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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Structural Certification of Human-Rated Inflatable Space Structures

This paper details the results of an initial study to develop a certification plan for human-rated inflatable space structures, including guidelines for qualification testing. Habitable softgoods inflatables are multi-layered shell structures that use high-strength webbing, cordage and broadcloth fabric to carry the skin loads of a variety of volumetric shapes and structural architectures. The primary objectives of this study are to define the key parameters that affect these structures and propose a statistically robust approach to defining safety and knockdown factors based on test and analysis. Current NASA standards for habitable inflatable space structures use a factor of safety of 4, which was inherited from airship design criteria. An updated approach to defining a design factor, taking into account material strength variability, load variability in the article, number of test samples, and damage and degradation effects is specified. Accurate analytical modeling of these structures is hindered by the difficulty of obtaining accurate and consistent material data due to load-history- dependent, nonlinear load versus strain behavior. A building block approach to certification is detailed that uses stochastic modeling and statistical test design and analysis to address the unique challenges these high-strength softgoods structures present. Human-rated inflatable modules are a transformative capability for launching much larger habitable volumes into space than is possible with rigid shell structures. This research aims to provide the framework for certifying these structures for future human space exploration missions.

Jones, Thomas C.↗
DOE OSTI2024

Cracked Gridline Wear Out Follows a Power Law

Cracks can form in Silicon solar cells in photovoltaic modules due to mechanical stresses arising from various extrinsic factors like handling and weather. While the immediate performance degradation may be minor, continuous loading overtime will degrade module performance. One probable reason is gridline surface wear across the cracked silicon with increased cyclic loading. In this work we propose a method to correlate gridline wear to module electrical degradation. We begin by conducting cyclic four-point bending tests on laminated silicon solar cells with a single crack and 22 intact gridlines for 10,000 cycles. We measure the progressive change in resistance during each loading cycle. We correlate it to a length scale called critical crack opening displacement (CCOD) that signifies failure of individual gridlines. By employing Weibull analysis, we determine the characteristic CCOD for all cycles and fit this data to a modified version of a wear power law. We observe that this i ts the data well. We also propose to study the effect of individual parameters in the power law equation and extend the equation to include material properties.

bending↗
NASA NTRS1999

"Ultra"-Fast Fracture Strength of Advanced Structural Ceramic Materials Studied at Elevated Temperatures

The accurate determination of inert strength is important in reliable life prediction of structural ceramic components. At ambient temperature, the inert strength of a brittle material is typically regarded as free of the effects of slow crack growth due to stress corrosion. Therefore, the inert strength can be determined either by eliminating active species, especially moisture, with an appropriate inert medium, or by using a very high test rate. However, at elevated temperatures, the concept or definition of the inert strength of brittle ceramic materials is not clear, since temperature itself is a degrading environment, resulting in strength degradation through slow crack growth and/or creep. Since the mechanism to control strength is rate-dependent viscous flow, the only conceivable way to determine the inert strength at elevated temperatures is to utilize a very fast test rate that either minimizes the time for or eliminates slow crack growth. Few experimental studies have measured the elevated-temperature, inert (or "ultra"-fast fracture) strength of advanced ceramics. At the NASA Lewis Research Center, an experimental study was initiated to better understand the "ultra"-fast fracture strength behavior of advanced ceramics at elevated temperatures. Fourteen advanced ceramics - one alumina, eleven silicon nitrides, and two silicon carbides - have been tested using constant stress-rate (dynamic fatigue) testing in flexure with a series of stress rates including the "ultra"-fast stress rate of 33 000 MPa/sec with digitally controlled test frames. The results for these 14 advanced ceramics indicate that, notwithstanding possible changes in flaw populations as well as flaw configurations because of elevated temperatures, the strength at 33 000 MPa/sec approached the room-temperature strength or reached a higher value than that determined at the conventional test rate of 30 MPa/sec. On the basis of the experimental data, it can be stated that the elevated-temperature, inert strength of an advanced ceramic material can be defined as the strength where no slow crack growth takes place at the temperature.

