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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 1,585 records · Page 88
All sourcesNASA NTRSDOE OSTI
NASA NTRS1977

Experimental and Analytical Load-Life Relation for AISI 9310 Steel Spur Gears

Life tests were conducted at three different loads with three groups of 8.9 cm pitch diameter spur gears made of vacuum arc remelted VAR AISI 9310 steel. Life was found to vary inversely with load to the 4.3 and 5.1 power at the L10 sub and L50 sub life levels, respectively. The Weibull slope varied linearly with maximum Hertz contact stress, having an average value of 2.5. The test data when compared to AGMA standards showed a steeper slope for the load-life diagram.

Townsend, D. P.↗
NASA NTRS1977

Experimental and analytical load-life relation for AISI 9310 steel spur gears

Life tests were conducted at three different loads with three groups of 8.9 cm, pitch diameter spur gears made of vacuum arc remelted AISI 9310 steel. Life was found to vary inversely with load to the 4.3 and 5.1 power at the L-10 and L-50 life levels, respectively. The Weibull slope varied linearly with maximum Hertz contact stress, having an average value of 2.5. The test data when compared to AGMA standards showed a steeper slope for the load-life diagram.

Townsend, D. P.↗
NASA NTRS2018

Electric Motor Noise Testing

A brief update of the progress towards RVLT Milestone L490 Initial acoustic model for kW class electric motors. A quiet loading device has been created that will allow for acoustic testing of a motor with different loads applied. Testing has also begun on a larger motor, the Scorpion SII-4020. Description of the installation of this motor as well as initial measurements reported. These include acoustic spectra and beamforming for source localization.

Cluts, Jordan↗
NASA NTRS1983

Evaluation of high-contact-ratio spur gears with profile modification

Scoring tests, surface fatigue tests, and single-tooth bending fatigue tests were conducted with four sets of spur gears of standard design and three sets of spur gears of the new tooth form (NTF) design. Scoring tests were conducted in a gear test rig at a speed of 10,000 rpm using a synthetic polyester C5, C6, C7 substituted pentaerythritol oil. Surface fatigue tests were conducted in the same rig at a speed of 10,000 rpm and Hertz stresses of 173 x 10 to the 7th power and 143 x 10 to the 7th power Pa (250,000 and 214,000 psi). Single tooth bending fatigue tests were conducted on both the standard and NTF gears at an initial load that produced a 10.35 x 10 to the eight power Pa (150,000-psi) bending stress. The gears were load cycled to failure or for 3 x 10 to the 6th power cycles, whichever occurred first. The load was increased after test until failure occurred at 3 x 10 to the 6th power cycles or less. Both the standard and NTF gears scored at a gear bulk temperature of approximately 409 K (277 F). At this temperature the load on the NTF gears was 22 percent less than the load on the standard gears. The scoring failure was a function of gear bulk temperature, where for a given lubricant the temperature is a function of gear design, operating load, and speed.

Townsend, D. P.↗
DOE OSTI2024

Experimental Examination of Additively Manufactured Patterns on Structural Nuclear Materials for Digital Image Correlation Strain Measurements

Abstract Background There are a limited number of commercially available sensors for monitoring the deformation of materials in-situ during harsh environment applications, such as those found in the nuclear and aerospace industries. Such sensing devices, including weldable strain gauges, extensometers, and linear variable differential transformers, can be destructive to material surfaces being investigated and typically require relatively large surface areas to attach (> 10 mm in length). Digital image correlation (DIC) is a viable, non-contact alternative to in-situ strain deformation. However, it often requires implementing artificial patterns using splattering techniques, which are difficult to reproduce. Objective Additive manufacturing capabilities offer consistent patterns using programmable fabrication methods. Methods In this work, a variety of small-scale periodic patterns with different geometries were printed directly on structural nuclear materials (i.e., stainless steel and aluminum tensile specimens) using an aerosol jet printer (AJP). Unlike other additive manufacturing techniques, AJP offers the advantage of materials selection. DIC was used to track and correlate strain to alternative measurement methods during cyclic loading, and tensile tests (up to 1100 µɛ) at room temperature. Results The results confirmed AJP has better control of pattern parameters for small fields of view and facilitate the ability of DIC algorithms to adequately process patterns with periodicity. More specifically, the printed 100 μm spaced dot and 150 μm spaced line patterns provided accurate measurements with a maximum error of less than 2% and 4% on aluminum samples when compared to an extensometer and commercially available strain gauges. Conclusion Our results highlight a new pattern fabrication technique that is form factor friendly for digital image correlation in nuclear applications.

