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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Ratchetting behavior in viscoplasticity - A technical note

Viscoplastic models that use the Armstrong and Frederick (1966) kinematic hardening relationship are known to generally overpredict the observed accumulation of ratchet strains. The reason for this behavior is a consequence of the mathematics used to describe Hooke's law and the evolution equations for plastic strain and back stress. Conditions for ratchetting exist whenever there is a cycle-averaged mean stress present over a cyclic loading path. Two types of controlled loading paths are often studied: cyclic relaxation is the ratchet mechanism associated with displacement (strain) control, while cyclic creep is the ratchet mechanism associated with load (stress) control. Overcoming the possible adverse trends in predicted ratchetting behavior is a difficult task, and how one ought to go about doing this is not yet completely clear. We therefore choose to discuss the mathematical cause of ratchetting and how it has been dealt with to date, but make no attempt to correct this flaw.

Freed, Alan D.↗
DOE OSTI2026

Drive Cycles, Battery Pack Scaling, and Usage Considerations for Long-Haul and Regional-Haul Electric Trucks

Electrifying Class-8 heavy-duty trucks presents a promising opportunity to enhance energy efficiency and reduce freight transport costs. Battery electric trucks (BETs), once considered niche, are gaining traction due to advancements in battery technology and cost reductions. However, accurately predicting battery lifespan under realistic usage conditions remains a key challenge. Understanding battery failure mechanisms and their links to design, operation, and management is essential for developers and fleet operators. This study introduces a method to develop simplified, lab-testable dynamic stress test (DST) cycles for regional and long-haul Class-8 BETs, derived from real-world diesel truck usage. These DSTs enable benchmarking of battery technologies, identification of aging stressors, and optimization of battery design, life, and cost. The approach supports evaluation of key metrics such as levelized cost of driving and total cost of ownership, aiding fair comparisons and adoption decisions. We also propose feasible battery pack sizes that meet current driving demands with strategic charging, and a method to scale pack-level DSTs to cell-level cycles for lab-based testing. These tools facilitate tradeoff analysis across battery chemistries, pack sizing, and charging strategies, while offering means to get insights into battery aging under realistic conditions-ultimately supporting informed BET deployment decisions.

25 ENERGY STORAGE↗
NASA NTRS1984

Effects of thermal cycling on magnetic properties of lunar analogs

An experimental study has been performed to determine whether stresses associated with thermal cycling cracks can affect the coercivity of remanence carried by iron in lunar samples. Initially, samples were cycled up to 100 times in a refrigerator over a period of about 30 min per cycle. In a second set of experiments, samples were dipped directly into liquid nitrogen up to 100 times at about 1 min per cycle. Comparison of AF demagnetization curves of weak field anhysteretic remanent magnetization before and after cycling revealed no systematic differences. Calculations based on a model of spherical iron grains within olivine or troilite indicate that it is unlikely that the iron will crack under thermal stress. Thus, thermal cycling does not appear to provide an explanation for increasing the stability of remanence in samples from the lunar surface.

Barron, A. M.↗
DOE OSTI2020

Comparison of woven and stitched out-of-autoclave E-glass/epoxy composites subjected to quasi-static and cyclic tensile loads

Tensile quasi-static and fatigue behaviors of out-of-autoclave, quasi-isotropic, E-glass/epoxy composites with woven and stitched fiber architectures are compared. Some specimens were cyclically loaded to failure, while others were tested for residual modulus and ultimate strength. Both laminates survived 10 7 cycles at a maximum stress of 94.8 MPa but failed prior to 10 7 cycles at a maximum stress greater than or equal to 124.1 MPa. For the stress-lifetime diagram and residual strength, the woven laminate had superior properties below 10 4 cycles and the stitched laminate had superior properties above 10 5 cycles. While intralaminar crack density was higher in the stitched laminate, the woven laminate demonstrated a higher percentage of delaminated area.

