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All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Composite Stress Rupture: A New Reliability Model Based on Strength Decay

A model is proposed to estimate reliability for stress rupture of composite overwrap pressure vessels (COPVs) and similar composite structures. This new reliability model is generated by assuming a strength degradation (or decay) over time. The model suggests that most of the strength decay occurs late in life. The strength decay model will be shown to predict a response similar to that predicted by a traditional reliability model for stress rupture based on tests at a single stress level. In addition, the model predicts that even though there is strength decay due to proof loading, a significant overall increase in reliability is gained by eliminating any weak vessels, which would fail early. The model predicts that there should be significant periods of safe life following proof loading, because time is required for the strength to decay from the proof stress level to the subsequent loading level. Suggestions for testing the strength decay reliability model have been made. If the strength decay reliability model predictions are shown through testing to be accurate, COPVs may be designed to carry a higher level of stress than is currently allowed, which will enable the production of lighter structures

Reeder, James R.↗
NASA NTRS2012

Use of Statistical Analysis of Acoustic Emission Data on Carbon-Epoxy COPV Materials-of-Construction for Enhanced Felicity Ratio Onset Determination

Broadband modal acoustic emission (AE) data were acquired during intermittent load hold tensile test profiles on Toray T1000G carbon fiber-reinforced epoxy (C/Ep) single tow specimens. A novel trend seeking statistical method to determine the onset of significant AE was developed, resulting in more linear decreases in the Felicity ratio (FR) with load, potentially leading to more accurate failure prediction. The method developed uses an exponentially weighted moving average (EWMA) control chart. Comparison of the EWMA with previously used FR onset methods, namely the discrete (n), mean (n (raised bar)), normalized (n%) and normalized mean (n(raised bar)%) methods, revealed the EWMA method yields more consistently linear FR versus load relationships between specimens. Other findings include a correlation between AE data richness and FR linearity based on the FR methods discussed in this paper, and evidence of premature failure at lower than expected loads. Application of the EWMA method should be extended to other composite materials and, eventually, composite components such as composite overwrapped pressure vessels. Furthermore, future experiments should attempt to uncover the factors responsible for infant mortality in C/Ep strands.

Abraham, Arick Reed A.↗
NASA NTRS2012

Demagnetization Tests Performed on a Linear Alternator for a Stirling Power Convertor

The NASA Glenn Research Center (GRC) is conducting in-house research on rare-earth permanent magnets and linear alternators to assist in developing free-piston Stirling convertors for radioisotope space power systems and for developing advanced linear alternator technology. This research continues at GRC, but, with the exception of Advanced Stirling Radioisotope Generator references, the work presented in this paper was conducted in 2005. A special arc-magnet characterization fixture was designed and built to measure the M-H characteristics of the magnets used in Technology Demonstration Convertors developed under the 110-W Stirling Radioisotope Generator (SRG110) project. This fixture was used to measure these characteristics of the arc magnets and to predict alternator demagnetization temperatures in the SRG110 application. Demagnetization tests using the TDC alternator on the Alternator Test Rig were conducted for two different magnet grades: Sumitomo Neomax 44AH and 42AH. The purpose of these tests was to determine the demagnetization temperatures of the magnets for the alternator under nominal loads. Measurements made during the tests included the linear alternator terminal voltage, current, average power, magnet temperatures, and stator temperatures. The results of these tests were found to be in good agreement with predictions. Alternator demagnetization temperatures in the Advanced Stirling Convertor (ASC-developed under the Advanced Stirling Radioisotope Generator project) were predicted as well because the prediction method had been validated through the SRG110 alternator tests. These predictions led to a specification for maximum temperatures of the ASC pressure vessel.

Geng, Steven M.↗
NASA NTRS2012

Potential Applications of Modularity to Enable a Deep Space Habitation Capability for Future Human Exploration Beyond Low-Earth Orbit

Evaluating preliminary concepts of a Deep Space Habitat (DSH) enabling long duration crewed exploration of asteroids, the Moon, and Mars is a technically challenging problem. Sufficient habitat volumes and equipment, necessary to ensure crew health and functionality, increase propellant requirements and decrease launch flexibility to deliver multiple elements on a single launch vehicle; both of which increase overall mission cost. Applying modularity in the design of the habitat structures and subsystems can alleviate these difficulties by spreading the build-up of the overall habitation capability across several smaller parts. This allows for a more flexible habitation approach that accommodates various crew mission durations and levels of functionality. This paper provides a technical analysis of how various modular habitation approaches can impact the parametric design of a DSH with potential benefits in mass, packaging volume, and architectural flexibility. This includes a description of the desired long duration habitation capability, the definition of a baseline model for comparison, a small trade study to investigate alternatives, and commentary on potentially advantageous configurations to enable different levels of habitability. The approaches investigated include modular pressure vessel strategies, modular subsystems, and modular manufacturing approaches to habitat structure. The paper also comments upon the possibility of an integrated habitation strategy using modular components to create all short and long duration habitation elements required in the current exploration architectures.

