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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 1,675 records · Page 93
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Effects of Aqueous Solutions on the Slow Crack Growth of Soda-Lime-Silicate Glass

The slow crack growth (SCG) parameters of soda-lime-silicate were measured in distilled and saltwater of various concentrations in order to determine if the presence of salt and the contaminate formation of a weak sodium film affects stress corrosion susceptibility. Past research indicates that solvents affect the rate of crack growth; however, the effects of salt have not been studied. The results indicate a small but statistically significant effect on the SCG parameters A and n at high concentrations; however, for typical engineering purposes, the effect can be ignored.

salt↗
NASA NTRS2008

Comparison of Signal Response Between EDM Notch and Cracks in Eddy-Current Testing

In the field of ET an eddy-current instrument is calibrated on a manufactured notch that is designed to simulate a defect in a part. The calibrated instrument is then used to scan parts with the assumption that any response that is over half the amplitude of the notch signal is taken to be defective. The purpose of this study is to attempt a direct comparison of the signal response observed from an EDM notch to a crack of the same size. To make this comparison test equipment will be set up and calibrated as per normal inspection procedures. Once this has been achieved both notches and as many different sizes of crack specimens will be scanned and the data recorded. This data will then be analyzed to provide a comparison of the response. The results should also provide information that shows it is acceptable to use the half-amplitude method for determining if a part is defective. The tests will be performed on two different materials commonly inspected, titanium and aluminum. This will allow a comparison of the results between materials.

Kane, Mary↗
NASA NTRS2016

A Modified Edge Crack Torsion Test for Measurement of Mode III Fracture Toughness of Laminated Tape Composites

Modifications to the edge crack torsion (ECT) test are studied to improve the reliability of this test for measuring the mode-III fracture toughness, G (sub IIIc), of laminated tape fiber-reinforced polymeric (FRP) composites. First, the data reduction methods currently used in the ECT test are evaluated and deficiencies in their accuracy are discussed. An alternative data reduction technique, which uses a polynomial form to represent ECT specimen compliance solution, is evaluated and compared to FEA (finite element analysis) results. Second, seven batches of ECT specimens are tested, each batch containing specimens with a preimplanted midplane edge delamination and midplane plies with orientations of plus theta divided by minus theta, with theta ranging from 0 degrees to 90 degrees in 15-degree increments. Tests on these specimens show that intralaminar cracking occurs in specimens from all batches except for which theta = 15 degrees and 30 degrees. Tests on specimens of these two batches are shown to result in mode-III delamination growth at the intended ply interface. The findings from this study are encouraging steps towards the use of the ECT test as a standardized method for measuring G (sub IIIc), although further modification to the data reduction method is required to make it suitable for use as part of a standardized test method.

Czabaj, Michael W.↗
NASA NTRS2017

Fracture-Based Mesh Size Requirements for Matrix Cracks in Continuum Damage Mechanics Models

This paper evaluates the ability of progressive damage analysis (PDA) finite element (FE) models to predict transverse matrix cracks in unidirectional composites. The results of the analyses are compared to closed-form linear elastic fracture mechanics (LEFM) solutions. Matrix cracks in fiber-reinforced composite materials subjected to mode I and mode II loading are studied using continuum damage mechanics and zero-thickness cohesive zone modeling approaches. The FE models used in this study are built parametrically so as to investigate several model input variables and the limits associated with matching the upper-bound LEFM solutions. Specifically, the sensitivity of the PDA FE model results to changes in strength and element size are investigated.

Leone, Frank A.↗
NASA NTRS2019

Slow Crack Growth of Boron Nitrides for Electric Propulsion Components

The Deep Space Gateway requires thruster systems to maintain spatial position. One control system being considered involves Hall thrusters. Historically, Hall thruster discharge channels have used several grades of hot-pressed hexagonal boron nitride. This study compliments data presented at ICACC (International Conference and Expo on Advanced Ceramics and Composites) 2018 and investigates the fracture toughness and slow crack growth parameters of several commercially available boron nitride grades including HP, M, M26, and Shapal Hi-M. The prior work revealed that some grades of BN absorb water and change strength thus presenting a philosophical conundrum on crack growth test methods. Advantages of different test methods will be discussed. The grades selected for this study are of interest because their available billet size is sufficient for Hall thruster discharge channels, or because they have heritage in Hall thruster applications. Ultimately, the data will be used to perform material selection, system design and reliability analyses.

