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The Mechanical Components Test Facility (MCTF), also known as "Leak Lab" at MSFC is a multi-capability lab that facilitates payload evolution from proof-of-concept to on-orbit operations. We also have the capability to bring our equipment to various location for off-site testing.
This report documents mechanical testing capability demonstration activities performed in fiscal year (FY)2025 at Oak Ridge National Laboratory(ORNL)on chromium-coated (Cr-coated) and uncoated advanced zirconium alloy claddings irradiated in the High Flux Isotope Reactor (HFIR) to approximately 4 displacements per atom (dpa), corresponding to ~13GWd/t burnup. Specimens were prepared in axial tension (ATT) and ring tension (RTT) geometries, and passive silicon carbide(SiC)thermometry (TM) was employed to determine irradiation temperatures, which averaged 38–43 °C below the 330 °C design target. Mechanical testing at ambient temperature demonstrated the expected irradiation-induced hardening, with yield strength(YS)and ultimate tensile strength(UTS)values increasing substantially relative to unirradiated counterparts. However, this strengthening was accompanied by a reduction in ductility, as indicated by lower uniform and total elongations(UE and TE). Both coated and uncoated claddings exhibited similar mechanical response, though Cr-coated specimens showed surface cracking perpendicular to the loading direction, attributable to the hardness mismatch between the coating and substrate. Fracture in all cases remained ductile, and no coating spallation was observed following HFIR irradiation. Complementary efforts were directed toward the fabrication of test specimens from commercially irradiated cladding (rod 47I, ~31.1 GWd/t average burnup). Axial sectioning and computer numerical control(CNC)machining successfully produced ATT geometries suitable for benchmarking against HFIR-irradiated specimens. This capability enables direct comparison of cladding behavior between test reactor and commercial reactor environments, thereby supporting the validation of HFIR as a surrogate irradiation platform for accident tolerant fuel (ATF) development. Once HFIR irradiations are completed in FY26,the relevant comparison tests will be completed. Collectively, the FY 2025 PIE campaign has provided mechanical performance data for irradiated advanced claddings The demonstrated capabilities support the framework for mechanical testing and further evaluations in subsequent years. These efforts will represent an important contribution toward the licensing and deployment of Cr-coated zirconium alloy cladding as a near-term ATF solution.
The response of silicon carbide (SiC) fiber-reinforced SiC matrix (SiC/SiC) composite cladding to mechanical interaction with fissile fuel is a knowledge gap that must be overcome to design and assess SiC-based cladding systems for advanced nuclear applications. This study developed the relevant mechanical testing capability and identified the failure behavior and the critical microstructural features and processing defects. Sections of SiC composite tube were subjected to a modified expansion-due-to-compression (EDC) test in an X-ray computed tomography microscope: a polyurethane plug pressed surrogate Al 2 O 3 into the inner walls of the SiC/SiC composite tubes to achieve hard contact. A pure EDC test with just a polyurethane plug was also performed as a reference. Through the use of displacement fields, digital volume correlation revealed inhomogeneous deformation fields in the tubes, even for pure EDC, which was related to the inherent defects in the structure. Deep learning–aided segmentation and systematic data analysis revealed that the presence of inhomogeneous deformation applied by the hard contact was exaggerated by the presence of inner surface imperfections left behind from the matrix densification process. In conclusion, the findings provide insights into the applications, highlighting the necessity for improvements in inner surface roughness and the incorporation of localized contacts in pellet–cladding mechanical interaction computational models.
