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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 1,693 records · Page 94

All sources NASA NTRS DOE OSTI

NASA NTRS2001

Development of a Novel Method for Determination of Residual Stresses in a Friction Stir Weld

Material constitutive properties, which describe the mechanical behavior of a material under loading, are vital to the design and implementation of engineering materials. For homogeneous materials, the standard process for determining these properties is the tensile test, which is used to measure the material stress-strain response. However, a majority of the applications for engineering materials involve the use of heterogeneous materials and structures (i.e. alloys, welded components) that exhibit heterogeneity on a global or local level. Regardless of the scale of heterogeneity, the overall response of the material or structure is dependent on the response of each of the constituents. Therefore, in order to produce materials and structures that perform in the best possible manner, the properties of the constituents that make up the heterogeneous material must be thoroughly examined. When materials exhibit heterogeneity on a local level, such as in alloys or particle/matrix composites, they are often treated as statistically homogenous and the resulting 'effective' properties may be determined through homogenization techniques. In the case of globally heterogeneous materials, such as weldments, the standard tensile test provides the global response but no information on what is Occurring locally within the different constituents. This information is necessary to improve the material processing as well as the end product.

Reynolds, Anthony P.↗

NASA NTRS2004

Outbrief - Long Life Rocket Engine Panel

This white paper is an overview of the JANNAF Long Life Rocket Engine (LLRE) Panel results from the last several years of activity. The LLRE Panel has met over the last several years in order to develop an approach for the development of long life rocket engines. Membership for this panel was drawn from a diverse set of the groups currently working on rocket engines (Le. government labs, both large and small companies and university members). The LLRE Panel was formed in order to determine the best way to enable the design of rocket engine systems that have life capability greater than 500 cycles while meeting or exceeding current performance levels (Specific Impulse and Thrust/Weight) with a 1/1,OOO,OOO likelihood of vehicle loss due to rocket system failure. After several meetings and much independent work the panel reached a consensus opinion that the primary issues preventing LLRE are a lack of: physics based life prediction, combined loads prediction, understanding of material microphysics, cost effective system level testing. and the inclusion of fabrication process effects into physics based models. With the expected level of funding devoted to LLRE development, the panel recommended that fundamental research efforts focused on these five areas be emphasized.

Quinn, Jason Eugene↗

NASA NTRS2004

The Effect of Hole Quality on the Fatigue Life of 2024-T3 Aluminum Alloy Sheet

This paper presents the results of a study whose main objective was to determine which type of fabrication process would least affect the fatigue life of an open-hole structural detail. Since the open-hole detail is often the fundamental building block for determining the stress concentration of built-up structural parts, it is important to understand any factor that can affect the fatigue life of an open hole. A test program of constant-amplitude fatigue tests was conducted on five different sets of test specimens each made using a different hole fabrication process. Three of the sets used different mechanical drilling procedures while a fourth and fifth set were mechanically drilled and then chemically polished. Two sets of specimens were also tested under spectrum loading to aid in understanding the effects of residual compressive stresses on fatigue life. Three conclusions were made from this study. One, the residual compressive stresses caused by the hole-drilling process increased the fatigue life by two to three times over specimens that were chemically polished after the holes were drilled. Second, the chemical polishing process does not appear to adversely affect the fatigue life. Third, the chemical polishing process will produce a stress-state adjacent to the hole that has insignificant machining residual stresses.

Everett, Richard A., Jr.↗

NASA NTRS2007

Experimental Methods Using Photogrammetric Techniques for Parachute Canopy Shape Measurements

NASA Langley Research Center in partnership with the U.S. Army Natick Soldier Center has collaborated on the development of a payload instrumentation package to record the physical parameters observed during parachute air drop tests. The instrumentation package records a variety of parameters including canopy shape, suspension line loads, payload 3-axis acceleration, and payload velocity. This report discusses the instrumentation design and development process, as well as the photogrammetric measurement technique used to provide shape measurements. The scaled model tests were conducted in the NASA Glenn Plum Brook Space Propulsion Facility, OH.