Choi, Sung R.↗
DOE OSTI2022

Unveiling the interaction of nanopatterned void superlattices with irradiation cascades

Nanopatterned microstructures in materials can have a profound impact on materials’ physical and chemical properties. While voids are typically considered as detrimental defects in irradiated materials, the patterning of nanoscale voids causes the formation of void superlattices and provides a highly efficient mechanism for gas storage. Despite the important applications of nanopatterned defect superlattices, how they degrade under irradiation remains unclear. Here we provide direct observation of the evolution of void superlattices under irradiation and elucidate the interaction of void superlattices with irradiation cascades. We reveal that the instability of void superlattices under irradiation is caused by heterogenous void shrinkage and demonstrate the imperative role of mixed 1D/3D diffusion of self-interstitial atoms and injected inert gas atoms on void shrinkage and void superlattice instability. Understanding the degradation mechanisms of nanopatterned microstructures is essential to designing damage-tolerant materials and broadening their applications in extreme environments.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Reliability of structural brittle materials

Traditionally, the use of brittle materials has been avoided in demanding structural applications because of their unreliability. They have been used however, due to other desirable properties, in nonstructural applications or where the mechanical load is minimal. The most common method utilized today for the design approach of brittle materials is the probabilistic, which takes into consideration the flaw and stress distribution within the brittle material. It does not take into consideration the fracture mechanics effect of strength degradation while aging under a mechanical load. This project will combine the two methods, probabilistic and fracture mechanics, into a more reliable design method for brittle materials.

Hall, W. B.↗
DOE OSTI2024

Interaction of Polymethyl Methacrylate with Boehmite-Filmed Aluminum Cladding Under Gamma Irradiation

This paper presents an overview of ongoing work to qualify the Advanced Test Reactor (ATR) driver fuel elements that have been affected by irradiation-degraded polymethyl methacrylate (PMMA) flux wands. Irradiation testing was performed on PMMA material in contact with aluminum clad material. The cladding was prefilmed with a boehmite oxide layer, an important feature of the ATR driver fuel. The effects on the boehmite layer due to gamma irradiation of the PMMA-aluminum clad system were investigated. PMMA embrittlement, followed by softening and degradation, occurred at high radiation levels. Adhesion between the cladding and irradiated PMMA was observed. Flow testing at prototypic ATR flow rates demonstrated the effective removal of the adhered material. Measurements of the boehmite layer thickness were performed, and Raman spectroscopy was utilized to detect the presence of boehmite in the irradiated PMMA material.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Degradation of Lithium Iron Phosphate Sulfide Solid-State Batteries by Conductive Interfaces

The superionic solid-state argyrodite electrolyte Li 6 PS 5 Br can improve lithium and lithium-ion batteries' safety and energy density. Despite many reports validating the conductivity of this electrolyte, it still suffers from passivating electrode degradation mechanisms. At first analysis, lithium iron phosphate (LFP) should be more thermodynamically stable in contact with sulfide electrolytes. However, without substantial improvements to interfacial engineering, we find that LFP is not inherently stable against Li 6 PS 5 Br. We hypothesize argyrodite oxidation favorably competes with LFPAs delithiation, insulating the electrolyte-electrode interface and causing large overpotential losses. We show that compared to LiNi x Mn y Co z O 2 , LFP has no actual electrochemical stability advantage despite operating at a lower voltage. We utilize tender energy XAS and XPS to show that chemical reactions occur between LFP and the Li 6 PS 5 Br solid electrolyte and these reactions are exacerbated by cycling. We also show that electrochemical degradation occurs at the interface between the solid electrolyte ion conductor and any electron conductor, namely the active material and carbon additives. We further demonstrate that LiNbO 3 cathode coatings on LFP can delay electrochemical degradation by electronically insulating the LFP-sulfide electrolyte interface but not prevent its occurrence at the carbon-electrolyte interface.

25 ENERGY STORAGE↗
DOE OSTI2024

Experimental Considerations for Estimating Degradation in PV Modules

Carefully controlled laboratory experiments and measurements can enable the determination of acceleration factors suitable for extrapolation to durability and performance of a fielded PV module. Ideally, a single mechanism can be identified with appropriate acceleration factors for extrapolation to the field. However, even with a single mechanism, the inherent uncertainty in these factors leads to uncertainty in the extrapolation which is greater the higher the acceleration factor. This course will explain how because of the wide range of acceleration factors for a given degradation mode, utilizing acceleration factors greater than about 10x will typically lead to unacceptable uncertainty in the results. Therefore, if even just a rank ordering of materials is desired, acceleration factors must be minimized which requires a good general understanding of the scale of the different acceleration factors for the degradation mode of interest. In this tutorial we will discuss what the different purposes are for many of the accelerated stress tests used today. E.g., what is a qualification test, a highly accelerated stress test, a rank ordering test, or a service life prediction test. We will discuss how one can understand the relationship between test results and expected field performance. A single accelerated stress test condition cannot duplicate outdoor exposure for all possible degradation pathways; therefore, one must use targeted evaluation of material properties at different stress levels to determine the relevant acceleration factors and fit it to a model. We will also discuss how to interpret the results of experiments understanding what is relevant/not relevant, or not e valuated in a test. There are many common error people make in their test interpretations because they push the stress levels to be too harsh. This creates biases and can mask the relevant failure modes and mechanisms or will erroneously lead one to over design materials against things that aren't relevant. Several case studies will be presented to illustrate appropriate interpretation of accelerated stress testing results.

