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At least 1,495 records · Page 83

Improved performance in NASTRAN (R)

Three areas of improvement in COSMIC/NASTRAN, 1989 release, were incorporated recently that make the analysis program run faster on large problems. Actual log files and actual timings on a few test samples that were run on IBM, CDC, VAX, and CRAY computers were compiled. The speed improvement is proportional to the problem size and number of continuation cards. Vectorizing certain operations in BANDIT, makes BANDIT run twice as fast in some large problems using structural elements with many node points. BANDIT is a built-in NASTRAN processor that optimizes the structural matrix bandwidth. The VAX matrix packing routine BLDPK was modified so that it is now packing a column of a matrix 3 to 9 times faster. The denser and bigger the matrix, the greater is the speed improvement. This improvement makes a host of routines and modules that involve matrix operation run significantly faster, and saves disc space for dense matrices. A UNIX version, converted from 1988 COSMIC/NASTRAN, was tested successfully on a Silicon Graphics computer using the UNIX V Operating System, with Berkeley 4.3 Extensions. The Utility Modules INPUTT5 and OUTPUT5 were expanded to handle table data, as well as matrices. Both INPUTT5 and OUTPUT5 are general input/output modules that read and write FORTRAN files with or without format. More user informative messages are echoed from PARAMR, PARAMD, and SCALAR modules to ensure proper data values and data types being handled. Two new Utility Modules, GINOFILE and DATABASE, were written for the 1989 release. Seven rigid elements are added to COSMIC/NASTRAN. They are: CRROD, CRBAR, CRTRPLT, CRBE1, CRBE2, CRBE3, and CRSPLINE.

Chan, Gordon C.↗

Gel-Filled Holders For Ultrasonic Transducers

In new technique, ultrasonic transducer embedded in rubbery, castable, low-loss gel to enable transducer to "look" into surface of test object or human body at any desired angle. Composed of solution of water and ethylene glycol in collagen matrix. Provides total contact of water bath, also used on bodies or objects too large for water baths, even if moving. Also provides look angles of poly(methyl methacrylate) angle block with potential of reduced acoustic impedance and refraction. Custom-tailored to task at hand, and gel sufficiently inexpensive to be discarded upon completion. Easy to couple ultrasound in and out of gel, minimizing losses and artifacts of other types of standoffs employed in ultrasonic testing.

Companion, John A.↗

Crack Development in Cross-Ply Laminates Under Uniaxial Tension

This study addresses matrix-dominated failures in carbon fiber/polymer matrix composite laminates in a cross-ply lay-up. The events of interest are interlaminar fracture in the form of transverse cracks in the 90' plies and longitudinal splitting in the 0 deg plies and interlaminar fracture in the form of 0/90 delamination. These events were observed using various nondestructive evaluation (NDE) techniques during static tensile tests. Acoustic emission (AE) x radiography, and edge view microscopy were the principal ones utilized in a real-time environment. A comparison of the NDE results with an analytical model based on the classical linear fracture mechanics concept of strain energy release rate as a criterion for crack growth was performed. The virtual crack closure theory was incorporated with a finite element model to generate strain energy release rate curves for the analytical case. Celion carbon fiber/polyimide matrix (G30-500/PMR-15) was the material tested with cross-ply lay-ups of (0(2)/90(6))s and (0(4)/90(4))s. The test specimens contained thermally induced cracks caused by the high-temperature processing. The analytical model was updated to compensate for the initial damage and to study further accumulation by taking into account the crack interactions. By correlating the experimental and analytical data, the critical energy release rates were found for the observable events of interest.

Gyekenyesi, Andrew L.↗

Effect of fiber diameter and matrix alloys on impact-resistant boron/aluminum composites

Efforts to improve the impact resistance of B/Al are reviewed and analyzed. Nonstandard thin-sheet charpy and Izod impact tests and standard full-size Charpy impact tests were conducted on composites containing unidirectional 0.10mm, 0.14mm, and 0.20mm diameter boron fibers in 1100, 2024, 5052, and 6061 Al matrices. Impact failure modes of B/Al are proposed in an attempt to describe the mechanisms involved and to provide insight for maximizing impact resistance. The impact strength of B/Al was significantly increased by proper selection of materials and processing. The use of a ductile matrix and large diameter boron fibers gave the highest impact strengths. This combination resulted in improved energy absorption through matrix shear deformation and multiple fiber breakage.