Jones, Thomas W.↗

NASA NTRS2006

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Agency's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar(TradeMark) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar(TradeMark) filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However, due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to the experimental investigation reported in [1] and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel's residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Greene, N.↗

NASA NTRS2009

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Administration's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to a previously reported experimental investigation and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel s residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Thesken, John C.↗

NASA NTRS2011

Six-Tube Freezable Radiator Testing and Model Correlation

Freezable radiators offer an attractive solution to the issue of thermal control system scalability. As thermal environments change, a freezable radiator will effectively scale the total heat rejection it is capable of as a function of the thermal environment and flow rate through the radiator. Scalable thermal control systems are a critical technology for spacecraft that will endure missions with widely varying thermal requirements. These changing requirements are a result of the spacecraft s surroundings and because of different thermal loads rejected during different mission phases. However, freezing and thawing (recovering) a freezable radiator is a process that has historically proven very difficult to predict through modeling, resulting in highly inaccurate predictions of recovery time. These predictions are a critical step in gaining the capability to quickly design and produce optimized freezable radiators for a range of mission requirements. This paper builds upon previous efforts made to correlate a Thermal Desktop(TradeMark) model with empirical testing data from two test articles, with additional model modifications and empirical data from a sub-component radiator for a full scale design. Two working fluids were tested, namely MultiTherm WB-58 and a 50-50 mixture of DI water and Amsoil ANT.

Lillibridge, Sean↗

NASA NTRS2013

Analysis-Driven Design Optimization of a SMA-Based Slat-Cove Filler for Aeroacoustic Noise Reduction

Airframe noise is a significant component of environmental noise in the vicinity of airports. The noise associated with the leading-edge slat of typical transport aircraft is a prominent source of airframe noise. Previous work suggests that a slat-cove filler (SCF) may be an effective noise treatment. Hence, development and optimization of a practical slat-cove-filler structure is a priority. The objectives of this work are to optimize the design of a functioning SCF which incorporates superelastic shape memory alloy (SMA) materials as flexures that permit the deformations involved in the configuration change. The goal of the optimization is to minimize the actuation force needed to retract the slat-SCF assembly while satisfying constraints on the maximum SMA stress and on the SCF deflection under static aerodynamic pressure loads, while also satisfying the condition that the SCF self-deploy during slat extension. A finite element analysis model based on a physical bench-top model is created in Abaqus such that automated iterative analysis of the design could be performed. In order to achieve an optimized design, several design variables associated with the current SCF configuration are considered, such as the thicknesses of SMA flexures and the dimensions of various components, SMA and conventional. Designs of experiment (DOE) are performed to investigate structural response to an aerodynamic pressure load and to slat retraction and deployment. DOE results are then used to inform the optimization process, which determines a design minimizing actuator forces while satisfying the required constraints.

Scholten, William↗

NASA NTRS2015

Design and Fabrication Development of J-2X Engine Metallic Nozzle Extension

Maximized rocket engine performance is in part derived from expanding combustion gasses through the rocket nozzle. For upper stage engines the nozzles can be quite large. On the J-2X engine, an uncooled extension of a regeneratively cooled nozzle is used to expand the combustion gasses to a targeted exit pressure which is defined by an altitude for the desired maximum performance. Creating a J-2X nozzle extension capable of surviving the loads of test and flight environments while meeting engine system performance requirements required development of new processes and facilities. Meeting the challenges of the development resulted in concurrent J-2X nozzle extension design and fabrication. This paper describes how some of the design and fabrication challenges were resolved.

Kopicz, C.↗

NASA NTRS2016

Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities

Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.

ceramic matrix composites↗

NASA NTRS2018

Influence of Core and Hexapod Geometry, and Local Reinforcement on the Performance of Ultra-Lightweight ULE Mirror

The Habitable Exoplanet Observatory (HabEx) mission has unique optical performance requirements which drive the mirror design process beyond the traditional criteria. While mass and stiffness are still important, the response to inertia loading (expressed in terms of Zernike coefficients) to omni-directional excitation dominates the effort. While a Zerodur mirror is the current baseline, as mass budgets change, a ULE design is being studied as a potential alternative. This trade study looked at over 264 design variations using the Arnold Mirror Modeler and ANSYS(c) to investigate the influence of various design elements, including: substrate thickness, core cell size, hexapod geometry and local reinforcement. Design 'goodness' was evaluated based on the mirror's inertial deformation response to omni-directional input. This response was calculated via RSSing Zernike polynomial responses to (XYZ) accelerations.

Space Telescope Technology↗

NASA NTRS2018

NASA Blazes a Different Path to Energy-Efficient Supercomputing

For years, NASA had a very straightforward process for replacing high-performance computing hardware: over a three-year period, when it became more expensive to operate an older suite of hardware than it did to replace it with new products that could accomplish the same work, we simply replaced the old hardware. For NASA’s High-End Computing Capability (HECC) Project, that process changed when we reached the limits of our facility’s power, cooling, and floor-loading capacity, becoming a strategy of decommissioning the least productive hardware and replacing it with more capable counterparts. The impact was that we provided our users with less supercomputing capability than we would have without the limitations. Additionally, with 25% of our total power consumption going to cool our systems and 50,000 gallons of water per day being evaporated, we wanted a solution that would expand our compute facility while being sensitive to the impact on our environment.