Novich, K. A. (ORCID:0000000204466022)↗
DOE OSTI2019

Effect of Grain Boundary and Crystallographic Orientation on the Stress Corrosion Behavior of an Al-Zn-Mg Alloy

The effect of grain boundary and crystallographic orientation on the stress corrosion behavior of an Al-4.5Zn-1.4Mg alloy was investigated by comparing the performance of constant load stress corrosion test (CLSCT) and tensile test of specimens parallel to the longitudinal and transverse directions of the extruded plate. The results revealed that the strength of the longitudinal and transverse specimens decreased by 9.68 and 18.13%, respectively, after 10-day CLSCT. The transverse specimens show poor resistance to stress corrosion cracking (SCC). The grain boundaries (GB) of the longitudinal section are less dense, and more of them are distributed along the extrusion direction compared with the cross section with selected areas of the same size. The SCC of all specimens starts from the side faces of the specimen, and it is dominated by intergranular cracking. But the corrosion of the transverse specimens was more serious. The cracks of all specimens tend to propagate along the GBs with misorientation of about 50°-60°, and the difference of Schmidt factor (SF) values of grains on both sides of the crack is significantly large. The crack of longitudinal specimens propagates relatively parallel to the tensile direction, while propagation of the crack in transverse specimens is more zigzag.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Investigation of microstructure, micro-mechanical and optical properties of HfTiO{sub 4} thin films prepared by magnetron co-sputtering

Highlights: • HfTiO{sub 4} thin films were deposited by magnetron co-sputtering. • As-prepared and annealed at 800 °C thin films were nanocrystalline. • Optical properties and hardness were investigated in relation to thin films structure. • Hardness was 3-times higher in the case of as-deposited thin films. • HfTiO{sub 4} thin films are suitable for use as optical coatings with protective properties. - Abstract: Titania (TiO{sub 2}) and hafnium oxide (HfO{sub 2}) thin films are in the focus of interest to the microelectronics community from a dozen years. Because of their outstanding properties like, among the others, high stability, high refractive index, high electric permittivity, they found applications in many optical and electronics domains. In this work discussion on the hardness, microstructure and optical properties of as-deposited and annealed HfTiO{sub 4} thin films has been presented. Deposited films were prepared using magnetron co-sputtering method. Performed investigations revealed that as-deposited coatings were nanocrystalline with HfTiO{sub 4} structure. Deposited films were built from crystallites of ca. 4–12 nm in size and after additional annealing an increase in crystallites size up to 16 nm was observed. Micro-mechanical properties, i.e., hardness and elastic modulus were determined using conventional load-controlled nanoindentation testing. the annealed films had 3-times lower hardness as-compared to as-deposited ones (∼9 GPa). Based on optical investigations real and imaginary components of refractive index were calculated, both for as-deposited and annealed thin films. The real refractive index component increased after annealing from 2.03 to 2.16, while extinction coefficient increased by an order from 10{sup −4} to 10{sup −3}. Structure modification was analyzed together with optical energy band-gap, Urbach energy and using Wemple–DiDomenico model.

36 MATERIALS SCIENCE↗
DOE OSTI2014

A Mechanism-based Model for Deformation Twinning in Polycrystalline FCC Steel

Deformation twinning, a common and important plastic deformation mechanism, is the key contributor to the excellent combination of strength and ductility in twinning-induced plasticity (TWIP) steel. In the open literature, a significant amount of research has been reported on the microstructural characteristics of deformation twinning and its influence on the overall deformation behavior of TWIP steel. In this study, we examine the feasibility of a mechanism-based crystal plasticity model in simulating the microstructural level deformation characteristics of TWIP steel. To this end, a model considering both double-slip and double-twin is developed to investigate the stress-strain behavior and local microstructural features related to the formation and growth of micro-twins in low stacking fault energy (SFE) TWIP steel. The twin systems are described as pseudo-slips that can be activated when their resolved shear stress reaches the corresponding critical value. A hardening law that accounts for the interaction among the slip and twin systems is also developed. Numerical simulations for dDifferent mesh sizes and single crystal patch tests under different loading modes are carried out to verify the modeling procedure. Our simulation results reveal that, despite its simple nature, the double-slip/double-twin model can capture the key deformation features of TWIP steel, including twin volume fraction evolution, continuous strain hardening, and the final fracture in the form of strain localization.