Mcdanels, D. L.↗

Accelerated Fuel Qualification of Fast Modular Reactor Fuel in a Thermal Reactor: Modeling and Simulation Paired with Irradiation Testing

The accelerated fuel qualification (AFQ) methodology is applied by simulating accelerated fuel tests of the General Atomics Electromagnetic Systems’ fuel system for its 44-MW(electric) gas-cooled, fast-spectrum fast modular reactor (FMR). This fuel is comprised of UO 2 pellets in SiGA® cladding, a silicon carbide ceramic matrix composite. Fast reactors, like the FMR, offer many benefits, including high fuel utilization and flexibility, but may require a lengthy material design process if tests are performed using fast neutron irradiation alone. A thermal neutron irradiation can instead be used to rapidly test how well key components of the current material models extend to high burnup. Thermal neutrons produce a different radial power distribution within the pin than fast neutrons. However, the temperature and burnup values for the two neutron types are comparable, and the differences between the simulated fuel responses are relatively small, demonstrating the weak sensitivity of the physics-based fuel model calculations on the neutron type and the irradiation rate. Furthermore, the deformation of the SiGA cladding saturates after about 1 displacement per atom for both neutron spectra. In an accelerated fuel test, the irradiation time required to reach the target fuel burnup can be reduced by a factor of 3 by using a small rodlet with a 45% smaller pellet diameter while maintaining the same linear power. Therefore, the time for data collection up to high burnup can be significantly reduced while maintaining the same temperature profile, which largely determines the material response. Tests of fuel rodlets of standard and compact size will be carried out in the Idaho National Laboratory’s Advanced Test Reactor (ATR), including full size and compact rodlets with varying gap sizes. By applying physics-based mechanistic modeling and simulation in accordance with the AFQ methodology, this type of compact rodlet testing in a thermal test reactor captures the necessary phenomena to test fuel material models up to high burnup and to simulate the expected impact of fast neutron radiation on the fuel in FMR operations. Finally, this approach to testing fast reactor fuels in existing thermal test reactors, paired with advanced physics-based mechanistic modeling and simulation, is expected to be applicable to a range of advanced fuels and will decrease the overall fuel qualification timeframe from decades to years.

Advanced test reactor (ATR)↗

Can Semi-Volatile Organic Aerosols Lead to Fewer Cloud Particles?

The impact of condensing organic aerosols on activated cloud number concentration is examined in a new aerosol microphysics box model, MATRIX-VBS. The model includes the volatility-basis set (VBS) framework coupled with the aerosol microphysical scheme MATRIX (Multiconfiguration Aerosol TRacker of mIXing state) that resolves aerosol mass and number concentrations and aerosol mixing state. By including the condensation of organic aerosols, the new model produces less activated particles compared to the original model, which treats organic aerosols as non-volatile. Parameters such as aerosol chemical composition, mass and number concentrations, and particle sizes which affect activated cloud number concentration are thoroughly tested via a suite of Monte-Carlo simulations. Results show that by considering semi-volatile organics in MATRIX-VBS, there is lower activated particle number concentration, except in cases with low cloud updrafts, in clean environment at above freezing temperatures, and in polluted environments at high temperature (310K) and extremely low humidity conditions.