Thigpen, William↗

NASA NTRS2019

Effect of 3D Roughness Patch on Instability Amplification in a Supersonic Boundary Layer

Surface roughness is known to have a substantial impact on the aerothermodynamic loading of high-speed vehicles, particularly via its influence on the laminar-turbulent transition process within the boundary layer. Numerical simulations are performed to investigate the effects of a distributed region of densely packed, sinusoidal shape roughness elements on a Mach 3.5 flat plate boundary layer for flow conditions corresponding to the planned conditions of an upcoming experiment in the Mach 3.5 Supersonic Low Disturbance Tunnel at the NASA Langley Research Center. Analysis of convective instabilities in the wake of the roughness patch was reported in a previous paper and the current work extends that analysis to instability amplification across the length of the roughness patch. Quasi-parallel stability analysis of the modified boundary layer flow over the patch indicates two dominant families of unstable disturbances, namely, a group of high frequency modes that amplify in localized regions along the roughness patch and another group of low frequency modes that have smaller peak amplification rates but amplify steadily both above the roughness patch and in the wake region behind it. The results suggest that the amplification factors associated with the high-frequency modes are sufficiently low, at least for the roughness patches considered in this paper, so that these modes are unlikely to have a major influence on the transition process. The amplification of the low-frequency modes within the region of the roughness patch is further quantified via direct numerical simulations. Results confirm the strongly destabilizing influence of the roughness patch on the first mode instabilities, yielding an N-factor increment of ΔN ≈ 3.6 for a roughness patch length of eight wavelengths.

Laminar turbulent transition↗

NASA NTRSDate not supplied

Thin-Ply: Exploration and Manufacturing with Automated Fiber Placement

Abstract Highly repeatable and nearly defect-free fabrication of composite parts is critical to the success and widespread acceptance of composite materials. Through optimization using thin-ply materials, composite parts can be manufactured to be lighter and tailored more specifically to anticipated design loads than with standard prepreg materials alone. However, defects arising from the thin-ply manufacturing process are not always similar to defects found with standard tows. These new defects warrant evaluation. At NASA Langley Research Center, the manufacturing process parameters associated with automated fiber placement (AFP), a slit tape-based composite manufacturing process, were optimized for the use of a thin-ply prepreg carbon-epoxy material. Carbon-epoxy tows with areal weights of 30 g/m2 and 70 g/m2 were used in these manufacturing trials. The AFP process parameters of heater output, compaction force, tow feed rate, and tow tension were adjusted and optimized for successful manufacturing. This article documents an exploration of thin-ply fabrication on both flat and complex-shaped surfaces. Ultimately, aerospace-quality laminates were made from the 70-g/m2 material, but imperfections in the 30-g/m2 material itself and the fact that the AFP machine was not designed for such a thin material meant that more research and trials are required to obtain flight-quality 30-g/m2 laminates.

Carbon-expoxy↗

NASA NTRSDate not supplied

Exploration and Manufacturing with Automated Fiber Placement

Highly repeatable and nearly defect-free fabrication of composite parts is critical to the success and widespread acceptance of composite materials. Through optimization using thin-ply materials, composite parts can be manufactured to be lighter and tailored more specifically to anticipated design loads than with standard prepreg materials alone. However, defects arising from the thin-ply manufacturing process are not always similar to defects found with standard tows. These new defects warrant evaluation. At NASA Langley Research Center, the manufacturing process parameters associated with automated fiber placement (AFP), a slit tape-based composite manufacturing process, were optimized for the use of a thin-ply prepreg carbon-epoxy material. Carbon-epoxy tows with areal weights of 30 g/m2 and 70 g/m2 were used in these manufacturing trials. The AFP process parameters of heater output, compaction force, tow feed rate, and tow tension were adjusted and optimized for successful manufacturing. This article documents an exploration of thin-ply fabrication on both flat and complex-shaped surfaces. Ultimately, aerospace-quality laminates were made from the 70-g/m2 material, but imperfections in the 30-g/m2 material itself and the fact that the AFP machine was not designed for such a thin material meant that more research and trials are required to obtain flight-quality 30-g/m2 laminates.

carbon-epoxy↗

DOE OSTI2022

Component-wise reduced-order model design optimization such as for lattice design optimization

Systems and methods for optimizing a lattice structure design are disclosed herein. In some embodiments, a method for optimizing a lattice structure design can include (i) modeling the lattice structure with a component-wise reduced-order model (CWROM) and (ii) optimizing the CWROM based on a selected criterion using a topology optimization algorithm for lattice design. The selected criterion can include a boundary condition and a load applied to the lattice structure. By modeling the lattice structure as a CWROM, the optimization process can be very fast while still permitting the accurate computation of physical quantities of the lattice structure.