Ceramics↗
NASA NTRS2017

Interaction of Delaminations and Matrix Cracks in a CFRP Plate, Part II: Simulation Using an Enriched Shell Finite Element Model

Numerical simulations are presented of a recently developed test which creates multiple delaminations in a CFRP laminate specimen that grow and interact via transverse matrix cracks. A novel shell element enriched with the Floating Node Method, and a damage algorithm based on the Virtual Crack Closure Technique, were used to successfully simulate the tests. Additionally, a 3D high mesh fidelity model based on cohesive zones and continuum damage mechanics was used to simulate the tests and act as a representative of other similar state-of-the-art high mesh fidelity modeling techniques to compare to the enriched shell element. The enriched shell and high mesh fidelity models had similar levels of accuracy and generally matched the experimental data. With runtimes of 36 minutes for the shell model and 55 hours for the high mesh fidelity model, the shell model is 92 times faster than the high- fidelity simulation.

Mark W McElroy↗
NASA NTRSDate not supplied

Investigating Transverse Ply Thickness and Cracking Effects on the Tensile Strain to Failure of Thin-ply, Cross-ply Carbon Composites using X-ray Computed Tomography

The effect of 90°-ply thickness on the fibre direction tensile failure strain of cross-ply laminates was investigated by designing four different cross-ply composite laminate configurations with 90° blocks of varying numbers of plies adjacent to a central block of 0° plies. The range of 90° block thicknesses evaluated included conventional ply thicknesses to allow for comparisons with conventional ply geometries. The central 0° ply block was subjected to primarily longitudinal tension with a small component of transverse tension due to the layup and thermal residual stresses. Advanced instrumentation, including acoustic emission and X-ray computed tomography, was used to detect and visualize damage accumulation in the specimens. It was found that decreasing the thickness of the 90° ply blocks reduced transverse matrix microcracking up to the point where no full-width transverse cracks developed prior to ultimate failure. A small degradation of the fibre direction failure strain in the central 0° plies was found as the 90°-layer thickness increased in the laminates, which corresponded with the development of edge/transverse cracks.

Tamas Rev↗
NASA NTRS2024

Cracking Failures in MLCCs and Military Specifications

Failures of MLCCs during applications might indicate problems with the screening and qualification system used. Several cracking related failures of military-grade MLCCs that have been observed over the last few years require analysis of the efficiency and completeness of the procedures used in military specifications. This presentation discusses deficiencies of the currently used procedures to reveal and prevent cracking failures in space projects and possible ways of their improvements.

reliability↗
DOE OSTI2023

Quantifying the impact of operating temperature on cracking in battery electrodes, using super-resolution of microscopy images and stereology

There are numerous factors that can have an impact on the degradation behavior of batteries, such as the number of recharge cycles or the charge rate. Here, we investigate the influence of operating temperature on the structural degradation of the microstructure in lithium-ion positive electrodes. For that purpose, the microstructure is characterized for cathodes which have been cycled for 200 cycles under 6C (10-minute) charging at different operating temperatures, namely, 20°C, 30°C, 40°C, and 50°C. For each operating condition scanning electron microscopy (SEM) images of cross-sectioned Li x Ni 0.5 Mn 0.3 Co 0.2 O 2 (NMC532) electrodes have been analyzed, to determine structural descriptors such as global particle porosity, crack size/length/width distribution, and porosity and specific surface area distribution of individual particles. Additionally, a stereological method has been deployed to investigate the local particle porosity as a function of distance to the particle center. Results show that particle porosity increases with increasing cycling temperature. Particle porosity is greatest at the particle center and decreases along the particle radius to the exterior. Particle surface area is similar across the four cycling-temperature aging conditions.

25 ENERGY STORAGE↗
DOE OSTI2022

Stress corrosion cracking mechanism of cold spray coating on a galvanically similar substrate

Here, the chloride-induced stress corrosion cracking (CISCC) mechanism of cold spray (CS) coating on a galvanically similar substrate is investigated. Arc welded 304L stainless steel (SS) specimens are loaded into four-point bend fixtures, cold sprayed with 304L SS, then immersed in boiling MgCl 2 . Interconnected porosity forms through crevice corrosion along CS splat boundaries, allowing corrosive species to penetrate through the CS layer. Nevertheless, the substrate is resistant to CISCC likely because of compressive stress introduced by peening during CS particle impacts. These findings underscore the importance of residual stress in the environmental degradation of CS coatings or repairs of engineering structures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A proposed criteria to identify wind turbine drivetrain bearing loads that induce roller slip based white-etching cracks