Gao, Chloe Y.↗

Metallic Powder Core Tubular Wire (PCTW) Development for Additive Manufacturing

NASA Langley Research Center (LaRC) in Hampton, VA, and the Center for Welding, Joining, and Coating Research (CWJCR) in the Department of Metallurgical and Materials Engineering at the Colorado School of Mines (CSM) in Golden, CO, have collaborated for nearly fifteen years to develop metallic powder core tubular wire (PCTW) feedstock for additive manufacturing (AM) using electron beam deposition. The motivation for this development was to offset dealloying observed during deposition of titanium and aluminum alloy solid wire feedstock in the LaRC electron beam freeform fabrication (EBF3) system and to explore novel alloy compositions by tailoring the powder fill. EBF3 is a fusion-based AM process that is performed under vacuum and is consequently prone to vaporization loss of low vapor pressure alloying elements. Research spanning four graduate student research projects succeeded in developing the basic methodology to fabricate PCTW, the mass balance equations used to define the powder fill, microstructure control through particulate inoculation, and the feasibility of producing metal matrix composite materials. Metallic PCTW is comprised of a thin foil sheath wrapped around a powder blend. Fabrication of PCTW at CSM was accomplished using a tubular wire mill system to first bend a flat strip into a u-shaped cross section, deposit a powder fill, create a lap joint to seal the wire, and draw to final diameter. Powder management systems were developed to ensure uniform mixing of powder constituents and identify feed rates for optimum fill ratios. Processing parameters were successfully developed for titanium and aluminum alloy sheaths to account for material work hardening during drawing. Mass balance equations were developed to account for compositional contributions of the sheath and powder fill. PCTW composition can be adjusted through selection of the sheath or powder materials. PCTWs were successfully developed to offset Al loss in deposits of Ti-6-4 and Mg loss in Al 6061, resulting in deposits that were within the composition limits for each material. Ti-6-4 deposits were fabricated using PCTW comprised of commercially pure (CP) titanium sheath and a fill of pre-alloyed Ti-6-4 powder with additions of elemental Al and V powders. Additions of both elements were required to account for the CP Ti from the sheath, and Al was further enhanced to offset documented losses in EBF3 deposits. For Al 6061 deposits, composition was modulated through the choice of sheath material. The PCTW was made using an Al 5052 sheath to supplement Mg content and a fill composition of pre-alloyed 6061 powder with additions of Si and Cu.The slower solidification rate of the EBF3 process compared with laser powder bed fusion processes can lead to coarse-grained microstructures and mechanical property anisotropy. EBF3deposits of Ti-6-4 exhibited large epitaxially grown β grains, which result in degraded mechanical properties in the deposition direction. Microstructure refinement was achieved through a combination of electron beam modulation and the use of a PCTW designed for Ti-6-4 deposits and modified by the addition of powder made from Fe and B. Resulting deposits exhibited reductions in β grain size, α phase colony intercept length and lath width, and an increased volume fraction of β phase. The mechanism of microstructure refinement was related to precipitation of boride particles. Hardness testing confirmed that mechanical property anisotropy was reduced and an overall increase in hardness was achieved.Metal matrix composite (MMC) materials offer strength and stiffness benefits over unreinforced materials. Two methods were investigated using PCTW technology for producing Al 6061 basedMMC materials; the direct addition of SiC reinforcing particles and the in-situ generation of reinforcements through reaction synthesis of precursor powders. Al 6061 based MMCs reinforced with SiC exhibited particle clustering and formation of aluminum carbides during deposition. The application of a Ni coating to the SiC particles prior to incorporation into the powder fill eliminated aluminum carbide formation and aided particle distribution during deposition. Modulation of beam focus and power further reduced aluminum carbide formation and aided particle distribution. In reaction synthesis, precursor additions undergo an exothermic reaction during deposition to form new ceramic products, generally of finer scale than the initial precursor components. The product phases provide reinforcement in the MMC and act as nucleation sites during solidification, resulting in grain refinement, improved mechanical properties, and reduced susceptibility to solidification cracking. Higher tensile strength and stiffness were demonstrated in Al 6061 based MMCs with 2 vol% reinforcement. These combined research efforts demonstrate the potential of PCTW technology for customizing of alloy composition and achieving microstructure control. A manufacturing process for titanium- and aluminum-based PCTWs was developed based on iterative design, theoretical calculations, and empirical data. PCTW technology successfully mitigated Al loss from Ti-6-4 and Mg loss in Al 6061, resulted in grain refinement in Ti-6-4, and demonstrated fabrication of Al based MMCs

