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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Weld Repair of Thin Aluminum Sheet

Weld repairing of thin aluminum sheets now possible, using niobium shield and copper heat sinks. Refractory niobium shield protects aluminum adjacent to hole, while copper heat sinks help conduct heat away from repair site. Technique limits tungsten/inert-gas (TIG) welding bombardment zone to melt area, leaving surrounding areas around weld unaffected. Used successfully to repair aluminum cold plates on Space Shuttle, Commercial applications, especially in sealing fractures, dents, and holes in thin aluminum face sheets or clad brazing sheet in cold plates, heat exchangers, coolers, and Solar panels. While particularly suited to thin aluminum sheet, this process also used in thicker aluminum material to prevent surface damage near weld area.

Beuyukian, C. S.↗
NASA NTRS1977

Testing of polyimide second-stage rod seals for single-state applications in advanced aircraft hydraulic systems

Machined polyimide second-stage rod seals were evaluated to determine their suitability for single-stage applications where full system pressure acts on the upstream side of the seal. The 6.35-cm (2.5-in.) K-section seal was tested in impulse screening tests where peak pressure was increased in 3.448-MPa (500-psi) increments each 20,000 cycles. Seal failure occurred at 37.92 MPa (5,500 psi), indicating a potential for acceptability in a 27.58-MPa (4,000-psi) system. Static pressurization for 600 sec at pressures in excess of 10.34 MPa (1,500 psi) revealed structural inadequacy of the seal cross section to resist fracture and extrusion. Endurance testing showed the seals capable of at least 65,000 1.27-cm (0.5-in.) cycles at 450 K (350 F) without leakage. It was concluded that the second-stage seals were proven to be exceptional in the 1.379-MPa (200-psi) applications for which they were designed, but polyimide material properties are not adequate for use in this design at pressure loading equivalent to that present in single-stage applications.

Waterman, A. W.↗
NASA NTRS1979

Device for pitching off metal tubes

Toggle mechanism is used to trap gas samples within small diameter metal tubes. Device is easily actuated and seals off without fracture.

Stengard, E. O.↗
NASA NTRS2011

Novel Low-Density Ablators Containing Hyperbranched Poly(azomethine)s

An ablative composite is low-density (0.25 to 0.40 g/cu cm), easy to fabricate, and superior to the current state-of-the-art ablator (phenolic impregnated carbon ablator, PICA) in terms of decomposition temperature, char yield, and mechanical strength. Initial ablative testing with a CO2 laser under high-heat-flux (1,100 W/sq cm) conditions showed these new ablators are over twice as effective as PICA in terms of weight loss, as well as transfer of heat through the specimen. The carbon fiber/poly(azomethine) composites have the same density as PICA, but are 8 to 11 times stronger to irreversible breaking by tensile compression. In addition, polyazomethine char yields by thermogravimetric analysis are 70 to 80 percent at 1,000 C. This char yield is 10 to 20 percent higher than phenolic resins, as well as one of the highest char yields known for any polymer. A high char yield holds the composite together better toward shearing forces on reentry, as well as reradiates high heat fluxes. This innovative composite is stronger than PICA, so multiple pieces can be sealed together without fracture. Researchers have also studied polyazomethines before as linear polymers. Due to poor solubility, these polymers precipitate from the polymerization solvent as a low-molecular-weight (2 to 4 repeat units) powder. The only way found to date to keep linear polyazomethines in solution is by adding solubilizing side groups. However, these groups sacrifice certain polymer properties. These hyperbranched polyazomethines are high molecular weight and fully aromatic.