In this article, the type of roller slip behavior that may result in the formation of white-etching cracks (WECs) in wind turbine gearbox bearings is identified. A new hypothesis based on the inner raceway normal contact load magnitude at the time of roller slip is proposed as the probable cause of WECs. For this purpose, the maximum normal contact loads are identified when roller slip occurs in high-speed shaft bearings at different mean wind speeds. Subsequently, the annual probability of occurrence of the maximum normal loads are obtained. The probability of maximum load under slip exceeding a limit probability is hypothesized as a probable cause for WEC. In order to apply the proposed hypothesis, two different wind turbines high-speed shaft bearings are used: the cylindrical roller bearing of the General Electric 1.5 SLE turbine and the tapered roller bearing of Vestas V52 turbine. Both the chosen bearings are on the generator side of the high-speed shaft. For both turbines, measurement data together with analytical models are used for identifying the slip and the maximum normal contact loads. We propose forecasting the probability of exceedance of a threshold maximum normal contact load level during slip to identify the possibility for inducing WECs.

17 WIND ENERGY↗
DOE OSTI2022

Investigation of the fatigue crack behavior of 304 stainless steels using synchrotron X-ray tomography and diffraction: Influence of the martensite fraction and role of inclusions

Here, the effect of fatigue on the microstructure of four-point bend specimens of three variations of 304 stainless steels (Commercial 304, 304H, and 304 L) was investigated using synchrotron x-ray tomography and diffraction. X-ray tomography revealed the formation of the fatigue-induced microvoids and crack while the diffraction data was used to quantify the amount of deformation-induced martensite found after fatigue in all samples. Transmission electron microscopy evidenced the role of the precipitates/inclusions on the microvoid formation. It was found to depend on their chemical nature. The shape of the precipitates/inclusions was also found to have an effect on the microvoid shape.

304 stainless steel↗
DOE OSTI2020

Development of Low-Cost, Crack-Tolerant Metallization Using Screen Printing

One of the ways to reduce the cost of solar electricity to 3/kWh, thus reaching parity with fossil-fuel-based generation, is to reduce the degradation rate of solar modules and extend their lifetime well beyond 30 years. The extended module lifetime in turn can positively influence the financial model and the bankability of utility-scale PV projects. Today, the highest-riskpriority solar module degradation mechanism is what is known as hot spots, often induced by cell cracks. In order to address this degradation mechanism, we make use of low-cost, multi-walled carbon nanotubes embedded in commercial screen-printable silver pastes. When the carbon nanotubes are properly functionalized and appropriately incorporated into commercial silver pastes, the resulting metal contacts on solar cells, after screen-printing and firing, show exceptional fracture toughness. These composite metal contacts possess increased ductility, electrical gap-bridging capability up to 50 um, and 'self-healing' to regain electrical continuity even after cycles of complete electrical failure under extreme strain.

14 SOLAR ENERGY↗
DOE OSTI2020

Development of Testing Methods to Predict Cracking in Photovoltaic Backsheets

In recent years there have been some significant failures of photovoltaic backsheets resulting from inadequacies of design that are not detected in current versions of the qualification standards. In some cases, this has resulted in catastrophic failure in less than 5 y of deployment. In this work, we develop a test sample construction and evaluate accelerated exposure conditions necessary to duplicate the cracking field failure of backsheets using a small and manageable coupon. This sample uses a piece of solder wire to put some controlled topology and stress into the backsheet. Through exposure to different environmental stressors it was found that the application of thermal cycling stresses, after ultraviolet radiation exposure, is of primary importance to duplicate field failures.

14 SOLAR ENERGY↗
DOE OSTI2021

Lithium-Ion Battery Life Model with Electrode Cracking and Early-Life Break-in Processes

This paper develops a physically justified reduced-order capacity fade model from accelerated calendar- and cycle-aging data for 32 lithium-ion (Li-ion) graphite/nickel-manganese-cobalt (NMC) cells. The large data set reveals temperature-, charge C-rate-, depth-of-discharge-, and state of charge (SOC)-dependent degradation patterns that would be unobserved in a smaller test matrix. Model structure is informed by incremental capacity analysis that shows loss of lithium inventory and cathode-material loss as the dominant capacity fade mechanisms. The model includes terms attributable to solid-electrolyte interface (SEI) growth, electrode cracking, cycling-driven acceleration of SEI growth, and "break-in" mechanisms that slightly decrease or increase available Li inventory early in life. The study explores what mathematical couplings of these mechanisms best describe calendar aging, cycle aging, and mixed calendar/cycle aging. Various approaches are discussed for extracting relevant stress factors from complex cycling profiles to predict lifetime during real-world battery loads using models trained on constant-current laboratory test results. The complexity of the present human-driven model identification process motivates future work in machine learning to more widely search and statistically discern the optimal model that correctly extrapolates capacity fade based on physical knowledge.

25 ENERGY STORAGE↗