Simon, Matthew A.↗
NASA NTRS2012

Development of Standards for Nondestructive Evaluation of COPVs Used in Aerospace Applications

Composite OverWrapped Pressure Vessels (COPVs) are currently accepted by NASA based on design and qualification requirements and generally not verified by NDE for the following reasons: (1) Manufactures and end users generally do not have experience and validated quantitative methods of detecting flaws and defects of concern (1-a) If detected, the flaws are not adequately quantified and it is unclear how they may contribute to degradation in mechanical response (1-b) Carbon-epoxy COPVs also extremely sensitive to impact damage and impacts may be below the visible detection threshold (2) If damage is detected, this generally results in rejection since the effect on mechanical response is generally not known (3) NDE response has not generally been fully characterized, probability of detection (POD) established, and processes validated for evaluation of vessel condition as manufactured and delivered.

Waller, Jess M.↗
NASA NTRS2012

Elastic Plastic Fracture Analysis of an Aluminum COPV Liner

Onboard any space-launch vehicle, composite over-wrapped pressure vessels (COPVs) may be utilized by propulsion or environmental control systems. The failure of a COPV has the potential to be catastrophic, resulting in the loss of vehicle, crew or mission. The latest COPV designs have reduced the wall-thickness of the metallic liner to the point where the material strains plastically during operation. At this time, the only method to determine the damage tolerance lifetime (safe-life) of a plastically responding metallic liner is through full-scale COPV testing. Conducting tests costs substantially more and can be far more time consuming than performing an analysis. As a result of this cost, there is a need to establish a qualifying process through the use of a crack growth analysis tool. This paper will discuss fracture analyses of plastically responding metallic liners in COPVs. Uni-axial strain tests have been completed on laboratory specimens to collect elastic-plastic crack growth data. This data has been modeled with the crack growth analysis tool, NASGRO 6.20 to predict the response of laboratory specimens and subsequently the complexity of a COPV.

Forth, Scott↗
NASA NTRS2012

NDT and SHM of Carbon Fiber Composites using Linear Drive MWM-Arrays

Carbon fiber composites are used in a wide range of structural applications due to their excellent specific strength and stiffness. However, the anisotropic mechanical and electrical properties associated with the fibers within each composite layer present challenges, and opportunities, for Nondestructive Testing (NDT) methods used to characterize and assess the structure condition. This includes composite condition after manufacture (such as fiber orientation and density, porosity, delamination, and bond strength) and during usage (such as damage from impact, fiber breakage, thermal exposure or applied stress). Ultrasonic and thermographic methods can address some of these challenges, but eddy current methods provide an alternative method for composite structures that contain a conducting material, such as carbon fibers or a metallic liner. This presentation reviews recent advances in the development of eddy current sensors and arrays for carbon fiber composite NDT and Structural Health Monitoring (SHM) applications. The focus is on eddy current sensor constructs with linear drive windings, such as MWM -Arrays, that induce currents primarily within the linear fibers of the composite. By combining this type of sensor construct with micromechanical models that relate composite constituent properties to measurable sensor responses, insight is obtained into the volumetric distribution of electrical properties within the composite and the associated manufacturing, damage, or strain conditions. With knowledge of the fiber layup, this MWM-Array technology is able to detect damage and strain/stress as a function of depth and fiber orientation. This work has been funded by NASA, NA V AIR and the Army for applications ranging from composite overwrapped pressure vessels (COPVs) to aircraft structures and rotorcraft blades. This presentation will specifically present background on the MWM-Array technology, results from the micromechanical modeling effort, and results from ongoing efforts for high resolution imaging and volumetric strain sensing.

Washabaugh, Andrew↗
NASA NTRS2009

PORT II

One unique project that the Prototype lab worked on was PORT I (Post-landing Orion Recovery Test). PORT is designed to test and develop the system and components needed to recover the Orion capsule once it splashes down in the ocean. PORT II is designated as a follow up to PORT I that will utilize a mock up pressure vessel that is spatially compar able to the final Orion capsule.

