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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 1,477 records · Page 82
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

WhiteWind: White Etching Crack (WEC) Bearing Failures in Wind Turbine: Cooperative Research and Development, CRADA Number CRD-18-00758 (Final Report)

A WEC is a particularly aggressive, unpredictable and wide spread rolling element bearing failure mode that is common for large multi-megawatt (MW) wind turbines. WEC is considered the single most expensive failure mode for all wind turbine components, and there is currently no commercial solution. The Technical University of Denmark (DTU) is leading the WhiteWind project to investigate WECs through funding provided by the Innovation Fund Denmark. Other project partners include Vestas, SKF, Expanite, Rheinisch-Westfalische Technische Hochschule Aachen University (RWTH Aachen), and Argonne National Laboratory. The objective of the overall project is to develop a new surface engineered WEC-resistant bearing material using novel surface engineering techniques that shall provide a commercially competitive alternative to existing wind turbine bearings. NREL will support the project by providing existing measured bearing loads and validating models of drivetrain loads.

17 WIND ENERGY↗
DOE OSTI2020

White-light interferometry for early-stage metal oxide growth characterization

Oxidation of metals can provide a functional oxide film or an oxide layer that can lead to material degradation causing performance limiting concerns. Because of the technological and economic impacts of oxidation, understanding early-stage oxidation growth and its mechanisms is of high importance. Unfortunately, poor empirical data during early-stage oxidation has left our current understanding of oxidation incomplete and woefully inadequate. Measurement techniques previously used for oxidation kinetics characterization include microbalance, x-ray diffraction, Fourier-transform infrared spectroscopy, and spectroscopic ellipsometry. However, these techniques lack the necessary time-resolution or vertical resolution in addition to not providing any spatial data, which is essential to early-stage oxidation studies to understand both oxidation kinetics and mechanisms. Here, a novel rapid and surface-sensitive data collection technique that provides three-dimensional spatial data of a growing oxide layer with sub-nanometer thickness resolution using white-light interferometry has been developed. This technique will be the first technique capable of providing real-time spatial results of early-stage oxidation growth. The effectiveness of this characterization tool is shown by observing the early-stage oxidation kinetics and film cracking of uranium heated to 90 °C under 500 torr of pure O 2 . Initially a parabolic oxidation growth is observed. Once the oxide layer reaches ≈ 30 nm, the epitaxial stresses between the uranium substrate and oxide film layer causes localized cracking in addition to the observed transition of the parabolic growth rate to a linear growth rate. The results of the white-light interferometry are verified by glancing incidence x-ray diffraction.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Low-Pressure Diffusion Bonding of Vanadium to Commercially Pure Titanium and Ti-6Al-4V

Modern technology increasingly requires components to be made from specific high-performance materials. To support complex multi-metal structures, a variety of techniques are required to join dissimilar metal parts with precise shapes. This study evaluates vacuum diffusion bonding as a method for joining titanium and vanadium, focusing on both pure titanium and the common alloy Ti-6Al-4V. We employ modest pressure provided by a weight and simple surface preparation to simulate the most commercially applicable process. Here, we show that Ti-6Al-4V alloy bonds readily to V, forming a continuous, clearly defined interdiffusion layer with predictable kinetics. Conversely, commercially pure Ti forms a crack-prone bond with V that fails to improve at higher bonding temperatures or longer times. We attribute this failure to the concentration of stress caused by the ß-to-α phase transformation in Ti. The contrasting bonding efficacy between pure Ti and the alloy provides insight into the crystallographic interactions that occur at the interface during bonding and cooling. These results provide surprising insight into a new method for bonding Ti alloys to V and possibly other metals that share the body-centered cubic crystal structure.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Detection of fiber cracking by acoustic emission.

A theoretical model is presented that relates acoustic emission to fiber cracking which occurs during a rising load tension test on a fiber reinforced composite. The percentage of broken fibers in an Al3Ni fiber reinforced aluminum was measured as a function of tensile strain by optical inspection of the polished surface of strained specimens. This information was used in conjunction with the proposed model to predict the acoustic emission response of the composite material. These predictions were compared with experimental observations, and a good agreement was obtained between the two sets of results. These results indicate that it is possible to relate acoustic emission quantitatively to the micromechanics of the deformation processes occurring within fiber reinforced composites, thereby demonstrating the applicability of acoustic emission to materials studies and also to nondestructive evaluation of the integrity of composite materials.