Materials Science↗
DOE OSTI2022

Carbon nanotubes decorated with Pt as a viable electrocatalyst system using electrochemical atomic layer deposition

Surface limited redox replacement (SLRR) is an electrochemical deposition method designed to deposit metal thin films, typically onto other metals, that are mere monolayers in thickness, where such low dimensions allows catalyst-support interactions to affect catalyst efficiency. Here we explore the growth of Pt, using iterative Cu-mediated SLRR cycles, directly onto carbon nanotubes (CNTs) which are potentially good candidates as electrocatalyst supports due to their electrical conductivity and chemical resistance. Here scanning electron microscope images showed that Pt grew as nanoparticles, and hydrogen underpotential deposition from cyclic voltammetry showed that the active surface area approached an asymptotic value around eight iterations. Catalytic activity, measured using the oxygen reduction reaction, reached a maximum at ten iterations. Both are shown to be influenced by the growth mode, but electrochemical modeling indicates that the trend in activity is also due to a change in activation energy, possibly due to changes in Pt electronic structure due to interactions with the CNTs. Durability cycling showed a greater than 85% retention of surface area for the first 10,000 cycles of accelerated stress testing but decayed steadily to about 50% after 30,000 cycles. This performance may be related to the phenomenon that limits surface area growth.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1990

Dissipation of mechanical work and temperature rise in AS4/PEEK thermoplastic composite

The dissipated mechanical work per cycle of sinusoidal stress in the thermoplastic composite material AS4/PEEK was measured as a function of stress amplitude for fixed frequency and fiber orientation. The experimental result shows that the dissipated work per cycle is proportional to the square of the stress amplitude. Using the concept of the equivalent isotropic material, it is shown that the relaxation modulus satisfies a proportionality condition. Also, the rate of temperature rise due to sinusoidal stresses has been measured as a function of stress amplitude. The result shows that the rate of temperature rise is not proportional to the square of the stress amplitude.

Georgiou, I.↗
DOE OSTI2023

Synergistic effect of polyaniline on stabilizing Pt nanoparticles in PEMFCs†

The stability of Pt nanoparticles on a carbon support is crucial for the lifespan of polymer electrolyte membrane fuel cells as well as other electrocatalysis systems such as electrolyzers. Here we took the approach of utilizing the covalently grafted polyaniline on carbon to stabilize Pt nanoparticles by simultaneously alleviating the particle migration and mitigating the Ostwald ripening, which are two major mechanisms for loss of the catalyst stability. A comprehensive investigation of the stability and performance of Pt catalyst nanoparticles on these supports reveals that the polyaniline can shift the Pt L edge binding energy and the Pt 4f peak energy, leading to the increased redox potential of the Pt nanoparticles and making them more resistant to oxidation. Interestingly, the highest polyaniline density (50 wt%) does not show the best catalyst stability, rather, the second (33 wt%) demonstrates the best catalyst stability among these catalysts. Combining the XPS, XAS and fuel cell stability studies, we concluded that the locations of the Pt nanoparticles over the polyaniline layer on the carbon surface depend on the surface density of the polyaniline over the carbon surface. The Pt nanoparticles in the 50 wt% polyaniline catalyst are wrapped by the polyaniline polymer but do not sit directly on the carbon surface, while Pt nanoparticles in the 33 wt% polyaniline catalyst sit on the carbon surface and are densely surrounded by the polyaniline polymer. The results show that the mass activity loss is 12.5% while the ECSA (electrochemically active surface area) loss is 37.1% after 30k cycles of accelerating stress test for the 33 wt% polyaniline catalyst, far exceeding the DOE 2020 target for MEA (i.e., mass activity loss < 50%, and ECSA loss < 40%). Overall, the polyaniline has a synergistic effect on mitigating the surface migration and slowing down the Ostwald ripening to stabilize the Pt nanoparticles in fuel cells. The novel strategy to stabilize Pt nanoparticles using polyaniline opens a new pathway in the development of highly stable catalysts: relying on the functionalization group on the carbon support, instead of just focusing on the catalyst itself.

