediction approaches as applied to continuously cycled isothermal specimen tests. The option program, of which one year is completed, is designed to develop models which can account for complex cycles and loadings, such as thermomechanical cycling, cumulative damage, multiaxial stress/strain rates, and environmental effects.

Nelson, Richard S.↗
NASA NTRS1989

Mean stress and the exhaustion of fatigue-damage resistance

Mean-stress effects on fatigue life are critical in isothermal and thermomechanically loaded materials and composites. Unfortunately, existing mean-stress life-prediction methods do not incorporate physical fatigue damage mechanisms. An objective is to examine the relation between mean-stress induced damage (as measured by acoustic emission) and existing life-prediction methods. Acoustic emission instrumentation has indicated that, as with static yielding, fatigue damage results from dislocation buildup and motion until dislocation saturation is reached, after which void formation and coalescence predominate. Correlation of damage processes with similar mechanisms under monotonic loading led to a reinterpretation of Goodman diagrams for 40 alloys and a modification of Morrow's formulation for life prediction under mean stresses. Further testing, using acoustic emission to monitor dislocation dynamics, can generate data for developing a more general model for fatigue under mean stress.

Berkovits, Avraham↗
NASA NTRS1988

Slip effects associated with Knudsen transport phenomena in porous media

Porous media used in phase separators and thermomechanical pumps have been the subject of characterization efforts based on the Darcy permeability of laminar continuum flow. The latter is not always observed at low speed, in particular at permeabilities below 10 to the -9th/squared cm. The present experimental and theoretical studies address questions of slip effects associated with long mean free paths of gas flow at room temperature. Data obtained are in good agreement, within data uncertainty, with a simplified asymptotic Knudsen equation proposed for porous plugs on the basis of Knudsen's classical flow equation for long mean free paths.

Frederking, T. H. K.↗
NASA NTRSDate not supplied

Thermomechanical Relaxation of Vibrationally Excited NO in a Hypersonic Turbulent Boundary Layer

The effects of thermal nonequilibrium are studied using a DC glow discharge plasma to selectively modify the vibrational temperature of an otherwise cold flow. These experiments were performed at 𝑴=5.7and 𝑹𝒆=6×10 6 /m in the Actively Controlled Expansion tunnel at Texas A&M University on a canonical 2.75° half-angle wedge test article. A∼47 W plasma was generated across spanwise electrodes, and removable trips produced either a laminar or turbulent boundary layer. NO planar laser-induced fluorescence (PLIF) quantified the extent of the NO 𝑿 2 𝚷 (𝒗=1) vibrational perturbation due to the plasma and its subsequent interplay with the boundary layer, the first such data of which the authors are aware. NOPLIF measurements were taken at three locations along the test article, and quasi-temperature measurements are reported at each. Despite not quantifiably perturbing the boundary layer, the plasma was shown to alter the NO vibrational temperature profile therein. Independent analysis of the thermodynamics and fluid mechanics of the system suggests each set of physics could explain the results observed near and far from the wall, respectively.

Casey J. Broslawski↗
NASA NTRSDate not supplied

Thermomechanical Relaxation of Vibrationally Excited NO in a Hypersonic Turbulent Boundary Layer

The effects of thermal nonequilibrium are studied using a DC glow discharge plasma to selectively modify the vibrational temperature of an otherwise cold flow. These experiments were performed at 𝑴=5.7and 𝑹𝒆=6×10 6 /m in the Actively Controlled Expansion tunnel at Texas A&M University on a canonical 2.75° half-angle wedge test article. A∼47 W plasma was generated across spanwise electrodes, and removable trips produced either a laminar or turbulent boundary layer. NO planar laser-induced fluorescence (PLIF) quantified the extent of the NO 𝑿 2 𝚷 (𝒗=1) vibrational perturbation due to the plasma and its subsequent interplay with the boundary layer, the first such data of which the authors are aware. NOPLIF measurements were taken at three locations along the test article, and quasi-temperature measurements are reported at each. Despite not quantifiably perturbing the boundary layer, the plasma was shown to alter the NO vibrational temperature profile therein. Independent analysis of the thermodynamics and fluid mechanics of the system suggests each set of physics could explain the results observed near and far from the wall, respectively.

Casey J. Broslawski↗