Harris, D. O.↗
NASA NTRS1972

A material selection method based on material properties and operating parameters

The influence of strength, fracture toughness, and crack growth resistance on the design stress level has been determined from a mathematical model of crack growth and failure. The results show that to select materials properly, the operating parameters of desired life and initial flaw size must be considered simultaneously with the material properties. To do this, a method for constructing an operating surface is derived, discussed, and illustrated.

Elber, W.↗
NASA NTRS1979

Brief note for consideration of active seismic exploration on Mars

Considerable controversy has arisen regarding the existence of water and water ice below the surface of Mars. Results of laboratory internal friction measurements on strongly outgassed rocks, recently made as part of an effort to interpret the high seismic Q values observed in the lunar crust, show that moisture absorbed in pores and cracks causes the low Q values. Unfortunately, the Viking seismology investigation found a surprisingly inactive planet. This note makes the case for active seismic exploration in order to ascertain the existence of liquid water in the crust from Q determinations.

Tittmann, B. R.↗
NASA NTRS1988

Monolithic ceramic analysis using the SCARE program

The Structural Ceramics Analysis and Reliability Evaluation (SCARE) computer program calculates the fast fracture reliability of monolithic ceramic components. The code is a post-processor to the MSC/NASTRAN general purpose finite element program. The SCARE program automatically accepts the MSC/NASTRAN output necessary to compute reliability. This includes element stresses, temperatures, volumes, and areas. The SCARE program computes two-parameter Weibull strength distributions from input fracture data for both volume and surface flaws. The distributions can then be used to calculate the reliability of geometrically complex components subjected to multiaxial stress states. Several fracture criteria and flaw types are available for selection by the user, including out-of-plane crack extension theories. The theoretical basis for the reliability calculations was proposed by Batdorf. These models combine linear elastic fracture mechanics (LEFM) with Weibull statistics to provide a mechanistic failure criterion. Other fracture theories included in SCARE are the normal stress averaging technique and the principle of independent action. The objective of this presentation is to summarize these theories, including their limitations and advantages, and to provide a general description of the SCARE program, along with example problems.

Manderscheid, Jane M.↗
NASA NTRS1994

Temperature measurement using infrared imaging systems during turbine engine altitude testing

This report details the use of infrared imaging for temperature measurement and thermal pattern determination during simulated altitude engine testing in the NASA Lewis Propulsion Systems Laboratory. Three identical argon-cooled imaging systems were installed in the facility exhaust collector behind sapphire windows to look at engine internal surfaces. The report describes the components of each system, presents the specifics of the complicated installation, and explains the operation of the systems during engine testing. During the program, several problems emerged, such as argon contamination system, component overheating, cracked sapphire windows, and other unexplained effects. This report includes a summary of the difficulties as well as the solutions developed. The systems performed well, considering they were in an unusually harsh exhaust environment. Both video and digital data were recorded, and the information provided valuable material for the engineers and designers to quickly make any necessary design changes to the engine hardware cooling system. The knowledge and experience gained during this program greatly simplified the installation and use of the systems during later test programs in the facility. The infrared imaging systems have significantly enhanced the measurement capabilities of the facility, and have become an outstanding and versatile testing resource in the Propulsion Systems Laboratory.

Burns, Maureen E.↗
NASA NTRS1995

Reliability Analysis of Uniaxially Ground Brittle Materials

The fast fracture strength distribution of uniaxially ground, alpha silicon carbide was investigated as a function of grinding angle relative to the principal stress direction in flexure. Both as-ground and ground/annealed surfaces were investigated. The resulting flexural strength distributions were used to verify reliability models and predict the strength distribution of larger plate specimens tested in biaxial flexure. Complete fractography was done on the specimens. Failures occurred from agglomerates, machining cracks, or hybrid flaws that consisted of a machining crack located at a processing agglomerate. Annealing eliminated failures due to machining damage. Reliability analyses were performed using two and three parameter Weibull and Batdorf methodologies. The Weibull size effect was demonstrated for machining flaws. Mixed mode reliability models reasonably predicted the strength distributions of uniaxial flexure and biaxial plate specimens.