Li, Chenzhao↗
NASA NTRS1972

Effect of residual stresses induced by prestressing on rolling element fatigue life

A mechanical prestress cycle suitable to induce compressive stress beneath the surface of the inner race of radially loaded 207-size bearings was determined. Compressive residual stress in excess 0.69 x 10 to the 9th power N/sq m (100,000 psi), as measured by X-ray diffraction, were induced at the depth of maximum shearing stress. The prestress cycle consisted of running the bearings for 25 hours at 2750 rpm at a radial load which produced a maximum Hertz stress of 3.3 x 10 to the 9th power N/sq m (480,000 psi) at the contact of the inner race and the heaviest loaded ball. Bearings subjected to this prestress cycle and subsequently fatigue tested gave a 10 percent fatigue life greater than twice that of a group of baseline bearings.

Parker, R. J.↗
NASA NTRS1971

Erosion of metals by multiple impacts with water

Investigation determines - relation between impact velocity and minimum number of impacts producing visible erosion, relation between high frequency fatigue stresses and number of cycles to failure, water-hammer stresses relation to high frequency endurance limit, erosion rate as exposure time function, and correlates experimental data with recent theory.

Rudy, S. L.↗
NASA NTRS1979

Characterization of an oxide dispersion strengthened superalloy, MA-6000E, for turbine blade applications

Alloy MA 6000E was developed by the mechanical alloying process for turbine blade applications. The nominal composition of the experimental alloy is Ni-15CR-2Mo-4W-4.5Al- 2.5Ti-2Ta- .15Zr-.05C-.01B-1.1Y2O3. The 1000 hour rupture strength in the longitudinal direction is about 145 MPa at 1093 C and about 483 MPa at 760 C. The alloy displays normal three-stage creep behavior. Typically the creep elongation is 3.5% at 760 C and 2% at 1093 C. The alloy is notch ductile (K sub 1 = 3.5). The rupture properties of the alloy are not significantly degraded by thermal cycling or prior stress isothermal exposure. The alloy also has excellent longitudinal high and low cycle fatigue resistance. Limited testing indicates that MA 6000E posesses good off-axis mechanical properties. The transverse tensile elongation at 760 C is about 3%. The 100 hour transverse rupture strength is 331 MPa at 760 C and about 55 MPa at 1093 C.

Kim, Y. G.↗
NASA NTRS2014

Test Methodology Development for Experimental Structural Assessment of ASC Planar Spring Material for Long-Term Durability

A vibration-based testing methodology has been developed that will assess fatigue behavior of the metallic material of construction for the Advanced Stirling Convertor displacer (planar) spring component. To minimize the testing duration, the test setup is designed for base-excitation of a multiplespecimen arrangement, driven in a high-frequency resonant mode; this allows completion of fatigue testing in an accelerated period. A high performance electro-dynamic exciter (shaker) is used to generate harmonic oscillation of cantilever beam specimens, which are clasped on the shaker armature with specially-designed clamp fixtures. The shaker operates in closed-loop control with dynamic specimen response feedback provided by a scanning laser vibrometer. A test coordinator function synchronizes the shaker controller and the laser vibrometer to complete the closed-loop scheme. The test coordinator also monitors structural health of the test specimens throughout the test period, recognizing any change in specimen dynamic behavior. As this may be due to fatigue crack initiation, the test coordinator terminates test progression and then acquires test data in an orderly manner. Design of the specimen and fixture geometry was completed by finite element analysis such that peak stress does not occur at the clamping fixture attachment points. Experimental stress evaluation was conducted to verify the specimen stress predictions. A successful application of the experimental methodology was demonstrated by validation tests with carbon steel specimens subjected to fully-reversed bending stress; high-cycle fatigue failures were induced in such specimens using higher-than-prototypical stresses