Marcia S Domack↗

Performance Evaluation of Fiber Bragg Gratings at Elevated Temperatures

The development of integrated fiber optic sensors for smart propulsion systems demands that the sensors be able to perform in extreme environments. In order to use fiber optic sensors effectively in an extreme environment one must have a thorough understanding of the sensor s limits and how it responds under various environmental conditions. The sensor evaluation currently involves examining the performance of fiber Bragg gratings at elevated temperatures. Fiber Bragg gratings (FBG) are periodic variations of the refractive index of an optical fiber. These periodic variations allow the FBG to act as an embedded optical filter passing the majority of light propagating through a fiber while reflecting back a narrow band of the incident light. The peak reflected wavelength of the FBG is known as the Bragg wavelength. Since the period and width of the refractive index variation in the fiber determines the wavelengths that are transmitted and reflected by the grating, any force acting on the fiber that alters the physical structure of the grating will change what wavelengths are transmitted and what wavelengths are reflected by the grating. Both thermal and mechanical forces acting on the grating will alter its physical characteristics allowing the FBG sensor to detect both temperature variations and physical stresses, strain, placed upon it. This ability to sense multiple physical forces makes the FBG a versatile sensor. This paper reports on test results of the performance of FBGs at elevated temperatures. The gratings looked at thus far have been either embedded in polymer matrix materials or freestanding with the primary focus of this paper being on the freestanding FBGs. Throughout the evaluation process, various parameters of the FBGs performance were monitored and recorded. These parameters include the peak Bragg wavelength, the power of the Bragg wavelength, and total power returned by the FBG. Several test samples were subjected to identical test conditions to allow for statistical analysis of the data. Test procedures, calibrations, and referencing techniques are presented in the paper along with directions for future research.

Juergens, Jeffrey↗

An investigation of the thermal cycling damage of 25 vol. pct SiCw/alumina ceramic matrix composite

An investigation was made of the thermal cycling damage of a 25 vol pct SiC whisker/alumina (SiCw/Al2O3) composite. Thermal cycling tests were conducted by subjecting a composite specimen to two different fluidized beds. After thermal cycling the composite specimens were subjected to elastic modulus and effective fracture toughness measurements. The thermal cycled specimens were investigated with SEM and TEM studies. It was found that this composite has a relatively high resistance to thermal cycling.

Armstrong, William D.↗

Modifying Matrix Materials to Increase Wetting and Adhesion

In an alternative approach to increasing the degrees of wetting and adhesion between the fiber and matrix components of organic-fiber/polymer matrix composite materials, the matrix resins are modified. Heretofore, it has been common practice to modify the fibers rather than the matrices: The fibers are modified by chemical and/or physical surface treatments prior to combining the fibers with matrix resins - an approach that entails considerable expense and usually results in degradation (typically, weakening) of fibers. The alternative approach of modifying the matrix resins does not entail degradation of fibers, and affords opportunities for improving the mechanical properties of the fiber composites. The alternative approach is more cost-effective, not only because it eliminates expensive fiber-surface treatments but also because it does not entail changes in procedures for manufacturing conventional composite-material structures. The alternative approach is best described by citing an example of its application to a composite of ultra-high-molecular- weight polyethylene (UHMWPE) fibers in an epoxy matrix. The epoxy matrix was modified to a chemically reactive, polarized epoxy nano-matrix to increase the degrees of wetting and adhesion between the fibers and the matrix. The modification was effected by incorporating a small proportion (0.3 weight percent) of reactive graphitic nanofibers produced from functionalized nanofibers into the epoxy matrix resin prior to combining the resin with the UHMWPE fibers. The resulting increase in fiber/matrix adhesion manifested itself in several test results, notably including an increase of 25 percent in the maximum fiber pullout force and an increase of 60-65 percent in fiber pullout energy. In addition, it was conjectured that the functionalized nanofibers became involved in the cross linking reaction of the epoxy resin, with resultant enhancement of the mechanical properties and lower viscosity of the matrix.

Zhong, Katie↗

Effects of intra- and inter-laminar resin content on the mechanical properties of toughened composite materials

Composite materials having multiphase toughened matrix systems and laminate architectures characterized by resin-rich interlaminar layers (RIL) have been the subject of much recent attention. Such materials are likely to find applications in thick compressively loaded structures such as the keel area of commercial aircraft fuselages. The effects of resin content and its interlaminar and intralaminar distribution on mechanical properties were investigated with test and analysis of two carbon-epoxy systems. The RIL was found to reduce the in situ strengthening effect for matrix cracking in laminates. Mode 2 fracture toughness was found to increase with increasing RIL thickness over the range investigated, and Mode 1 interlaminar toughness was negligibly affected. Compressive failure strains were found to increase with increasing resin content for specimens having no damage, holes, and impact damage. Analytical tools for predicting matrix cracking of off-axis plies and damage tolerance in compression after impact (CAI) were successfully applied to materials with RIL.