Tigelaar, Dean↗
NASA NTRS2013

Model Verification and Validation Concepts for a Probabilistic Fracture Assessment Model to Predict Cracking of Knife Edge Seals in the Space Shuttle Main Engine High Pressure Oxidizer

Physics-based models are routinely used to predict the performance of engineered systems to make decisions such as when to retire system components, how to extend the life of an aging system, or if a new design will be safe or available. Model verification and validation (V&V) is a process to establish credibility in model predictions. Ideally, carefully controlled validation experiments will be designed and performed to validate models or submodels. In reality, time and cost constraints limit experiments and even model development. This paper describes elements of model V&V during the development and application of a probabilistic fracture assessment model to predict cracking in space shuttle main engine high-pressure oxidizer turbopump knife-edge seals. The objective of this effort was to assess the probability of initiating and growing a crack to a specified failure length in specific flight units for different usage and inspection scenarios. The probabilistic fracture assessment model developed in this investigation combined a series of submodels describing the usage, temperature history, flutter tendencies, tooth stresses and numbers of cycles, fatigue cracking, nondestructive inspection, and finally the probability of failure. The analysis accounted for unit-to-unit variations in temperature, flutter limit state, flutter stress magnitude, and fatigue life properties. The investigation focused on the calculation of relative risk rather than absolute risk between the usage scenarios. Verification predictions were first performed for three units with known usage and cracking histories to establish credibility in the model predictions. Then, numerous predictions were performed for an assortment of operating units that had flown recently or that were projected for future flights. Calculations were performed using two NASA-developed software tools: NESSUS(Registered Trademark) for the probabilistic analysis, and NASGRO(Registered Trademark) for the fracture mechanics analysis. The goal of these predictions was to provide additional information to guide decisions on the potential of reusing existing and installed units prior to the new design certification.

Pai, Shantaram S.↗
NASA NTRS2017

Normally-Closed Zero-Leak Valve with Magnetostrictive Actuator

A non-pyrotechnic, normally-closed, zero-leak valve is a replacement for the pyrovalve used for both in-space and launch vehicle applications. The valve utilizes a magnetostrictive alloy for actuation, rather than pyrotechnic charges. The alloy, such as Terfenol-D, experiences magnetostriction, i.e. a gross elongation, when exposed to a magnetic field. This elongation fractures a parent metal seal, allowing fluid flow through the valve. The required magnetic field is generated by redundant coils that are isolated from the working fluid.

Ramspacher, Daniel J.↗
NASA NTRS1971

Cadmium plated steel caps seal anodized aluminum fittings

Cadmium prevents fracturing of hard anodic coating under torquing to system specification requirements, prevents galvanic coupling, and eliminates need for crush washers, which, though commonly used in industry, do not correct leakage problem experienced when anodized aluminum fittings and anodized aluminum cap assemblies are joined.

Padden, J.↗
NASA NTRS1999

Characterization of Optical Lenses to be Considered for the Imaging of Crystal Dendrite Growth

Dynamic fracture is a phenomenon that is extremely sensitive to small perturbations in system parameters. This phenomenon is, in some ways, similar to that of dendritic crystal growth, although it is governed by different physical principles. Crystal dendrite growth patterns are affected by parameters such as temperature, pressure, and gravity. By studying the behavior of crystal dendrites in a controlled, microgravity environment, a greater understanding of dynamic fracture could be revealed. A sealed cubical container contains four stingers, which facilitate the growth of crystal dendrites. The container has five windows and is emersed in a liquid, for thermal isolation. The tip of a dendrite can advance in any direction, therefore three-dimensional images of the process are desired. Furthermore, because of the rapid growth rate, a fast image frame rate is required for accurate tracking of dendrite tip velocity. In addition, optical parameters such as field of view, depth of focus, and resolution are examined, as well as the working distance between a lens and the target of observation.

Wing, Frank M.↗
NASA NTRS1998

An Overview: NASA LeRC Structures Programs

A workshop on National Structures Programs was held, jointly sponsored by the AIAA Structures Technical Committee, the University of Virginia's Center for Advanced Computational Technology and NASA. The Objectives of the Workshop were to: provide a forum for discussion of current Government-sponsored programs in the structures area; identify high potential research areas for future aerospace systems; and initiate suitable interaction mechanisms with the managers of structures programs. The presentations covered structures programs at NASA, DOD (AFOSR, ONR, ARO and DARPA), and DOE. This publication is the presentation of the Structures and Acoustics Division of the NASA Lewis Research Center. The Structures and Acoustics Division has its genesis dating back to 1943. It is responsible for NASA research related to rotating structures and structural hot sections of both airbreathing and rocket engines. The work of the division encompasses but is not limited to aeroelasticity, structural life prediction and reliability, fatigue and fracture, mechanical components such as bearings, gears, and seals, and aeroacoustics. These programs are discussed and the names of responsible individuals are provided for future reference.