Muniz, Beau↗
NASA NTRS2013

Lightweight Liquid Helium Dewar for High-Altitude Balloon Payloads

Astrophysical observations at millimeter wavelengths require large (2-to-5- meter diameter) telescopes carried to altitudes above 35 km by scientific research balloons. The scientific performance is greatly enhanced if the telescope is cooled to temperatures below 10 K with no emissive windows between the telescope and the sky. Standard liquid helium bucket dewars can contain a suitable telescope for telescope diameter less than two meters. However, the mass of a dewar large enough to hold a 3-to-5-meter diameter telescope would exceed the balloon lift capacity. The solution is to separate the functions of cryogen storage and in-flight thermal isolation, utilizing the unique physical conditions at balloon altitudes. Conventional dewars are launched cold: the vacuum walls necessary for thermal isolation must also withstand the pressure gradient at sea level and are correspondingly thick and heavy. The pressure at 40 km is less than 0.3% of sea level: a dewar designed for use only at 40 km can use ultra thin walls to achieve significant reductions in mass. This innovation concerns new construction and operational techniques to produce a lightweight liquid helium bucket dewar. The dewar is intended for use on high-altitude balloon payloads. The mass is low enough to allow a large (3-to-5-meter) diameter dewar to fly at altitudes above 35 km on conventional scientific research balloons without exceeding the lift capability of the balloon. The lightweight dewar has thin (250- micron) stainless steel walls. The walls are too thin to support the pressure gradient at sea level: the dewar launches warm with the vacuum space vented continuously during ascent to eliminate any pressure gradient across the walls. A commercial 500-liter storage dewar maintains a reservoir of liquid helium within a minimal (hence low mass) volume. Once a 40-km altitude is reached, the valve venting the vacuum space of the bucket dewar is closed to seal the vacuum space. A vacuum pump then evacuates the dewar vacuum space to provide the necessary thermal isolation. Liquid helium may then be transferred from the storage dewar into the bucket dewar to cool the telescope inside the bucket dewar. By splitting the functions of helium storage and in-flight thermal isolation, the parasitic mass associated with the dewar pressure vessel is eliminated to achieve factor-of-five or better reduction in mass. The lower mass allows flight on conventional scientific research balloons, even for telescopes 3 to 5 meters in diameter.

Kogut, Alan↗
NASA NTRS2013

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

A key technology element in Nuclear Thermal Propulsion is the development of fuel materials and components which can withstand extremely high temperatures while being exposed to flowing hydrogen. NTREES provides a cost effective method for rapidly screening of candidate fuel components with regard to their viability for use in NTR systems. The NTREES is designed to mimic the conditions (minus the radiation) to which nuclear rocket fuel elements and other components would be subjected to during reactor operation. The NTREES consists of a water cooled ASME code stamped pressure vessel and its associated control hardware and instrumentation coupled with inductive heaters to simulate the heat provided by the fission process. The NTREES has been designed to safely allow hydrogen gas to be injected into internal flow passages of an inductively heated test article mounted in the chamber.

Emrich, William↗
NASA NTRS2014

America's Next Great Ship: Space Launch System Core Stage Transitioning from Design to Manufacturing

The Space Launch System (SLS) Program is essential to achieving the Nation's and NASA's goal of human exploration and scientific investigation of the solar system. As a multi-element program with emphasis on safety, affordability, and sustainability, SLS is becoming America's next great ship of exploration. The SLS Core Stage includes avionics, main propulsion system, pressure vessels, thrust vector control, and structures. Boeing manufactures and assembles the SLS core stage at the Michoud Assembly Facility (MAF) in New Orleans, LA, a historical production center for Saturn V and Space Shuttle programs. As the transition from design to manufacturing progresses, the importance of a well-executed manufacturing, assembly, and operation (MA&O) plan is crucial to meeting performance objectives. Boeing employs classic techniques such as critical path analysis and facility requirements definition as well as innovative approaches such as Constraint Based Scheduling (CBS) and Cirtical Chain Project Management (CCPM) theory to provide a comprehensive suite of project management tools to manage the health of the baseline plan on both a macro (overall project) and micro level (factory areas). These tools coordinate data from multiple business systems and provide a robust network to support Material & Capacity Requirements Planning (MRP/CRP) and priorities. Coupled with these tools and a highly skilled workforce, Boeing is orchestrating the parallel buildup of five major sub assemblies throughout the factory. Boeing and NASA are transforming MAF to host state of the art processes, equipment and tooling, the most prominent of which is the Vertical Assembly Center (VAC), the largest weld tool in the world. In concert, a global supply chain is delivering a range of structural elements and component parts necessary to enable an on-time delivery of the integrated Core Stage. SLS is on plan to launch humanity into the next phase of space exploration.