Grande, Dodd H.↗

Flight Test Techniques Used to Evaluate Performance Benefits During Formation Flight

The Autonomous Formation Flight research project has been implemented at the NASA Dryden Flight Research Center to demonstrate the benefits of formation flight and develop advanced technologies to facilitate exploiting these benefits. Two F/A-18 aircraft have been modified to precisely control and monitor relative position, and to determine performance of the trailing airplane. Flight test maneuvers and analysis techniques have been developed to determine the performance advantages, including drag and fuel flow reductions and improvements in range factor. By flying the trailing airplane through a matrix of lateral, longitudinal, and vertical offset positions, a detailed map of the performance benefits has been obtained at two flight conditions. Significant performance benefits have been obtained during this flight test phase. Drag reductions of more than 20 percent and fuel flow reductions of more than 18 percent have been measured at flight conditions of Mach 0.56 and an altitude of 25,000 ft. The results show favorable agreement with published theory and generic predictions. An F/A-18 long-range cruise mission at Mach 0.8 and an altitude of 40,000 ft has been simulated in the optimum formation position and has demonstrated a 14-percent fuel reduction when compared with a controlled chase airplane of similar configuration.

Ray, Ronald J.↗

Fabrication Of Carbon-Boron Reinforced Dry Polymer Matrix Composite Tape

Future generation aerospace vehicles will require specialized hybrid material forms for component structure fabrication. For this reason, high temperature composite prepregs in both dry and wet forms are being developed at NASA Langley Research Center (LaRC). In an attempt to improve compressive properties of carbon fiber reinforced composites, a hybrid carbon-boron tape was developed and used to fabricate composite laminates which were subsequently cut into flexural and compression specimens and tested. The hybrid material, given the designation HYCARB, was fabricated by modifying a previously developed process for the manufacture of dry polymer matrix composite (PMC) tape at LaRC. In this work, boron fibers were processed with IM7/LaRC(TradeMark)IAX poly(amide acid) solution-coated prepreg to form a dry hybrid tape for Automated Tow Placement (ATP). Boron fibers were encapsulated between two (2) layers of reduced volatile, low fiber areal weight poly(amide acid) solution-coated prepreg. The hybrid prepreg was then fully imidized and consolidated into a dry tape suitable for ATP. The fabrication of a hybrid boron material form for tow placement aids in the reduction of the overall manufacturing cost of boron reinforced composites, while realizing the improved compression strengths. Composite specimens were press-molded from the hybrid material and exhibited excellent mechanical properties.

Belvin, Harry L.↗

Post-irradiation examination of the Sirius-1 nuclear thermal propulsion fuel test

Nuclear Thermal Propulsion (NTP) systems hold promise in reducing transit times for exploration of the solar system by both crewed and uncrewed missions. NTP systems currently under investigation include a once-through high-temperature gas-cooled fission reactor to provide thermal energy to heat the coolant, which also serves as the propellant. The fuel system consists of angular UN fuel particles dispersed in a matrix of W/Re, creating a ceramic and metallic composite or cermet, which has been irradiated in Idaho National Laboratory's (INL) Transient Reactor Test Facility (TREAT). This enabled evaluation of these materials under representative nuclear heating rates (~95 K/s) and peak surface temperatures (~2527 K). Further, these surface conditions were indicative of achievement of the target peak internal temperature of approximately 2850 K. These tests named Sirius-1 (UN–W/Re), have been irradiated and this paper will present post-irradiation examination results. The Sirius-1 test produced minor, stable cracks in the fuel specimen and spalling of surface material. Volatilized uranium ‘soot’ was found deposited on the inner wall of the irradiation capsule indicating loss of some fissile material from the fuel specimen. Spalling from the surfaces was also noted upon visual inspection. Uranium diffusion from the fuel particles resulted in the formation of U/Re phases and the production of a laminar microstructure on the edge of the fuel system. Overall, the specimen was stable and remained within a coolable geometry upon conclusion of multiple thermal cycles to prototypical operating temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Residual flexibility test method for verification of constrained structural models

A method is described for deriving constrained modes and frequencies from a reduced model based on a subset of the free-free modes plus the residual effects of neglected modes. The method involves a simple modification of the MacNeal and Rubin component mode representation to allow development of a verified constrained (fixed-base) structural model. Results for two spaceflight structures having translational boundary degrees of freedom show quick convergence of constrained modes using a measureable number of free-free modes plus the boundary partition of the residual flexibility matrix. This paper presents the free-free residual flexibility approach as an alternative test/analysis method when fixed-base testing proves impractical.