Environmental Molecular Sciences Laboratory↗
DOE OSTI2017

Ionic cross-linked polyether and silica gel mixed matrix membranes for CO 2 separation from flue gas

Mixed matrix membranes (MMMs) were prepared by incorporating 10 wt%, 20 wt% and 30 wt% silica gel filler particles into novel ionic cross-linked polyether (IXPE) polymers. Porous silica gel has the advantage of high surface area that can increase the free volume and permeability in a polymer film while also being commercially available and low cost. The MMMs featured high chemical and thermal stability as well as a modest improvement in storage modulus. These features are due to the excellent interfacial interaction between silica gel filler particles and the polymer matrix. Increasing the loading of silica gel particles in MMMs resulted in higher permeability up to 120 Barrer for CO 2 , which is about 40% higher than the neat polymer matrix. Finally, most importantly, the MMMs maintained a very high CO 2 /N 2 selectivity performance of around 41 for all particle loadings that were tested.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Carbon nanotube (CNT) reinforced 316L stainless steel composites made by laser powder bed fusion: Microstructure and wear response

Carbon nanotube (CNT) reinforced 316L stainless steel (SS) composites were fabricated by laser powder bed fusion (LPBF) additive manufacturing (AM). This study focuses on microstructure evolution, hardness, and wear behavior. The wear behavior for AM 316L SS and 1 wt% CNT/316L SS was studied by a dry sliding test under normal loads of 10, 15, and 25 N. The addition of CNT to 316L SS led to the change of solidification mode from cellular/columnar to dendritic growth, producing grain refinement. Nanoscale dendrites were observed. Although TEM characterization confirmed the existence of CNT in cell interior, most CNT were damaged, resulting in carbon material segregation along cellular/dendritic boundaries. The wear rate was found dramatically decreased due to the improved hardness. Compared to the adhesive and abrasive wear in AM 316L SS, the wear mechanism of CNT/316L composite was adhesion and oxidative wear. Furthermore, enhanced cellular/dendritic boundary strengthening by carbon segregation was the main strengthening mechanism of CNT/316L composite.

36 MATERIALS SCIENCE↗
DOE OSTI2020

3D Printing of Liquid Crystal Elastomer Foams for Enhanced Energy Dissipation Under Mechanical Insult

Polymer foams are an essential class of lightweight materials used to protect assets against mechanical insults, such as shock and vibration. Two features are important to enhance their energy absorption characteristics: the foam structure and the matrix phase mechanical behavior. This study investigates novel approaches to control both of these features to enhance the energy absorption capability of flexible lattice foams. First, we consider 3D printing via digital light processing (DLP) as a method to control the foam mesostructure across a suite of periodic unit cells. Second, we introduce an additional energy dissipation mechanism in the solid matrix phase material by 3D printing the lattice foams with polydomain liquid crystal elastomer (LCE), which undergo a mechanically induced phase transition under large strains. This phase transition is associated with LC mesogen rotation and alignment and provides a second mechanism for mechanical energy dissipation in addition to the viscoelastic relaxation of the polymer network. Here, we contrast the 3D printed LCE lattices with conventional, thermomechanically near-equivalent elastomer lattice foams to quantify the energy-absorbing enhancement the LCE matrix phase provides. Under cyclic quasi-static uniaxial compression conditions, the LCE lattices show dramatically enhanced energy dissipation in uniaxial compression compared to the non-LCE equivalent foams printed with a commercially available photocurable elastomer resin. The lattice geometry also plays a prominent role in determining the energy dissipation ratio between the LCE and non-LCE foams. We show that when increasing the lattice connectivity, the foam deformation transitions from bending-dominated to stretching-dominated deformations, which generates higher axial strains in the struts and higher energy dissipation in the lattice foam, as stretching allows greater mesogen rotation than bending. The LCE foams demonstrate superior energy absorption during the repeated dynamic loading during drop testing compared with the non-LCE equivalent foams, demonstrating the potential of LCEs to enhance physical protection systems against mechanical impact.