Choi, Youngsoo↗

DOE OSTI2020

Consequence Analysis of Residual Water in a Storage Canister - 20484

Recent observations from projects sponsored under the DOE-Nuclear Energy Spent Fuel and Waste Disposition campaign show that residual free water, well above the 0.4 gm-moles that correspond to a 3 torr rebound pressure after a 30-minute hold following prototypic drying, may remain within SNF canisters used for long-term dry storage. Specifically, experimental observations in an Integrated Research Project showed subzero temperatures and a local pocket of frozen water in a mockup fuel assembly subjected to an industry practiced drying process. In gas sampling and analysis from the High Burnup (HBU) Demonstration project, using a fully loaded and dried SNF canister, indicated presence of 100 g of residual water had remained in the canister. The effects of residual water in terms of potential adverse impacts on the condition of the SNF and the canister internals during long-term dry storage has been rigorously evaluated to address inadvertent residual water contents. The impact of residual water on the fuel and canister internals, with a focus on the oxidation of the cladding and of postulated exposed (breached-clad) fuel, were evaluated using an integrated set of time-dependent environmental conditions with semi-empirical materials oxidation models. An 'integration model,' with coupled sub-models, developed and previously used by the Center for Nuclear Waste Regulatory Analysis (CNWRA), was applied and expanded with improved sub-models for water radiolysis, and for cladding and fuel oxidations. Cladding oxidation models for various alloys were developed using the rate constants for various cladding alloys in the dry storage temperature range. A burnup-dependent fuel oxidation model was developed; it accounted for inhibition effect of fission products on fuel oxidation rates. The potential for extension of the initial breach flaw (1 mm hole) was evaluated by two separate mechanics criteria. In the first case, a critical cladding strain criterion was used. In the second case, a critical stress intensity was used to evaluate stability of a planar axial flaw postulate. A failure condition exists when a sufficient amount of fuel oxidation (at the postulated breached-clad location) causes fuel pellet swelling to load the cladding to meet a mechanics criterion for flaw extension. The integration model's results provide the following insights. The radiolysis-generated oxygen is consumed with a partitioning between the cladding and the fuel. The extent of cladding oxidation is no more than 2 μm additional consumption of the cladding metal even with 10 moles of residual water, indicating that changes in cladding conditions due to water are expected to be negligible. The conditions for cladding failure (breach opening size extension) directly correlates with the extent of fuel oxidation. Fuel oxidation significant to extend the breach could occur even with 5.5 moles of residual water. The results indicate that fuel oxidation vis-a-vis cladding oxidation is more likely under a higher radiation field, i.e., when radiolytic decomposition of the residual water occurs in few years compared to several decades, and that the conditions to cause failure are increased with fuel and cladding temperatures approaching the peak storage temperature limit of 400 deg. C. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Reference Fuel Development for Non-Aluminum Spent Nuclear Fuel Management

The Savannah River Site (SRS) L Area Facility provides for the safe receipt, storage, handling, and shipping of spent nuclear fuel (SNF) and has received more than 47,000 SNF assemblies since 1964. In order to consolidate receipt and storage analysis, L Area criticality safety has historically used several aluminum-clad “reference fuels” to establish bounding storage, handling, and cask loading limits and then applied a reactivity comparison approach to demonstrate that candidate fuels may be processed under the reference fuel limits. Currently, only aluminum-clad SNF from off-site research reactors are transferred on-site. The Accelerated Basin De-Inventory (ABD) program will begin the removal of bundled Non-Aluminum Spent Nuclear Fuel (NASNF) from the L Area disassembly basin for dissolution and disposition, which has driven the need for a non-aluminum reference fuel. This paper discusses the process and results of creating a new fictional homogenous NASNF highly enriched uranium reference fuel, “MITZ,” to be used in nuclear criticality safety evaluations for upcoming SNF disposition operations. Data demonstrating the relationship between neutron multiplication behavior and fuel spacing is generated for the new reference fuel MITZ as well as existing reference fuels representing several types of SNF assemblies.

Reference Fuel↗