Zaretsky, Erwin V.↗
NASA NTRS2025

Sealing Europa’s Vents By Vapor Deposition: An Order-of-Magnitude Study

Fractures and vents in the ice crust of Europa, exposing the sub-surface ocean or liquid-water inclusions to the vacuum, might be responsible for the generation of planetary-scale water-vapor plumes. During its passage through the ice, the plume vapor is expected to partially condense on the cold ice walls. Together with other effects (water spillage, compression forces, etc.) this mechanism likely contributes to sealing the vent. In this work, we develop a lumped-parameter model to analyze the sealing timescales associated to water-vapor deposition alone. Neglecting all other possible mechanisms, we find shutting-off times roughly compatible with the 7-hour plume observed in 2012 by the Hubble Space Telescope, suggesting that vapor deposition might have played a major role in sealing the vent. A map of sealing times vs. plume density, mass flow rate and aperture areas is given. Plume quantities from the literature are analyzed and compared to our results. For a given plume density/mass flow rate, small apertures would be sealed quickly by vapor deposition and are thus incompatible with observations.

Europa↗
NASA NTRS1972

Lunar rock splitter/can sealer

A manually powered and operated force generating device fractures lunar material as received from the moon and seals cans containing lunar samples. The rock splitting and can sealing operations are carried out in a vacuum environment. Can sealing is a cold welding process that requires a pressure of 125,000 psi (generating 32,000 lb for the largest can used). The design and modification of the device and the operating experience are described.

Johnson, K. G.↗
NASA NTRS1976

Microcracks, micropores, and their petrologic interpretation for 72415 and 15418

Lunar samples 72415 and 15418 have complex microstructures that indicate a series of fracturing and healing events. Both samples contain relatively few open microcracks but many sealed and healed microcracks. Dunite 72415 contains abundant healed cracks that formed tectonically, symplectic intergrowths spatially and probably genetically related to microcracks, and a cataclastic matrix that has been extensively sintered. Metamorphosed breccia 15418 contains many post-metamorphic healed cracks, large shock induced cracks that have been sealed with glass, and a few younger, thin, open shock induced cracks.

Richter, D.↗
NASA NTRS1983

Analogy between fluid cavitation and fracture mechanics

When the stresses imposed on a fluid are sufficiently large, rupture or cavitation can occur. Such conditions can exist in many two-phase flow applications, such as the choked flows, which can occur in seals and bearings. Nonspherical bubbles with large aspect ratios have been observed in fluids under rapid acceleration and high shear fields. These bubbles are geometrically similar to fracture surface patterns (Griffith crack model) existing in solids. Analogies between crack growth in solid and fluid cavitation are proposed and supported by analysis and observation (photographs). Healing phenomena (void condensation), well accepted in fluid mechanics, have been observed in some polymers and hypothesized in solid mechanics. By drawing on the strengths of the theories of solid mechanics and cavitation, a more complete unified theory can be developed.

Hendricks, R. C.↗
NASA NTRS2011

Explosive Bolt Dual-Initiated from One Side

An explosive bolt has been developed that has a one-sided dual initiation train all the way down to the pyro charge for high reliability, while still allowing the other side of the bolt to remain in place after actuation to act as a thermal seal in an extremely high-temperature environment. This lightweight separation device separates at a single fracture plane, and has as much redundancy/reliability as possible. The initiation train comes into the explosive bolt from one side.