Salem, Jonathan A.↗
NASA NTRS1999

Teflon FEP Analyzed After Retrieval From the Hubble Space Telescope

During the Hubble Space Telescope (HST) Second Servicing Mission, 6.8 years after the telescope was deployed in low Earth orbit, degradation of unsupported Teflon FEP (DuPont; fluorinated ethylene propylene), used as the outer layer of the multilayer insulation (MLI) blankets, was evident as large cracks on the telescope light shield. A sample of the degraded outer layer (see the photograph) was retrieved during the second servicing mission and returned to Earth for ground testing and evaluation. Also retrieved was a Teflon FEP radiator surface from a cryogen vent cover that was exposed to the space environment on the aft bulkhead of the HST. NASA Goddard Space Flight Center directed the efforts of the Hubble Space Telescope MLI Failure Review Board, whose goals included determining the FEP degradation mechanisms. As part of the investigations into the degradation mechanisms, specimens retrieved from the first and second HST servicing missions, 3.6 and 6.8 years after launch, respectively, were characterized through exhaustive mechanical, optical, and chemical testing. Testing led by Goddard included scanning electron microscopy, optical microscopy, tensile testing, solar absorptance measurements, time-of-flight secondary ion mass spectroscopy (TOF-SIMS), Fourier transform infrared microscopy (m-FTIR), attenuated total reflectance infrared microscopy (ATR/FTIR), and x-ray diffraction (XRD). The NASA Lewis Research Center contributed significantly to the analysis of the retrieved HST materials by leading efforts and providing results of bend testing, surface microhardness measurements, x-ray photoelectron spectroscopy, solid-state nuclear magnetic resonance spectroscopy, and density measurements. Other testing was conducted by Nano Instruments, Inc., and the University of Akron.

Dever, Joyce A.↗
NASA NTRS2026

Influences of Introduced Yttrium Oxide Particles on Superalloy 718

Additive manufacturing has proven useful for introducing oxide particles into superalloys, to provide oxide dispersion strengthening (ODS) at high temperatures. This study screened how such an approach can influence microstructure and failure modes for superalloy 718. The objective of this study was to compare tensile and creep failure modes for additively manufactured superalloy 718 having introduced oxide particles. Fine yttrium-oxide (yttria) particles were introduced into 718 powder using two different powder mixing methods. Additive manufacturing by laser powder bed fusion was then used to prepare specimen blanks for each case, oriented parallel and transverse to the building direction. These were subsequently given consistent stress relief, hot isostatic pressurization, and final heat treatments, then subjected to tensile and creep tests at varied temperatures. Additively manufactured 718 without ODS (“no-ODS”) had nearly equiaxed grains at 50 μm in width. Roll-mixed ODS material had a bimodal grain size distribution, with fine grains at 9 μm and coarse grains at 66 μm in average width. The fine grains were elongated about 5x in the building direction. Acoustic-mixed ODS materials had grains at 10 μm in width that were elongated about 10x in the build direction. Compared to no-ODS, roll-mixed and acoustic mixed ODS materials did not show improved tensile strengths at room temperature, 760 °C, and 1093 °C. The tensile failure strains parallel to the building direction of roll-mixed ODS material were lowest in these tests. Flattened clumps of yttria had formed transverse to the building direction in roll-mixed material, which were easily cracked. Creep rupture response at 760 °C in the building direction was highest for acoustic-mixed material test. Creep tests at 1093 °C showed varied results, with low rupture lives associated with enhanced cavitation at grain boundaries and surface oxidation. Transverse to the building direction, all three materials had low failure strains in tests at 760 °C. The elongated grain boundaries failed readily in all transverse specimens tested at 760 °C and 1093 °C.

oxide dispersion strengthening↗
NASA NTRS2010

Ultrasonic Monitoring of Ply Crack and Delamination Formation in Composite Tube Under Torsion Load

As a simple model of a rotor spar, a circular graphite-epoxy composite laminate cylinder was subjected to cyclic torsional load. The test section of the cylindrical specimen varied from four to six plies of plus or minus 45 degree fibers, due to intentional ply overlaps and gaps. A layer of 13-micrometer Teflon film was inserted between plies at three locations to serve as delamination initiators. A commercial X-Y scanner was mounted to the load frame to enable ultrasonic inspection without removing the specimen. A focused immersion probe was mounted in a captive water column with a rugged Nitrile membrane tip, which was coupled to the cylinder using a mist of soapy water. The transducer was aligned normal to the cylinder surface using the X-axis. Scanning was performed along the length of the specimen with the Y-axis and the specimen was incrementally rotated by the torsion head of the load frame. After 350k cycles of torsion, several linear 45 degree diagonal indications appeared as 5-40% attenuation of the back wall echo, with no apparent echoes from the interior of the composite, suggesting through-ply cracks in the innermost ply. Crack indications grew and new cracks appeared as torsion cycling continued. Internal reflections from delaminations associated with the growing ply cracks appeared after 500k cycles. Three areas of extensive multi-layer delaminations appeared after 1150k cycles. Failure of the specimen occurred at 1600k cycles. The observed progressive damage was not associated with the Teflon inclusions. Concurrent thermographic measurements provided lower resolution confirmation of the damage observed.