Admire, John R.↗

Effects of matrix toughness on fatigue response of graphite fiber composite laminates

The effect of the matrix toughness on the fatigue response of graphite-fiber-composite laminates was investigated by comparing the fatigue-response results, obtained using the test method of Bakis et al. (1989), for two graphite-epoxy specimens subjected to constant-amplitude fully-reversed loading, namely, (0/ +45/90/ -45)s4 AS4/PEEK samples with drilled center holes and T300-5208 samples. It was found that, although similar matrix damage modes were observed in the two materials, several significant differences occurred in the S-N data and in stiffness data taken over the lives of the two materials, especially at high cyclic stresses.

Simonds, Robert A.↗

Embedding Sensors in 3D Printed Metal Structures

The Transformational Challenge Reactor (TCR) program is leveraging recent advances in modeling and simulation, materials, and additive manufacturing (AM) technologies to design a modern nuclear reactor. Some of the main TCR technologies include in situ monitoring and the integration of sensors during the manufacturing of quality-significant nuclear reactor components. This report describes the general procedure and process optimization for embedding sensors within generic stainless steel 316 (SS316) components using laser powder bed fusion (LPBF). A more detailed, quality-significant test plan and supporting procedures are available upon request (ORNL/TM-2021/2127). LPBF involves the use of a scanning laser to selectively melt regions of a powder bed, additively building a part layer by layer. This report describes the LPBF processing technique and discusses the effects of LPBF processing parameters on the success of the sensor embedding process. Experiments used machined cavities in the form of channels in an SS316 base for the sensors to lay in while material is additively built over the top, thereby embedding them in an SS316 matrix. A preliminary investigation involved using empty SS316 sheaths as surrogates to explore the effects of various LPBF processing parameters and the dimensional requirements of the machined channels. Microstructural investigations showed that a smaller channel width/depth combination closer to the sensor’s diameter was best for the embedding process. After the desired parameters were selected, Type-K thermocouples were embedded and evaluated post-embedding using nondestructive thermal testing, as well as destructive sectioning and microscopy. Post-build characterization showed that the thermocouples were well-bonded to the SS316 matrix and were fully functional after embedding. During thermal testing to temperatures up to 500 °C, the embedded thermocouples read consistently with one another and deviated only slightly from the readings of a nonembedded thermocouple located within the furnace. This slight discrepancy was most likely due to differences in the thermal time constants for a nonembedded thermocouple vs. a thermocouple embedded in a solid SS316 block. The results presented in this report will serve as the foundation for future work that will focus on embedding sensors in relevant TCR reactor components and eventually testing those components under neutron irradiation.

36 MATERIALS SCIENCE↗

Count Every Trip: Finding the Uncertainty in Energy Estimates Made from Inferred Travel Modes

To properly inform transport policy and infrastructure changes, transportation related metrics need both measured values and uncertainties of those values. Travel monitoring smartphone apps can record people's travel behavior, but trip data quality is limited by sensor errors, user labeling rates and the accuracy of inference algorithms used for travel diary creation. We discuss the use of phone app recorded travel diary data to estimate energy consumption, and propose the use of propagation of variance to find error bars for such estimates. We define energy consumption for one trip as trip length times the energy intensity per distance unit of the travel mode used. We characterize trip length errors with relative error and inferred trip mode errors with confusion matrix columns. The resulting variances of each measurement are then propagated to the final calculated energy consumption. We tested our uncertainty methods on a dataset that used phone app data combined with prompted recall, consisting of 92,234 labeled trips for over 500,000 miles. Accounting for uncertainty using expected energy intensities and variance propagation gives a dataset-wide aggregate energy consumption percent error of about 9%, within one standard deviation from the truth. Future work could involve applying similar methods to other travel diary based metrics.

ADVANCED PROPULSION SYSTEMS↗