degradation↗
DOE OSTI2020

Systems and devices for pumping and controlling high temperature fluids

The disclosed technology includes pumps, pipes, valves, seals, and systems for pumping and controlling high temperature fluids, such as liquid tin, at temperatures of between 1000-3000° C. The systems and device may be partially or entirely constructed using brittle materials, such as ceramics, that are capable of withstanding extreme heat without significantly degrading, and may be secured using components made of refractory metals, such as tungsten. The systems and devices may utilize static and dynamic seals made from brittle materials, such as graphite, to enable the high temperature operation of such pumps, pipes, valves, and systems without leakage.

Henry, Asegun↗
DOE OSTI2023

The Center for Performance and Design of Nuclear Waste Forms and Containers (WastePD) Energy Frontier Research Center (Final Report)

The DOE Office of Environmental Management is responsible for high level nuclear waste that must be safely isolated from humans and the environment for extremely long periods. The waste forms and containers are made of glass, ceramics, and metals. Verified safe disposal requires understanding the fundamental mechanisms of waste form degradation and the design of new waste forms with improved performance, which comprise the goals of the Energy Frontier Research Center known as the Center for the Performance and Design of Nuclear Waste Forms and Containers, WastePD. WastePD was constructed to develop innovative approaches and solutions to those goals through the synergistic interactions of individuals who are experts in the degradation behavior, modeling, and design of glasses, ceramics and metal alloys. WastePD is the first center ever created to address this diverse group of materials in a comprehensive and coordinated manner. The science goals are grouped into three common topics: corrosion mechanisms via advanced characterization, environmental impacts, and materials design. Synergistic interactions in these areas were a key component of WastePD. The fundamental understanding of the degradation mechanisms of the waste forms and containers as well as the development of new materials with improved properties will allow DOE to prevent environmental contamination and to explore totally new repository concepts. WastePD was operational from August 2016 through July 2022, but the DOE support was drastically reduced for the last two years. This final technical report covers the full period of performance. However, much of what was accomplished in the first four years is nicely summarized in a review paper published in 2021, which is appended to this report. Therefore, this final report focuses on the technical findings from the last two years of WastePD activities. Considerable progress was made in the areas of a) the environmental and compositional impacts on the corrosion of borosilicate and aluminosilicate glasses, b) the mechanism of glass corrosion and the structure and evolution of the surface alteration layer, c) the effects of environment and composition on the corrosion of pyrochlore, perovskite, hollandite, and other oxide ceramics, d) the corrosion mechanism of multi-principal element metallic alloys, and e) a new framework for understanding the pitting corrosion of metals.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Influence of alkali-silica reaction on the shear capacity of reinforced concrete beams with minimum transverse reinforcement

A growing number of critical concrete infrastructure are affected by alkali-silica reaction (ASR) damage such as the Seabrook Nuclear Power Plant in New Hampshire, Parker arch-gravity dam in Arizona, and several highway bridges in California and Texas. ASR causes expansion and cracking and degrades the concrete mechanical properties. Despite a wealth of material level studies there is still limited large-scale experimental data regarding the effects of ASR on reinforced concrete (RC) members. Due to the brittle nature of the shear failure in RC structures, this study focuses on the shear response of full-scale ASR damaged RC beams with minimum shear reinforcement. Six RC beams were built with different levels of ASR susceptibility and conditioned in different environments during which continuous expansion monitoring was performed. The beams all contained reactive fine aggregate (sand) and two of them had additional alkali, 1.25% by weight of cement, to accelerate ASR. The highest expansion rate of the beams happened during the first 150 days and the expansions stayed constant after 240 days and 330 days for beams conditioned in outdoor and laboratory conditions, respectively, until the last measurement at 575 days. The highest expansion, 0.4%, was seen in the beams with additional alkali and conditioned outside with regular water spray. Out of the six beams, three were selected at different levels of ASR damage and two shear tests were performed on the minimally reinforced spans close to the ends of each beam. Results indicated that beams gain shear strength from ongoing cement hydration in the presence of moisture for ASR expansions less than 0.2%. Compared to one of the beams with 0.2% ASR expansion, one of the other samples with 0.4% expansion lost 6% of its shear strength, 25% of its shear stiffness, and showed about two times larger shear cracks and shear deformations at peak load. Finally, the shear reinforcement yielded at 20% less load in the beam with 0.4% expansion compared to the beam with 0.2% expansion.