Johnston, P. H.↗
DOE OSTI2021

A comprehensive review on the loss of wellbore integrity due to cement failure and available remedial methods

With the recent abrupt fluctuations in oil pricing and the need of complying with environmental and social requirements, nowadays it is an urgent call for the oil and gas industry to produce the hydrocarbon without any loss as well as in a safe manner. Cements are placed in the annular space of casing to provide zonal isolation in between wellbore and surface during the operational life cycle of the well or even after the abandonment. But this is not what happens most of the time. Cement degrades or loses its integrity through debonding either from the casing or formation and generates cracks or fractures due to varied reasons throughout the life of the well. Multiple causes contribute to the loss of wellbore integrity – either by physical, mechanical, or chemical processes. These failures lead to sustained casing pressure (SCP) and contamination of surrounding environment. To combat this issue or to restore the well integrity, multiple remedial actions have also been either implemented in the industry or proposed based on experimental research to prevent the damage or to seal the leakage in the cement sheath. Here, this paper will provide an extensive review of the underlying reasons of cement failure and the available remedial actions to minimize the loss of well integrity issue. These information are not only useful to know about the different corrective options available for us to implement in industry but also it will provide us a knowledge base regarding how we can enhance the performance of the exiting systems to battle the cement integrity problem more efficiently.

02 PETROLEUM↗
NASA NTRS1981

Thermal fatigue behavior of H-13 die steel for aluminum die casting with various ion sputtered coatings

Sputtered coatings of Mo, W, Pt, Ag, Au, Co, Cr, Ni, Ag + Cu, Mo + Pt, Si3N4, A1N, Cr3C2, Ta5Si3, and ZrO2 were applied to a 2-inch-square, 7-inch-long thermal fatigue test specimen which was then internally water cooled and alternately immersed in molten aluminum and cooled in air. After 15,000 cycles the thermal fatigue cracks at the specimen corners were measured. Results indicate that a significant improvement in thermal fatigue resistance was obtained with platinum, molybdenum, and tungsten coatings. Metallographic examination indicates that the improvement in thermal fatigue resistance resulted from protection of the surface of the die steel from oxidation. The high yield strength and ductility of molybdenum and tungsten contributed to the better thermal fatigue resistance.

Nieh, C. Y.↗
NASA NTRS1992

Damage and failure mechanisms of continuous glass fiber reinforced polyphenylene sulfide

The damage that accompanies flexural deformation of a unidirectional glass fiber composite of polyphenylene sulfide was examined by AE and SEM. These complementary techniques were used to identify damage mechanisms at the microscale and correlate them with the macroscopic stress state in four-point bending. The flexural stress-strain curve was nominally linear to about 1.0 percent strain, but the onset of damage detectable by AE occurred at 0.3 percent strain. Two peaks in the AE amplitude distribution were observed at 35 dB and 60 dB. Low-amplitude events were detected along the entire length of the specimen, and correlation with direct observations of damage made by deforming the composite on the SEM stage suggested that these events arose from matrix cracking and fiber debonding concentrated at flaws on the composite. High amplitude events occurred primarily in the region of highest flexural stress between the inner loading points. They were attributed to fracture of glass fibers on the tension side and surface damage on the compressive side.

Chen, F.↗
DOE OSTI2023

Accelerated Aging of PV Cables - The Development of Methods Towards Combined-Accelerated Stress Testing

PV cables allow the collection and distribution of electricity from modules to the energy grid. Durable cabling allows continuous operation of PV installations. Cables with a life less than that of the modules must be replaced - reducing electricity generation and adding to the system operating expense. We have examined the durability of a variety of representative cable samples using artificial UV weathering (IEC TS 62788-7-2) and combined accelerated stress testing (C-AST). Jackets in this study include PV-rated (polyolefin), building wire (PVC/PA), and multi-conductor (rubber, as in PV trackers), with some examples of black and red cables. Characterizations at read points include appearance (camera and optical microscope), surface roughness (linear profilometry), instrumented indentation, surface morphology (SEM), chemical composition (EDS), thermal decomposition (TGA), phase transition (DSC), crystalline structure (WAXS), and polymer chemical structure (FTIR). Complimentary examinations confirm damage to the external and interior layer(s) of less durable samples, including changes in morphology (e.g., cracking), chemistry (e.g., oxidation), structure, and mechanical performance (e.g., through-thickness modulus and hardness). The results may be generally compared to other examples from the field (PV installations) or after accelerated testing (IEC 61215). The methods in this study are presently being applied in a follow-on C-AST study, incorporating both dynamic and kinematic fixtures.