Birkenstock, Benjamin↗
NASA NTRS2014

Yield Behavior of Solution Treated and Aged Ti-6Al-4V

Post yield uniaxial tension-compression tests were run on a solution treated and aged (STA), titanium 6-percent aluminum 4-percent vanadium (Ti-6Al-4V) alloy to determine the yield behavior on load reversal. The material exhibits plastic behavior almost immediately on load reversal implying a strong Bauschinger effect. The resultant stress-strain data was compared to a 1D mechanics model and a finite element model used to design a composite overwrapped pressure vessel (COPV). Although the models and experimental data compare well for the initial loading and unloading in the tensile regime, agreement is lost in the compressive regime due to the Bauschinger effect and the assumption of perfect plasticity. The test data presented here are being used to develop more accurate cyclic hardening constitutive models for future finite element design analysis of COPVs.

Strain↗
NASA NTRS2014

The Inclusion of Arbitrary Load Histories in the Strength Decay Model for Stress Rupture

Stress rupture is a failure mechanism where failures can occur after a period of time, even though the material has seen no increase in load. Carbon/epoxy composite materials have demonstrated the stress rupture failure mechanism. In a previous work, a model was proposed for stress rupture of composite overwrap pressure vessels (COPVs) and similar composite structures based on strength degradation. However, the original model was limited to constant load periods (holds) at constant load. The model was expanded in this paper to address arbitrary loading histories and specifically the inclusions of ramp loadings up to holds and back down. The broadening of the model allows for failures on loading to be treated as any other failure that may occur during testing instead of having to be treated as a special case. The inclusion of ramps can also influence the length of the "safe period" following proof loading that was previously predicted by the model. No stress rupture failures are predicted in a safe period because time is required for strength to decay from above the proof level to the lower level of loading. Although the model can predict failures during the ramp periods, no closed-form solution for the failure times could be derived. Therefore, two suggested solution techniques were proposed. Finally, the model was used to design an experiment that could detect the difference between the strength decay model and a commonly used model for stress rupture. Although these types of models are necessary to help guide experiments for stress rupture, only experimental evidence will determine how well the model may predict actual material response. If the model can be shown to be accurate, current proof loading requirements may result in predicted safe periods as long as 10(13) years. COPVs design requirements for stress rupture may then be relaxed, allowing more efficient designs, while still maintaining an acceptable level of safety.

Reeder, James R.↗
NASA NTRS2010

Supercritical CO2 Cleaning for Planetary Protection and Contamination Control

We have designed and built a prototype Supercritical CO? Cleaning (SCC) system at JPL. The key features of the system are: 1) the parts inside a high-pressure vessel can be rotated at high speeds; 2) the same thermodynamic condition is maintained during First-In First-Out flushing to keep solvent power constant; and 3) the boil-off during decompression is induced in a separate vessel downstream. Our goal is to demonstrate SCC's ability to remove trace amounts of microbial and organic contaminants down to parts per billion levels from spacecraft material surfaces for future astrobiology missions. The initial cleaning test results showed that SCC can achieve cleanliness levels of 0.01 microgram/cm(sup 2) or less for hydrophobic contaminants such as dioctyl phthalate and silicone and it is less effective in the removal and inactivation of the hydrophilic bacterial spores as expected. However, with the use of a polar co-solvent, the efficacy may improve dramatically. The same results were obtained using liquid CO?. This opens up the possibility of using subcritical cleaning conditions, which may prove to be more compatible with certain spacecraft hardware.

Lin, Ying↗
NASA NTRS2009

Venus Mobile Explorer with RPS for Active Cooling: A Feasibility Study

We present our findings from a study to evaluate the feasibility of a radioisotope power system (RPS) combined with active cooling to enable a long-duration Venus surface mission. On-board power with active cooling technology featured prominently in both the National Research Council's Decadal Survey and in the 2006 NASA Solar System Exploration Roadmap as mission-enabling for the exploration of Venus. Power and cooling system options were reviewed and the most promising concepts modeled to develop an assessment tool for Venus mission planners considering a variety of future potential missions to Venus, including a Venus Mobile Explorer (either a balloon or rover concept), a long-lived Venus static lander, or a Venus Geophysical Network. The concepts modeled were based on the integration of General Purpose Heat Source (GPHS) modules with different types of Stirling cycle heat engines for power and cooling. Unlike prior investigations which reported on single point design concepts, this assessment tool allows the user to generate either a point design or parametric curves of approximate power and cooling system mass, power level, and number of GPHS modules needed for a "black box" payload housed in a spherical pressure vessel.