42 ENGINEERING↗
DOE OSTI2020

Mixing in ICF implosions on the National Ignition Facility caused by the fill-tube

The micrometer-scale tube that fills capsules with thermonuclear fuel in inertial confinement fusion experiments at the National Ignition Facility is also one of the implosion's main degradation sources. It seeds a perturbation that injects the ablator material into the center, radiating away some of the hot-spot energy. This paper discusses how the perturbation arises in experiments using high-density carbon ablators and how the ablator mix interacts once it enters the hot-spot. Both modeling and experiments show an in-flight areal-density perturbation and localized x-ray emission at stagnation from the fill-tube. Simulations suggest that the fill-tube is degrading an otherwise 1D implosion by ~2×, but when other degradation sources are present, the yield reduction is closer to 20%. Characteristics of the fill-tube assembly, such as the through-hole size and the glue mass, alter the dynamics and magnitude of the degradation. Overall, these aspects point the way toward improvements in the design, some of which (smaller diameter fill-tube) have already shown improvements.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Physical Properties of Hilti HIT-RE 500 V3 After Irradiation: Slant Shear, Tensile, Flexural, and Compressive

There are various applications in which epoxy adhesives may be used within hot-cell environments. These epoxies currently see limited use within hot cells since it is known that organics see degradation after small doses even as low as 50 kilogray (kGy). These losses in physical property strengths limit the use of these epoxies to non-structural applications. In modern construction, however, the use of epoxies to bond structural components such as rebar or threaded anchors is becoming increasingly prevalent. To employ these types of materials the Idaho National Laboratory (INL) has begun investigating the specific degradation properties of epoxies for use in structural applications in environments where radiation is present. Hilti HIT-RE 500 V3 is used extensively in new construction and renovation projects across the world. The INL has conducted various tests on this epoxy for low dose environments. These tests include tensile, flexural, compression, and slant shear tests following the American Society for Testing Material International (ASTM) standards D638, D790, D695, and C882/882M respectively. Two sample sets for each test were created where the baseline specimens were not irradiated, and another set was irradiated to an accumulated dose of approximately 50-60 kGy. All the samples were destructively tested and analyzed focusing on the change in physical properties, examples of these tests are shown in Figures 1-4. Tensile testing results indicate a 0.9% loss in maximum load capacity, a 0.5% loss in tensile stress at maximum load, a 1.4% loss in tensile strain at break, and a 15% decrease in modulus of elasticity. Flexural testing results display an increase in all the following: 12% in strain at maximum load, 10% in maximum load capacity, 5% in stress at maximum load, and 3% in young’s modulus. The compressive physical properties after irradiation display a 1% increase in maximum load, a 3% decrease in stress at yield, and a 5% decrease in modulus of elasticity. The maximum compressive stress saw no measurable change after irradiation. The slant shear specimens after irradiation displayed a 2% increase in maximum load capacity and maximum compressive stress. Though a structural analysis would have to be completed as is normal for building design the increases and decreases in the measured physical properties indicate that this material may be used for structural applications in low dose hot-cell environments without adhesive failure.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mitigating Process Induced Degradation in p- and n-Czochralski Silicon Wafers with Tabula Rasa

We report on the bulk properties of of n- and p- type Czochralski silicon (Cz-Si) after a high-temperature annealing process known as Tabula Rasa (TR), which is primarily used to annihilate oxygen precipitates. We find significant differences in n- and p-type substrates as well as a strong dependence on the ambient in the resulting process induced degradation. We attribute this ambient dependence to either injection of interstitials or vacancies into the bulk during TR. Finally, we show that subsequent gettering is enhanced due to the annihilation of oxygen precipitates.

