Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Materials Design”

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.

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

At least 1,495 records · Page 83
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Materials and Processes for New Propulsion Systems with Reduced Environmental Impact

Aeronautics research at NASA Glenn Research Center includes development, characterization and modeling of high temperature, lightweight materials and fabrication processes for aircraft propulsion systems with increased efficiency and reduced emissions, fuel burn and noise. Current propulsion materials research includes Ceramic Matrix Composites and Environmental Barrier Coatings, Polymer Matrix Composites and Additive Manufacturing processes. This presentation will summarize recent progress and plans in these areas. Ceramic Matrix Composites for Turbine Components: As part of NASA's Aeronautics research, Glenn Research Center has developed Ceramic Matrix Composites for 2700 degrees Fahrenheit turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of advanced fiber and matrix constituents that enabled this advancement will be reviewed, and characterization of the resulting improvements in mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Progress and plans for collaborative research with industry and other government agencies will be reviewed. Polymer Matrix Composites for Powertrain and Impact Protection: A lightweight, hybrid polymer matrix composite/steel gear concept for rotorcraft power transmission applications was evaluated at realistic speed, torque, and power conditions. Dynamic testing was performed at 5000 horsepower and 5400 revolutions per minute with no performance degradation. Test results demonstrated the potential of hybrid composite / metal gears to reduce gear weight by approximately 15 percent, enabling the implementation of multi-speed drive systems, which would otherwise have a weight penalty, for increased speed and efficiency. Results of post-test inspection and endurance tests will be presented. Separately, ballistic impact tests demonstrated improved damage tolerance in polymer matrix composites by incorporating lightweight, thermoplastic veil materials between selected composite plies during the composite fabrication process. Results of impact tests and post-test inspection will be presented. Additive Manufacturing for Electric Propulsion: Additive Manufacturing processes offer the potential to fabricate new, high power density electric motor designs with complex geometries, multi-material components and optimally designed components that would not be feasible with traditional manufacturing processes. High performance stator components using advanced 3-phase conductive coils were fabricated using direct printing with optimized silver pastes. Additional additive manufacturing methods are being used to fabricate rotors and motor housing components. Systems studies show that the higher performance and lower weight motors offer improved energy efficiency and reduced emissions. Improvements to motor performance resulting from optimized materials and component designs will be presented.

Additive Manufacturing↗
NASA NTRS1989

Photovoltaic array environmental protection program

During the photovoltaic array environmental protection program, a coating material, application technique, and design approach intended to protect flexible solar array blankets during a nominal fifteen-year operating lifetime were developed. Numerous thin-film coatings for protecting the Kapton polyimide material used in the construction of the Space Station Freedom flexible solar array blanket were evaluated. The critical solar array design features and protection measures are discussed with special emphasis on the effects of solar array fabrication and flexible printed circuit manufacturing processes on coating durability. The results of the mechanical and environmental test evaluation, including oxygen plasma, neutral oxygen beam, and UV/charged-particle combined exposure, are discussed. These results led to the selection of a silicon dioxide thin-film coating to protect the solar array blanket from the low-earth-orbit atomic oxygen environment.

Bilger, Kevin M.↗
NASA NTRSDate not supplied

Machine Learning Approaches for Rare-Earth Silicate Environmental Barrier Coating Thermochemical and Thermomechanical Property Predictions