Snow, Eric↗
NASA NTRS2018

An Internship in Cryogenic Propulsion

Presentation on intern rotations. Summer 2013 I worked in cryolab and learned about calorimitry testing. Spring 2014 I helped create themalcouple arm for GODU-LH2. Summer 2014 I assisted with hardware failures on GPIM fracture mechanics testing. Summer 2017 I created a qualification test plan and test fixture to test vacuum seal-off valves.

Tucker, Corey J.↗
NASA NTRS2013

The Komplast Experiment: Space Environmental Effects after 12 Years in LEO (and Counting)

The Komplast materials experiment was designed by the Khrunichev State Research and Production Space Center, together with other Russian scientific institutes, and has been carried out by Mission Control Moscow since 18. Komplast panels fitted with material samples and sensors were located on the International Space Station (ISS) Functional Cargo Block (FGB) module exterior surface. Within the framework of this experiment, the purpose was to study the effect of the low earth orbit (LEO) environment on exposed samples of various materials. The panels were sent into orbit with the FGB when it launched on November 20, 1998. Panels #2 and #10 were retrieved during Russian extravehicular activity in February 2011 and sealed within cases to temporarily protect the samples from exposure to air until they could be studied on the ground. Panel #2 contained an experiment to detect micrometeoroid and orbital debris (MMOD) impacts, radiation and UV sensors, several pieces of electrical cable, and samples made from elastomeric and fluoroplastic materials. Panel #10 contained a temperature sensor, and both carbon composite and adhesive-bonded samples. A figure shows the location of panels #2 and #10 on the FGB module aft endcone. The panels were subsequently returned to Earth by Space Shuttle Discovery on the STS-133/ULF-5 mission after 12 years of LEO exposure and opened in an argon chamber at the Institute of Nuclear Physics at Moscow State University in July 2011. Based on the results of analyzing the readings from sensors located on Komplast panels and in studying material samples from the panels, the comprehensive effect of spaceflight factors on the FGB (at the locations of Panels #2 and #10) was evaluated. Total solar exposure was determined to be 960 +/- 200 kJ/square cm or 21,000 equivalent solar hours. Because of location of these two panels and the ISS flight attitude, atomic oxygen (AO) fluence was relatively low for such a long duration exposure, approximately 1.5x10 (exp 21) O atoms/sq. cm. Most of the AO fluence occurred during the early phase of ISS assembly. Temperatures ranged from a maximum of 107 C to a minimum of -80 C. The MMOD environment was determined, as is shown. Interestingly, the distribution of craters and low-velocity impact particles observed in the 5-50 micron size range was approx 2-3 orders of magnitude higher than that predicted by the ORDEM2000 model of natural and artificial origin microparticles in the ISS orbit. Contamination observations were also made, through the evaluation of optical properties on thermal control coatings and by the examination of visible deposits located near several samples on the panels, primarily from elastomeric samples. These elastomer samples were extensively investigated for their physical property changes and sealing capability. In addition, 16 samples of adhesive-bonded joints using three types of epoxy adhesive were evaluated studying fracture toughness, failure surface, and adhesive volume properties. Both rubber and adhesive-bonded specimens also underwent additional (post-flight) ground-based exposures to simulate a total 30 years in LEO prior to their evaluation. Overall, results indicate that space environmental effects will not adversely impact the service life of the FGB through 2028. Our investigation is complete and a summary of the results obtained from this uniquely long-duration exposure experiment will be presented.

Shaevich, S. K.↗
NASA NTRS2005

Solid Oxide Fuel Cell Seal Glass - BN Nanotubes Composites

Solid oxide fuel cell seal glass G18 composites reinforced with approx.4 weight percent of BN nanotubes were fabricated via hot pressing. Room temperature strength and fracture toughness of the composite were determined by four-point flexure and single edge V-notch beam methods, respectively. The strength and fracture toughness of the composite were higher by as much as 90% and 35%, respectively, than those of the glass G18. Microscopic examination of the composite fracture surfaces using SEM and TEM showed pullout of the BN nanotubes, similar in feature to fiber-reinforced ceramic matrix composites with weak interfaces. Other mechanical and physical properties of the composite will also be presented.

Bansal, Narottam P.↗