14 SOLAR ENERGY↗
DOE OSTI2023

Characterizing Density and Spatial Distribution of Trap States in Ta 3 N 5 Thin Films for Rational Defect Passivation

Tantalum nitride (Ta 3 N 5 ) has gained significant attention as a potential photoanode material, yet it has been challenged by material quality issues. Defect-induced trap states are detrimental to the performance of any semiconductor material. Beyond influencing the performance of Ta 3 N 5 films, defects can also accelerate the degradation in water during desired electrochemical applications. Defect passivation has provided an enormous boost to the development of many semiconductor materials but is currently in its infancy for Ta 3 N 5 . This is in part due to a lack of experimental understanding regarding the spatial and energetic distribution of trap states throughout Ta 3 N 5 thin films. Here, we employ drive-level capacitance profiling (DLCP) to experimentally resolve the spatial and energetic distribution of trap states throughout Ta 3 N 5 thin films. The density of deeper energetic traps is found to reach ∼2.5 to 6 × 10 22 cm –3 at the interfaces of neat Ta 3 N 5 thin films, over an order of magnitude greater than the bulk. In addition to the spatial profile of deep trap states, we report neat Ta 3 N 5 thin films to be highly n-type in nature, owning a free carrier density of ∼9.74 × 10 17 cm –3 . This information, coupled with the present understanding of native oxide layers on Ta 3 N 5 , has facilitated the rational design of a targeted passivation strategy that simultaneously provides a means for catalyst immobilization. Loading catalyst via silatrane moieties suppresses the density of defects at the surface of Ta 3 N 5 thin films by two orders of magnitude, while also reducing the free carrier density of films by over one order of magnitude, effectively dedoping the films to ∼2.40 × 10 16 cm –3 . The surface passivation of Ta 3 N 5 films translates to suppressed defect-induced trapping and recombination of photoexcited carriers, as determined through absorption, photoluminescence, and transient photovoltage. Here, this illustrates how developing a deeper understanding of the distribution and influence of defects in Ta 3 N 5 thin films has the potential to guide future works and ultimately accelerate the integration and development of high-performance Ta 3 N 5 thin film devices.

defect passivation↗
NASA NTRS1984

Effect of space environment on space-based radar phased-array antenna (A0133)

Kapton polyimide film was selected as the baseline material for the Grumman spce based radar (SBR) concept. To gain the requisite confidence for long-term service durability, it is desirable to subject material specimens as well as a portion of the SBR antenna directly to the combined space environment and compare property degradation to that caused by laboratory simulation. The overall objective of this program is to evauate the effect of the space environment on polymeric materials currently being considered for the Grumman SBR Phased-Array Antenna. Degradation mechanisms caused by thermal cycling, ultraviolet and charged-particle irradiation, applied load, and high-voltage plasma interaction will be evaluated. The experiment occupies a 6-in.-deep end corner tray located on the space end of the Long Duration Exposure Facility and consists of both passive and active parts. The passive part addresses the effect of environment and stress on the dimensional stability spliced and continuous Kapton, both plain and reinforced. The active part will study the interaction of high voltage and low-Earth-orbit plasma.

Delasi, R. J.↗
NASA NTRS1992

Space environmental effects on silvered Teflon thermal control surfaces

Cumulative space environmental effects on silver/fluorinated ethylene propylene (Ag/FEP) were a function of exposure orientation. Samples from nineteen silvered Teflon (Ag/FEP) thermal control surfaces recovered from the Long Duration Exposure Facility (LDEF) were analyzed to determine changes in this material as a function of position on the spacecraft. Although solar absorptance and infrared emittance of measured thermal blanket specimens are relatively unchanged from control specimen values, significant changes in surface morphology, composition, and chemistry were observed. We hypothesize that the FEP surfaces on the LDEF are degraded by UV radiation at all orientations, but that the damaged material has been removed by erosion from the blankets exposed to atomic oxygen flux and that contamination is masking the damage in some areas on the trays flanking the trailing edge.

Hemminger, C. S.↗
NASA NTRS2010

Refractory Materials for Flame Deflector Protection

Fondu Fyre (FF) is currently the only refractory material qualified for use in the flame trench at KSC's Shuttle Launch Pads 39A and 3913. However, the material is not used as it was qualified and has undergone increasingly frequent and severe degradation due to the launch blasts. This degradation is costly as well as dangerous for launch infrastructure, crew and vehicle. The launch environment at KSC is unique. The refractory material is subject to the normal seacoast environment, is completely saturated with water before launch, and is subjected to vibrations and aggressive heat/blast conditions during launch. This report presents results comparing two alternate materials, Ultra-Tek FS gun mix and Kruzite GR Plus, with Fondu Fyre. The materials were subjected to bulk density, porosity, compression strength, modulus of rupture and thermal shock tests. In addition, test specimens were exposed to conditions meant to simulate the launch environment at KSC to help better understand how the materials will perform once installed.

Calle, Luz M.↗