Environmental barrier coatings (EBCs) are a necessary enabling technology for the transition from superalloys to silicon carbide (SiC) ceramic matrix composites (CMCs) in gas turbine engines for increased efficiency and decreased fuel costs. SiC-based CMCs are prone to oxidation-based degradation in the engine hot section, and rare-earth (RE) silicates are promising candidates for EBCs due to their close thermal expansion match to the composite substrate and oxidation resistance. However, the design of EBCs is hindered by the large chemical space of candidate materials and the difficulty in obtaining material properties for engineering optimization. This is especially difficult as research continues into mixed-cation or “high-entropy” RE silicates. First-principles computational methods such as density functional theory (DFT) are highly effective at calculating material properties to guide coating design but are limited by their computational cost. Atomistic simulations have the potential to both accelerate property calculations and expand the properties able to be calculated due to their lower computational compared to DFT. However, they require interatomic potentials (IAPs) specific to the material system of interest, and, to our knowledge, there are no suitable IAPs for RE silicates. Machine learning (ML) is a promising technique to accelerate material property predictions indirectly by generating IAPs for atomistic simulations or via direct prediction. In this work, we present two ML approaches to accelerate the calculation of RE silicate properties relevant to EBC design: 1) a ML-derived interatomic potential (IAP) for atomistic simulations of yttrium disilicate (Y2Si2O7) from DFT training data, and 2) a neural network (NN) model to directly predict thermochemical properties of RE silicates and oxides directly from easily obtainable unit cell parameters. Classical MD simulations using the IAP yield lattice properties and bond lengths in good agreement with both DFT and experimental results from x-ray diffraction. Thermodynamic properties calculated using the finite-displacement phonon method and quasi-harmonic approximation were orders of magnitude faster than DFT with good agreement to the DFT results. The IAP was also used to calculate properties such as coefficient of thermal expansion (CTE) that require large simulation supercells and are therefore difficult with DFT. The IAP correctly predicted the anisotropic nature of the CTE in three different phases of Y2Si2O7. The NN model predicts constant pressure heat capacity, Cp, orders of magnitude faster than DFT calculations, which can enable its use as a surrogate model for multiscale simulations. The two methods presented in this work demonstrate the utility of ML for accelerating the prediction of RE silicate properties, which can in turn accelerate EBC design and optimization.

machine learning↗
NASA NTRS2005

NASA Research Center Contributions to Space Shuttle Return to Flight (SSRTF)

Contributions provided by the NASA Research Centers to key Space Shuttle return-to-flight milestones, with an emphasis on debris and Thermal Protection System (TPS) damage characterization, are described herein. Several CAIB recommendations and Space Shuttle Program directives deal with the mitigation of external tank foam insulation as a debris source, including material characterization as well as potential design changes, and an understanding of Orbiter TPS material characteristics, damage scenarios, and repair options. Ames, Glenn, and Langley Research Centers have performed analytic studies, conducted experimental testing, and developed new technologies, analysis tools, and hardware to contribute to each of these recommendations. For the External Tank (ET), these include studies of spray-on foam insulation (SOFI), investigations of potential design changes, and applications of advanced non-destructive evaluation (NDE) technologies to understand ET TPS shedding during liftoff and ascent. The end-to-end debris assessment included transport analysis to determine the probabilities of impact for various debris sources. For the Orbiter, methods were developed, and validated through experimental testing, to determine thresholds for potential damage of Orbiter TPS components. Analysis tools were developed and validated for on-orbit TPS damage assessments, especially in the area of aerothermal environments. Advanced NDE technologies were also applied to the Orbiter TPS components, including sensor technologies to detect wing leading edge impacts during liftoff and ascent. Work is continuing to develop certified TPS repair options and to develop improved methodologies for reinforced carbon-carbon (RCC) damage progression to assist in on-orbit repair decision philosophy.

Cockrell, Charles E., Jr.↗
NASA NTRS1973

Investigation of high temperature antennas for space shuttle

The design and development of high temperature antennas for the space shuttle orbiter are discussed. The antenna designs were based on three antenna types, an annular slot (L-Band), a linear slot (C-Band), and a horn (C-Band). The design approach was based on combining an RF window, which provides thermal protection, with an off-the-shelf antenna. Available antenna window materials were reviewed and compared, and the materials most compatible with the design requirements were selected. Two antenna window design approaches were considered: one employed a high temperature dielectric material and a low density insulation material, and the other an insulation material usable for the orbiter thermal protection system. Preliminary designs were formulated and integrated into the orbiter structure. Simple electrical models, with a series of window configurations, were constructed and tested. The results of tests and analyses for the final antenna system designs are given and show that high temperature antenna systems consisting of off-the-shelf antennas thermally protected by RF windows can be designed for the Space Shuttle Orbiter.

Kuhlman, E. A.↗
NASA NTRS1981

Ceramics for the AGT101 automotive gas turbine

An advanced gas turbine powertrain for automotive application is being developed. Objectives of the program include a fuel consumption of 42.8 mpg on No. 2 diesel fuel in a 3000 pound car, same overall vehicle performance as obtained with a conventional spark ignition internal combustion engine, low emission, multiple fuel capacity, reliability, and competitive cost. The AGT101 powertrain consists of a power section, gearbox and transmission, and the design and analysis conducted thus far support the initial engine concept, as no significant design changes have been required. The ceramic rotor design approach and component materials are discussed, and it is projected that the AGT powertrain will be competitive with any other alternative powertrain in meeting the design objectives.