balance of systems↗
DOE OSTI2020

History of Ultrasonic Inspection of High-Level Waste Tanks at SRS - 20220

The Liquid Waste Disposition Projects (LWDP) Structural Authority and Inspection Engineering Support Group has teamed with the Materials Science and Technology Non-destructive Evaluation Group of Savannah River National Laboratory (SRNL) to implement a comprehensive In-Service Inspection (ISI) program for the High-Level Waste (HLW) tanks in the sites tank farms. The purpose of this program is to demonstrate the structural and leak integrity of the tanks to maintain the function of waste containment throughout the desired service life. Four types of waste tanks were constructed at Savannah River Site (SRS) from 1951 thru 1981 to store radioactive nuclear waste from the separations process. The Type I, II and III are carbon steel cylindrical tanks with varying degrees of access to the side walls and very limited access to the tank bottom. The tanks contain 750,000 to 1.3 million gallons of waste and are buried or backfilled with soil. The tanks are 75'-85' in diameter and 24'-33' from tank bottom to the tank roof. Inspection of the HLW tanks is made difficult by radiation, contamination, and small access openings. Through the years these challenges have been overcome by progressive improvements to programs and equipment resulting in the sophisticated wall crawler Ultrasonic Testing (UT) technology of today. A formal inspection program was developed and put in service in 1972. UT thickness measurements were first made in 1967 and 1969 of selected waste tanks using an analog-type instrument to measure the thickness of the carbon steel walls. Routine inspections for thinning were performed from 1972-1985 and then discontinued because no thinning had been observed and this technique could not detect pitting or cracking. UT inspections resumed in 1994 using a sophisticated robotic wall crawler with UT technology capable of detecting thinning, cracking and pitting. The current program focuses on the newer Type III tanks that are used primarily for storage. The program was upgraded in 2003 to include selected regions of the tank wall, secondary wall and annulus floor on a 7 to 10-year frequency. The facility is currently in its third cycle of tank inspections. Thus far, there have been no reportable indications of service induced degradation. This result provides assurance that the chemistry control program has been effective at mitigating corrosion and that the tanks remain structurally sound even after more than 40 years of service. This paper will present the UT technology first used at SRS and the evolution to the current systems and their capabilities. Additionally, plans for equipment upgrades that will improve the extent of inspection will be discussed. (authors)

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

Thermal Chemistry of Nickel Diketonate Atomic Layer Deposition (ALD) Precursors on Tantalum and Silicon Oxide Surfaces

The mechanism of the thermal conversion of both bis(2,2,6,6-tetramethyl-3,5-heptanedionato)nickel(II) (Ni(TMHD) 2 ) and the protonated ligand (TMHD-H) adsorbed on TaO x and SiO 2 /TaO x surfaces was characterized under ultrahigh vacuum (UHV) by a combination of temperature-programmed desorption (TPD) and X-ray photoelectron spectroscopy (XPS) experiments. In this work, A stepwise decomposition was observed with Ni(TMHD) 2 encompassing at least four different stages: (1) a ligand loss, to release TMHD-H; (2) a surprising ligand fractioning via the scission of an inner C–C bond within the central β-diketonate moiety to produce an aldehyde (pivaldehyde) and a ketone (pinacolone); (3) further ligand splitting following a more extensive cracking to yield an olefin (from dehydrogenation of the terminal tert-butyl group), carbon monoxide, and adsorbed methylene groups; and finally, (4) the loss of one oxygen atom from the remaining ligands to produce the corresponding enone. As these conversions take place, the Ni ion is reduced, first to a partially oxidized intermediate, as the first ligand is removed, and then to its metallic state as the remaining organic fragments migrate to the surface. A similar sequence was seen on both surfaces, but with the transitions taking place at higher temperatures on SiO 2 . The implications of these results to the surface chemistry of other ALD precursors and to the design of ALD processes are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