A novel, in-situ, scanning electron microscope (SEM) mechanical testing capability for materials at the microscale which provides experimental validation to a machine learning (ML) toolset for full-field validation of physics-based micromechanics models is being developed by researchers at NASA Glenn Research Center. These are enabling technologies for the integration of multiscale digital twins for materials into system level models which will result in the improved performance, material discovery, reduced production cost and time, rapid characterization, and prognostic structural health monitoring (SHM) for materials and structures for extreme environments in support of NASA space exploration missions. In order to bridge the material structure-to-system gap for digital twins, physics-based models must be experimentally validated at multiple length scales. Seminal microscale experiments, conducted at the Air Force Research Laboratory (AFRL), were limited to transverse compression of single-layer, unidirectional thermoset polymer matrix composite (PMC) micropillar specimens [1]. The early phases of the current project followed those initial results and setup to reproduce the compression testing of PMC material on the custom-built piezoelectric actuated micromechanical testing rig built by MicroTesting Solutions LLC. In this work, samples of thermoplastic PMC material were first machined into 3 mm cubes, and then further machining and final milling was done using a Focused Ion Beam (FIB). The initial experiment was done on a pillar roughly 20 µm x 20 µm x 40 µm tall. Additional pillars were milled with final sizes ranging from 20 µm x 20 µm x 40 µm tall to 40 µm x 40 µm x 65 µm tall. A speckle pattern for in-situ full-field measurements using Digital Image Correlation (DIC) was applied with platinum, which was coated on the surface, and then the FIB was used to mill away some of the coating to produce an irregular pattern of Pt on the pillar surface. The samples were loaded into the custom testing rig and placed into the SEM and loaded under compression until failure. Images were collected in the SEM during testing. Post-processing of the images was conducted using DIC to obtain full-field displacement and strain measurements elucidating the role of the matrix as well as fiber-fiber interaction at the microscale within the composite subjected to compression loading well into the non-linear regime of the material. Moreover, the evolution of fiber-matrix debonding and matrix cracking is observed in-situ at the microscale. This data, along with images segmented with a newly developed ML toolset [2], was used to create and validate physics-based micromechanics models. An image of the failed micropillar is shown in Figure 1. The techniques developed in the initial compression experiment was tailored to the validation needs of the models and expanded to include different sized samples as well as possibly tension and fatigue.
The Mechanical Components Branch at NASA Glenn Research Center formulates, conducts, and manages research focused on propulsion systems for both present and advanced aeronautical and space vehicles. The branch is comprised of research teams that perform basic research in three areas: mechanical drives, aerospace seals, and space mechanisms. Each team has unique facilities for testing aerospace hardware and concepts. This report presents an overview of the Mechanical Components Branch test facilities.
The results of a research task to investigate the capabilities of electrodynamic vibrators (shakers) to perform mechanical shock tests are presented. The simulation method employed was that of developing a transient whose shock response spectrum matched the desired shock response spectrum. Areas investigated included the maximum amplitude capabilities of the shaker systems, the ability to control the shape of the resultant shock response spectrum, the response levels induced at frequencies outside the controlled bandwidth, and the nonlinearities in structural response induced by a change in test level.
Hold Down and Release Mechanisms (HDRMs) are a common piece of spacecraft hardware which restrain components during launch, transit, and later allow them to be extended, jettisoned, separated, etc. at the spacecraft’s destination. Due to prohibitively high cost, long lead times, and limited reset capability, testing of mechanisms that require HDRMs is often difficult. This project explored the possibility of designing HDRM-analogue devices that would replicate the function of flight HDRMs during ground-based testing for a fraction of the cost of a flight HDRM. These devices were designed with the requirements of the Spin Eject Mechanism to be used on the Mars Sample Return (MSR) Capture, Containment, and Return System (CCRS) in mind. A trade study was conducted to determine the optimal internal mechanism design of the device, comparing several mechanisms from existing HDRMs to several simpler, more novel mechanisms. CAD software was used to create a preliminary design of the device utilizing a mix of commercial off-the-shelf parts and custom-manufactured parts. Several straightforward analyses were conducted to determine the most effective models for the off-the-shelf parts. A prototype largely composed of 3D-printed components was also created to proof the design concept. Although this HDRM simulator was designed for a particular mechanism for the CCRS mission, its general design is useful for ground testing of a variety of mechanisms requiring similar HDRM simulators.
A thorough procedure was developed to efficiently manufacture dogbone samples using focused ion beam (FIB) milling for micro-tensile testing. A Bruker PI 89 PicoIndenter, Billerica, MA, USA, was used as a case study, although the analysis and results are applicable to other micro-mechanical testing systems capable of mounting a standard, Ø12.7 mm × Ø3.2 mm pin, scanning electron microscopy (SEM) pin stub (Ted Pella, Redding, CA, USA). Nine dogbones were made from an Fe-45Cu alloy additively manufactured using powder-fed laser-directed energy deposition (DED-LB). Testing showed that fracture was confined to the gauge section for all dogbones and that the fracture mode, ductile vs. brittle, was entirely dependent on the grain orientation relative to the loading direction. The analysis showed that the measured plastic strain to failure can vary from >11% (optimal geometry) to <1% (non-optimal geometry) in micro-tensile testing of high-tensile-strength (>1 GPa) metallic materials. Subsequently, a finite element analysis (FEA) was conducted to identify the improved dogbone geometries. A total of ten thousand dogbone geometries were tested, and their dimensions were defined by a set of four adjustable parameters (corner radius, load surface angle, load surface length, and dogbone head length). The gauge width and gauge length were fixed to 4 µm and 10 µm, respectively. Three-dimensional surface plots of the stress concentration as a function of two parameters were used to identify the optimal ranges of parameter values. The addition of maximum width and length constraints, measuring 25 µm and 30 µm, respectively, allowed us to identify an optimal geometry at load surface angles of 30° and 45°. Their respective dimensions (corner radius, load surface length, and dogbone head length) are, in µm, 12, 6, and 7 and 10, 7, and 7. Testing these two optimal geometries with a range of gauge lengths from 4 to 20 µm showed that smaller gauge lengths only slightly reduced the detrimental stress concentration outside the gauge section. However, smaller gauge lengths will notably improve the FIB surface polishing step as tapering is reduced with smaller dogbone lengths.