Kreiner, D. M.↗
NASA NTRS1973

Material and structural studies of metal and polymer matrix composites

Fiber-reinforced composites and design analysis methods for these materials are being developed because of the vast potential of composites for decreasing weight and/or increasing use temperature capability in aerospace systems. These composites have potential for use in airbreathing engine components as well as aeronautical and space vehicle structures. Refractory wire-superalloy composites for use up to 2200 F or more and metal-matrix composites for lower temperature applications such as aerospace structures and turbojet fan and compressor blades are under investigation and are discussed. The development of a number of resin systems, including the polyimides and polyphenylquinoxalines, is described and their potential for use at temperatures approaching 315 C (600 F) is indicated. Various molecular modifications that improve processability and/or increase thermal and oxidative resistance of the resins are also described. Structural analysis methods are discussed for determining the stresses and deformations in complex composite systems. Consideration is also given to residual stresses resulting from the curing process and to the foreign object damage problem in fan blade applications.

Signorelli, R. A.↗
NASA NTRS1977

Feasibility of modern airships - Preliminary assessment

Attention is given to the NASA program, Feasibility Study of Modern Airships, initiated to investigate potential research and technology programs associated with airship development. A historical survey of the program is presented, including the development of past airship concepts, aerodynamical and design improvements, structure and material concepts, and research in controls, avionics, instrumentation, flight operations, and ground handling. A mission analysis was carried out which considered passenger and cargo transportation, heavy-lift, short-haul applications, surveillance missions, and the transportation of natural gas. A vehicle parametric analysis examined the entire range of airship concepts, discussing both conventional airships and hybrids. Various design options were evaluated, such as choice of structural materials, use of boundary-layer control, and choice of lifting gas.

Ardema, M. D.↗
NASA NTRS2000

Age and Stress Prediction

Genoa is a software product that predicts progressive aging and failure in a variety of materials. It is the result of a SBIR contract between the Glenn Research Center and Alpha Star Corporation. Genoa allows designers to determine if the materials they plan on applying to a structure are up to the task or if alternate materials should be considered. Genoa's two feature applications are its progressive failure simulations and its test verification. It allows for a reduction in inspection frequency, rapid design solutions, and manufacturing with low cost materials. It will benefit the aerospace, airline, and automotive industries, with future applications for other uses.

Source record↗
NASA NTRSDate not supplied

Risks of Depress as a Fire Suppression Technique in Spacecraft

Spacecraft are designed to prevent fires through careful material selection and configuration control combined with electrical design controls and isolation of ignition sources. Despite these best efforts, fire risk still exists due to the potential for configuration changes with the introduction of crew and the potential for a ‘failure of imagination’ by designers in anticipating all fuel and ignition sources. Therefore, fire suppression is a critical capability for any crewed spacecraft as a last resort for crew survival. Many spacecraft suppression methods have relied on fire suppressants such as compressed carbon dioxide, nitrogen, and water. A proposed alternative is depressurization of the cabin as a method to extinguish a fire. Limited testing was conducted during Skylab and showed that depress could result in stirring the air flow and aggravating a fire before extinguishing. However, limited information was available on how the test was conducted. To better characterize the approach, testing was conducted at NASA’s White Sands Test Facility to evaluate the effect of depressurization on material extinguishment. The results showed that depressurization does not provide a safe and effective fire suppression capability. The testing approach, results, and conclusions are described and discussed.

Toni Griego↗
NASA NTRS2002

Ti-48Al-2Cr-2Nb Evaluated Under Fretting Conditions

Material parameters govern many of the design decisions in any engineering task. When two materials are in contact and microscopically small, relative motions (either vibratory or creeping) occur, and fretting fatigue can result. Fretting fatigue is a material response influenced by the materials in contact as well as by such variables as loading and vibratory conditions. Fretting produces fresh, clean interacting surfaces and induces adhesion, galling, and wear in the contact zone. Time, money, and materials are unnecessarily wasted when galling and wear result in excessive fretting fatigue that leads to poorly performing, unreliable mechanical systems. Fretting fatigue is a complex problem of significant interest to aircraft engine manufacturers. It can occur in a variety of engine components. Numerous approaches, depending on the component and the operating conditions, have been taken to address the fretting problems. The components of interest in this investigation were the low-pressure turbine blades and disks. The blades in this case were titanium aluminide, Ti-48Al-2Cr- 2Nb, and the disk was a nickel-base superalloy, Inconel 718 (IN 718). A concern for these airfoils is the fretting in fitted interfaces at the dovetail where the blade and disk are connected. Careful design can reduce fretting in most cases, but not completely eliminate it, because the airfoils frequently have a skewed (angled) blade-disk dovetail attachment, which leads to a complex stress state. Furthermore, the local stress state becomes more complex when the influence of the metal-metal contact and the edge of contact are considered.