Leifer, Stephanie D.↗
NASA NTRS2015

Phase 1 Final Report: Titan Submarine

The conceptual design of a submarine for Saturn's moon Titan was a funded NASA Innovative Advanced Concepts (NIAC) Phase 1 for 2014. The proposal stated the desire to investigate what science a submarine for Titan's liquid hydrocarbon seas might accomplish and what that submarine might look like. Focusing on a flagship class science system (100 kg), it was found that a submersible platform can accomplish extensive science both above and below the surface of the Kraken Mare. Submerged science includes mapping using side-looking sonar, imaging and spectroscopy of the lake, as well as sampling of the lake's bottom and shallow shoreline. While surfaced, the submarine will not only sense weather conditions (including the interaction between the liquid and atmosphere) but also image the shoreline, as much as 2 km inland. This imaging requirement pushed the landing date to Titan's next summer period (2047) to allow for lighted conditions, as well as direct-to-Earth communication, avoiding the need for a separate relay orbiter spacecraft. Submerged and surfaced investigation are key to understanding both the hydrological cycle of Titan as well as gather hints to how life may have begun on Earth using liquid, sediment, and chemical interactions. An estimated 25 Mb of data per day would be generated by the various science packages. Most of the science packages (electronics at least) can be safely kept inside the submarine pressure vessel and warmed by the isotope power system.The baseline 90-day mission would be to sail submerged and surfaced around and through Kraken Mare investigating the shoreline and inlets to evaluate the sedimentary interaction both on the surface and then below. Depths of Kraken have yet to be sensed (Ligeia to the north is thought to be 200 m (656 ft) deep), but a maximum depth of 1,000 m (3,281 ft) for Kraken Mare was assumed for the design). The sub would spend 20 d at the interface between Kraken Mare and Ligeia Mare for clues to the drainage of liquid methane into the currently predicted predominantly ethane Kraken Mare. During an extended ninety-day mission, it would transit the throat of Kraken (now Seldon Fretum) and perform similar explorations in other areas of Kraken Mare. Once this half year of exploration is completed the submarine could be tasked to revisit points of interest and perhaps do a complete sonar mapping of the seas. All in all, the submarine could explore over 3,000 km (1,864 mi) in its primary mission at an average speed of 0.3 meters per second.

Titan↗
NASA NTRS2015

Cryogenic Fluid Management Technology Development for Nuclear Thermal Propulsion

The purpose of this paper is to investigate, facilitate a discussion and determine a path forward for technology development of cryogenic fluid management technology that is necessary for long duration deep space missions utilizing nuclear thermal propulsion systems. There are a number of challenges in managing cryogenic liquids that must be addressed before long durations missions into deep space, such as a trip to Mars can be successful. The leakage rate of hydrogen from pressure vessels, seals, lines and valves is a critical factor that must be controlled and minimized. For long duration missions, hydrogen leakage amounts to large increases in hydrogen and therefore vehicle mass. The size of a deep space vehicle, such as a mars transfer vehicle, must be kept small to control cost and the logistics of a multi launch, assembled in orbit vehicle. The boil off control of the cryogenic fluid is an additional obstacle to long duration missions. The boil off caused by heat absorption results in the growth of the propellant needs of the vehicle and therefore vehicle mass. This is a significant problem for a vehicle using nuclear (fission) propulsion systems. Radiation from the engines deposits large quantities of heat into the cryogenic fluid, greatly increasing boil off beyond that caused by environmental heat leakage. Addressing and resolving these challenges is critical to successful long duration space exploration. This paper discusses the state of the technology needed to address these challenges and discuss the path forward needed in technology development.

Taylor, Brian↗
NASA NTRS2015

NASA NDE Program

The current activities in the National Aeronautics and Space Administration Nondestructive Evaluation (NDE) Program are presented. The topics covered include organizational communications, orbital weld inspection, electric field imaging, fracture critical probability of detection validation, monitoring of thermal protection systems, physical and document standards, image quality indicators, integrity of composite pressure vessels, and NDE for additively manufactured components.

Generazio, Ed↗