3D printing↗
DOE OSTI2025

Feasibility of carbon foam-based sorbents for the abatement of gaseous mercury and iodine

The U.S. Department of Energy Hanford Site in Washington State is in the process of commissioning the Waste Treatment and Immobilization Plant to process a portion of the 54 million gallons of radioactive and chemical waste from cold war weapon production. Technologies for the capture of volatile species of concern are still being assessed, and new methods and materials are developed as operational and flowsheet mission risks are identified. One such area still being assessed is the abatement efficacy of the Carbon Adsorber units to retain gaseous mercury and 129 I released during processing. It is challenging to predict the mercury chemistry due to the variability of the feed, and different methods/materials are required for the capture of gaseous Hg 0 and Hg II compounds. In this study, the feasibility of using developmental carbon foam (CF) sorbents for the capture of iodine and mercury was assessed using static and dynamic flow testing and compared against a commercially available sorbent, BATII-37. Both CF and CF functionalized with bismuth particles (CF-Bi) chemisorbed iodine, and CF-Bi had similar mercury capture performance to BATII-37 in dynamic flow tests. While species loading concentrations were measurable, limitations in achieving a mass balance prevented a full evaluation of capture efficacy. Nonetheless, the results serve as an important first step in demonstrating the potential for simultaneous iodine and mercury capture.

Hanford site↗
DOE OSTI2023

Effect of Interlayer Time-Lapse and Workability Retention on Printed Concrete Performance

The rapid advancement of additive manufacturing technologies for concrete construction requires further understanding of material performance and its relationship with print parameters such as interlayer time-lapse and workability retention during the print. Here this study addresses the effects of the time delay between consecutive extruded layers on the mechanical performance of printed concrete using a mix designed by Quikrete. A series of specimens were prepared with printing delays of 10, 15, 30, and 60 min. This work correlates the change in fracture properties, mechanical performance, and workability retention with the interlayer time-lapse between two consecutive concrete layers. Interlayer time-lapse is defined as the time difference in printing of two consequent layers of concrete. It affects individual properties differently based on the loading direction and test types, but it is consistent in terms of interlayer performance. The understanding of the effect of interlayer time-lapse on the fracture properties between two consecutive printed layers fills the knowledge gaps in printed concrete research. Therefore, this study can help researchers perform required optimization and safely estimate the performance of printed concrete.

3D printing↗
DOE OSTI2011

Mechanical joining with self piercing solid-rivets at elevated tool velocities

In the present paper the influence of a higher setting velocity in the joining process of self piercing solid-rivets is shown. In the conventional process tool velocities well below 1 m/s are common. The present research results show the potential of increasing them in the range of about 5 m/s. The results are especially relevant for joining high-strength steels. These steel sheets often cause problems in the process of riveting mixed materials, e. g. aluminium-steel compound. The high strength of the steel sometimes leads to undesirable material flow in the joining process or unwanted burr development. These effects, which are described in detail in the article, can be reduced significantly for the investigated cases by the use of higher tool velocities. Using a high speed camera and a load cell, a test setup based on a drop tower was realized. It was used to time the force signals and the motion profile of the high speed riveting process. The results of the force analysis show an oscillating force progression. Within a numerical research the principal effects influencing the results of the riveting process can be shown. It was found that the pulse-like force transmission between riveting machine and punch, results in various vibrations especially of long and thin tool parts. Hence the rivet penetrates the sheet metal with non-uniform velocities. As a result the early indentation of die into the lower sheet metal at the beginning of the process is reduced, so that the final process step provides a sufficient material flow into the circular rivet groove. A strain-rate dependent process model with elastic tool properties and consideration of inertia effects is presented.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Finite Element Analysis of the Amontons-Coulomb's Model using Local and Global Friction Tests