Four rubber erasers from the campus bookstore, two green and two white, have been cut to have identical dimensions. These are loaded in compression with a mechanical test machine capable of applying cyclic loads and providing output to an X-Y plotter. The anelastic behavior of rubber as well as the relative stiffnesses of composite materials loaded transversely and longitudinally may be demonstrated to beginning students or used as input for computer analysis by students.
Long-term operations on the Moon’s surface require materials that can withstand the harsh lunar environment. Lunar dust and regolith pose significant threats to the long-term durability of materials used in lunar applications. Lunar dust, easily perturbed and dispersed, adheres and abrades materials due to its rough and irregular grain morphology. More closely representing this abrasion action through experimental laboratory testing is critical in assessing the durability of potential lunar candidate materials used in mechanical, sensor, and human-based systems. In this study, the performance of materials using Taber abrasive wheels made from lunar regolith simulant was assessed and compared to results obtained using standard ceramic-based abrasion materials. The results highlight a difference in the abrasive wear rates between the lunar regolith simulant and the standard ceramic-based abrasive. Utilizing the mechanisms and testing capabilities of this two-body abrasive interaction leveraging regolith-based abrasives may more closely represent the interplay between materials and lunar dust, which is vital for assessing the long-term viability of materials for extended lunar missions. Improved lunar testing capabilities may also enhance evaluations of the long-term performance degradation of passive and active dust mitigation methods.
A survey of wind tunnel research facilities in the United States is presented. The inventory includes all subsonic, transonic, and hypersonic wind tunnels operated by governmental and private organizations. Each wind tunnel is described with respect to size, mechanical operation, construction, testing capabilities, and operating costs. Facility performance data are presented in charts and tables.
Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes rapid, innovative and cost-effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up fast, with lean development processes and a hands-on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. It consists of several teams with associated laboratories and test capabilities. The Granular Mechanics and Regolith Operations (GMRO) Laboratory and the Electrostatics and Surface Physics Laboratory (ESPL) are co-located in the Engineering Development Lab (EDL) facility high bay. The Applied Chemistry Lab (ACL) is in an adjacent facility and other KSC labs are being influenced by the innovation methods pioneered at the Swamp Works. The Swamp Works was founded in January 2013 by a group of scientists and engineers at KSC with the over-arching vision of expanding humanity and civilization into the solar system by the use of space resources via advanced technology. Ultimately, this will create a solar system economy that will improve the human condition due to the abundance of energy and resources. This paper will summarize the projects and technology development that have been performed by the Swamp Works to celebrate its 10th Anniversary of innovation success.
Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes efficient, innovative and cost-effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up momentum, with lean development processes and a hands-on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. It consists of several teams with associated laboratories and test capabilities. The Granular Mechanics and Regolith Operations (GMRO) Laboratory and the Electrostatics and Surface Physics Laboratory (ESPL) are co-located in the Engineering Development Lab (EDL) facility high bay. The Applied Chemistry Lab (ACL) is in an adjacent facility and other KSC labs are being influenced by the innovation methods pioneered at the Swamp Works. The Swamp Works was founded in January 2013 by a group of scientists and engineers at KSC with the over-arching vision of expanding humanity and civilization into the solar system by the use of space resources via advanced technology. Ultimately, this will create a solar system economy that will improve the human condition due to the abundance of energy and resources. This presentation will summarize the projects and technology development that have been performed by the Swamp Works to celebrate its 10th Anniversary of innovation success.
Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes rapid, innovative and cost-effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up efficiently, with lean development processes and a hands-on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. It consists of several teams with associated laboratories and test capabilities. The Granular Mechanics and Regolith Operations (GMRO) Laboratory and the Electrostatics and Surface Physics Laboratory (ESPL) are co-located in the Engineering Development Lab (EDL) facility high bay. The Applied Chemistry Lab (ACL) is in an adjacent facility and other KSC labs are being influenced by the innovation methods pioneered at the Swamp Works. The Swamp Works was founded in January 2013 by a group of scientists and engineers at KSC with the over-arching vision of expanding humanity and civilization into the solar system by the use of space resources via advanced technology. Ultimately, this will create a solar system economy that will improve the human condition due to the abundance of energy and resources. This presentation will summarize the projects and technology development that have been performed by the Swamp Works to celebrate its 10th Anniversary of innovation success.
Automated test capability for extensive low-level hardware fault insertion testing is developed. The test capability is used to calibrate fault detection coverage and associated latency times as relevant to projecting overall system reliability. Described are modifications made to the NASA Ames Reconfigurable Flight Control System (RDFCS) Facility to fully automate the total test loop involving the Draper Laboratories' Fault Injector Unit. The automated capability provided included the application of sequences of simulated low-level hardware faults, the precise measurement of fault latency times, the identification of fault symptoms, and bulk storage of test case results. A PDP-11/60 served as a test coordinator, and a PDP-11/04 as an instrumentation device. The fault injector was controlled by applications test software in the PDP-11/60, rather than by manual commands from a terminal keyboard. The time base was especially developed for this application to use a variety of signal sources in the system simulator.
Elements of the analytical/experimental program to characterize the response of silicon carbide titanium (SCS-6/Ti-15-3) composite tubes under biaxial loading are outlined. The analytical program comprises prediction of initial yielding and subsequent inelastic response of unidirectional and angle-ply silicon carbide titanium tubes using a combined micromechanics approach and laminate analysis. The micromechanics approach is based on the method of cells model and has the capability of generating the effective thermomechanical response of metal matrix composites in the linear and inelastic region in the presence of temperature and time-dependent properties of the individual constituents and imperfect bonding on the initial yield surfaces and inelastic response of (0) and (+ or - 45)sub s SCS-6/Ti-15-3 laminates loaded by different combinations of stresses. The generated analytical predictions will be compared with the experimental results. The experimental program comprises generation of initial yield surfaces, subsequent stress-strain curves and determination of failure loads of the SCS-6/Ti-15-3 tubes under selected loading conditions. The results of the analytical investigation are employed to define the actual loading paths for the experimental program. A brief overview of the experimental methodology is given. This includes the test capabilities of the Composite Mechanics Laboratory at the University of Virginia, the SCS-6/Ti-15-3 composite tubes secured from McDonnell Douglas Corporation, a text fixture specifically developed for combined axial-torsional loading, and the MTS combined axial-torsion loader that will be employed in the actual testing.
The study of dynamic stall of rapidly pitching airfoils is being conducted at NASA Ames Research Center. Understanding this physical phenomenon will aid in improving the maneuverability of fighter aircraft as well as civilian aircraft. A wind tunnel device which can linearly pitch and control an airfoil with rapid dynamic response is needed for such tests. To develop a mechanism capable of high accelerations, an accurate model and control system is created. The model contains mathematical representations of the mechanical system, including mass, spring, and damping characteristics for each structural element, as well as coulomb friction and servovalve saturation. Electrical components, both digital and analog, linear and nonlinear, are simulated. The implementation of such a high-performance system requires detailed control design as well as state-of-the-art components. This paper describes the system model, states the system requirements, and presents results of its theoretical performance which maximizes the structural and hydraulic aspects of this system.
The study of dynamic stall of rapidly pitching airfoils is being conducted at NASA Ames Research Center. Understanding this physical phenomenon will aid in improving the maneuverability of fighter aircraft as well as civilian aircraft. A wind tunnel device which can linearly pitch and control an airfoil with rapid dynamic reponse is needed for such tests. To develop a mechanism capable of high accelerations, an accurate model and control system is created. The model contains mathematical representations of the mechanical system, including mass, spring, and damping characteristics for each structural element, as well as coulomb friction and servovalve saturation. Electrical components, both digital and analog, linear and nonlinear, are simulated. The implementation of such a high-performance system requires detailed control design as well as state-of-the-art components. This paper describes the system model, states the system requirements, and presents results of its theoretical performance which maximizes the structural and hydraulic aspects of this system.