Miyoshi, Kazuhisa↗
NASA NTRS1978

Effect of impact damage on the compression strength of filamentary-composite hat-stiffened panels

An experimental investigation was conducted to evaluate the effect of low-velocity impact damage on the compression strength of filamentary-composite hat-stiffened panels. Twenty-four specimens of three design configurations fabricated from graphite-epoxy and boron-epoxy materials were tested. All three design configurations met the design buckling requirements in the undamaged condition. The impact damage was caused by firing aluminum spheres at the panels to simulate impact on aircraft from runway stones. Panels were damaged by impact in the hat cap or in the skin beneath the hat cap (regions of high axial stiffness) and in the skin between stiffeners (region of low axial stiffness). The panels were relatively insensitive to impact damage in the regions of low axial stiffness but were very sensitive to impact damage in the regions of high axial stiffness. Test results suggest that impact damage may be more dependent on the matrix properties than on the fiber properties of the composite materials considered.

Rhodes, M. D.↗
NASA NTRS1976

Optical mass memories

Optical and magnetic variants in the design of trillion-bit read/write memories are compared and tabulated. Components and materials suitable for a random access read/write nonmoving memory system are examined, with preference given to holography and photoplastic materials. Advantages and deficiencies of photoplastics are reviewed. Holographic page composer design, essential features of an optical memory with no moving parts, fiche-oriented random access memory design, and materials suitable for an efficient photoplastic fiche are considered. The optical variants offer advantages in lower volume and weight at data transfer rates near 1 Mbit/sec, but power drain is of the same order as for the magnetic variants (tape memory, disk memory). The mechanical properties of photoplastic film materials still leave much to be desired.

Bailey, G. A.↗
NASA NTRS1970

Medical vest broadens treatment capability

Universal sized vest, with specially tailored pockets designed to hold medical supplies, provides first aid/first care medical teams with broadened on-site capability. Vest is made of nylon, tough fibrous materials, and polyvinyl chloride. Design facilitates rapid donning, doffing, and adjustment.

Johnson, G. S.↗
NASA NTRS1983

Robotic Water Blast Cleaner

Water blasting system under development removes hard, dense, extraneous material from surfaces. High pressure pump forces water at supersonic speed through nozzle manipulated by robot. Impact of water blasts away unwanted material from workpiece rotated on air bearing turntable. Designed for removing thermal-protection material, system is adaptable to such industrial processes as cleaning iron or steel castings.

Sharpe, M. H.↗
NASA NTRS1985

Research and development activities in unified control-structure modeling and design

Results of work to develop a unified control/structures modeling and design capability for large space structures modeling are presented. Recent analytical results are presented to demonstrate the significant interdependence between structural and control properties. A new design methodology is suggested in which the structure, material properties, dynamic model and control design are all optimized simultaneously. Parallel research done by other researchers is reviewed. The development of a methodology for global design optimization is recommended as a long-term goal. It is suggested that this methodology should be incorporated into computer aided engineering programs, which eventually will be supplemented by an expert system to aid design optimization.

Nayak, A. P.↗
NASA NTRS1985

Research and development activities in unified control-structure modeling and design

Results of work sponsored by JPL and other organizations to develop a unified control/structures modeling and design capability for large space structures is presented. Recent analytical results are presented to demonstrate the significant interdependence between structural and control properties. A new design methodology is suggested in which the structure, material properties, dynamic model and control design are all optimized simultaneously. The development of a methodology for global design optimization is recommended as a long term goal. It is suggested that this methodology should be incorporated into computer aided engineering programs, which eventually will be supplemented by an expert system to aid design optimization. Recommendations are also presented for near term research activities at JPL. The key recommendation is to continue the development of integrated dynamic modeling/control design techniques, with special attention given to the development of structural models specially tailored to support design.

Nayak, A. P.↗