In spite of the abundant number of experimental friction tests that have been reported, the contact with friction modeling persists to be one of the factors that determine the effectiveness of sheet metal forming simulation. This difficulty can be understood due to the nature of the friction phenomena, which comprises the interaction of different factors connected to both sheet and tools' surfaces. Although in finite element numerical simulations friction models are commonly applied at the local level, they normally rely on parameters identified based on global experimental tests results. The aim of this study is to analyze the applicability of the Amontons-Coulomb's friction coefficient identified using complementary tests: (i) load-scanning, at the local level and (ii) draw-bead, at the global level; to the numerical simulation of sheet metal forming processes.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Arc plasma generator of atomic driver for steady-state negative ion source

The paper reviews the results of development of steady-state arc-discharge plasma generator with directly heated LaB{sub 6} cathode. This arc-discharge plasma generator produces a plasma jet which is to be converted into an atomic one after recombination on a metallic plate. The plate is electrically biased relative to the plasma in order to control the atom energies. Such an intensive jet of hydrogen atoms can be used in negative ion sources for effective production of negative ions on a cesiated surface of plasma grid. All elements of the plasma generator have an augmented water cooling to operate in long pulse mode or in steady state. The thermo-mechanical stresses and deformations of the most critical elements of the plasma generator were determined by simulations. Magnetic field inside the discharge chamber was optimized to reduce the local power loads. The first tests of the steady-state arc plasma generator prototype have performed in long-pulse mode.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2014

Measurement of the internal stress and electric field in a resonating piezoelectric transformer for high-voltage applications using the electro-optic and photoelastic effects

The high output voltages from piezoelectric transformers are currently being used to accelerate charged particle beams for x-ray and neutron production. Traditional methods of characterizing piezoelectric transformers (PTs) using electrical probes can decrease the voltage transformation ratio of the device due to the introduction of load impedances on the order of hundreds of kiloohms to hundreds of megaohms. Consequently, an optical diagnostic was developed that used the photoelastic and electro-optic effects present in piezoelectric materials that are transparent to a given optical wavelength to determine the internal stress and electric field. The combined effects of the piezoelectric, photoelastic, and electro-optic effects result in a time-dependent change the refractive indices of the material and produce an artificially induced, time-dependent birefringence in the piezoelectric material. This induced time-dependent birefringence results in a change in the relative phase difference between the ordinary and extraordinary wave components of a helium-neon laser beam. The change in phase difference between the wave components was measured using a set of linear polarizers. The measured change in phase difference was used to calculate the stress and electric field based on the nonlinear optical properties, the piezoelectric constitutive equations, and the boundary conditions of the PT. Maximum stresses of approximately 10 MPa and electric fields of as high as 6 kV/cm were measured with the optical diagnostic. Measured results were compared to results from both a simple one-dimensional (1D) model of the piezoelectric transformer and a three-dimensional (3D) finite element model. Measured stresses and electric fields along the length of an operating length-extensional PT for two different electrical loads were within at least 50 % of 3D finite element simulated results. Additionally, the 3D finite element results were more accurate than the results from the 1D model for a wider range of electrical load impedances under test.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Influence of electron beam irradiation on mechanical and thermal properties of polypropylene/polyamide blend

The effects of electron beam irradiation on the mechanical and thermal properties of polypropylene (PP) and polyamide6 (PA6) blends-with talc 20 wt% as filler, SEBS-g-MAH as compatibilizer, and triallyl isocyanurate as crosslinking agent-were investigated. Although the tensile and flexural moduli and strengths of the PP/PA6 blends with talc, SEBS-g-MAH, and TAIC could be increased by the application of electron beam irradiation, the impact strength was decreased. Ddifferential scanning calorimetryer measurements showed that the melting temperatures of all PP/PA6 blends were decreased with increases in the electron beam irradiationdose. From dynamic mechanical analyzer results, a storage modulus curve in the plateau region was observed only in the PP/PA6 blends with talc, SEBS-g-MAH, and TAIC; the storage modulus increased with increasing electron beam irradiation dose, indicating that the three-dimensional network developed gradually in the more amorphous PA6. As a result, the most significant improvement observed in heat distortion tests under high load (1.8 MPa) occurred at 200 kGy.

36 MATERIALS SCIENCE↗