fatigue testing machines↗
NASA NTRS1982

A simplified design procedure for life prediction of rocket thrust chambers

An analytical procedure for predicting thrust chamber life is developed. The hot-gas-wall ligaments separating the coolant and combustion gas are subjected to pressure loading and severe thermal cycling. The resulting stresses interact during plastic straining causing incremental bulging of the ligaments during each firing cycle. This mechanism of plastic ratcheting is analyzed and a method using a yield surface for combined bending and membrane loading developed for determining the incremental permanent deflection and progressive thinning near the center of the ligaments. Fatigue and tensile instability are analyzed as possible failure modes. Results of the simplified analyses compare favorably with available experimental data and finite element analysis results for OFHC (Oxygen Free High Conductivity) copper. They are also in reasonably good agreement with experimental data for NARloy Z, a copper-zirconium-silver alloy developed by the Rocketdyne Division of Rockwell International.

Porowski, J. S.↗
NASA NTRS2011

A New High-Speed, High-Cycle, Gear-Tooth Bending Fatigue Test Capability

A new high-speed test capability for determining the high cycle bending-fatigue characteristics of gear teeth has been developed. Experiments were performed in the test facility using a standard spur gear test specimens designed for use in NASA Glenn s drive system test facilities. These tests varied in load condition and cycle-rate. The cycle-rate varied from 50 to 1000 Hz. The loads varied from high-stress, low-cycle loads to near infinite life conditions. Over 100 tests were conducted using AISI 9310 steel spur gear specimen. These results were then compared to previous data in the literature for correlation. Additionally, a cycle-rate sensitivity analysis was conducted by grouping the results according to cycle-rate and comparing the data sets. Methods used to study and verify load-path and facility dynamics are also discussed.

Stringer, David B.↗
NASA NTRS2012

Probabilistic Fatigue Damage Program (FATIG)

FATIG computes fatigue damage/fatigue life using the stress rms (root mean square) value, the total number of cycles, and S-N curve parameters. The damage is computed by the following methods: (a) traditional method using Miner s rule with stress cycles determined from a Rayleigh distribution up to 3*sigma; and (b) classical fatigue damage formula involving the Gamma function, which is derived from the integral version of Miner's rule. The integration is carried out over all stress amplitudes. This software solves the problem of probabilistic fatigue damage using the integral form of the Palmgren-Miner rule. The software computes fatigue life using an approach involving all stress amplitudes, up to N*sigma, as specified by the user. It can be used in the design of structural components subjected to random dynamic loading, or by any stress analyst with minimal training for fatigue life estimates of structural components.

Michalopoulos, Constantine↗
NASA NTRS2013

Modelling of Fiber/Matrix Debonding of Composites Under Cyclic Loading

The micromechanics theory, generalized method of cells (GMC), was employed to simulate the debonding of fiber/matrix interfaces, within a repeating unit cell subjected to global, cyclic loading, utilizing a cyclic crack growth law. Cycle dependent, interfacial debonding was implemented as a new module to the available GMC formulation. The degradation of interfacial stresses, with applied load cycles, was achieved via progressive evolution of the interfacial compliance. A periodic repeating unit cell, representing the fiber/matrix architecture of a composite, was subjected to combined normal and shear loadings, and degradation of the global transverse stress in successive cycles was monitored. The obtained results were compared to values from a corresponding finite element model. Reasonable agreement was achieved for combined normal and shear loading conditions, with minimal variation for pure loading cases. The local effects of interfacial debonding, and fatigue damage will later be combined as sub-models to predict the experimentally obtained fatigue life of Ti-15-3/Sic composites at the laminate level.

Naghipour, Paria↗
NASA NTRS1993

Fabrication and properties of functionally graded NiAl/Al2O3 composites

A modified sedimentation process was used in the production of a functionally gradient material (FGM), NiAl/Al2O3. A simple finite element model was used to guide our design and fabrication efforts by estimating residual stress states as a function of composite structure. This approach could lead to tailored designs that enhance or avoid specific residual stress states. Thermal cycling tests were factored into the model to predict time dependent or steady-state internal temperature and stress profiles. Four-point bend tests were conducted to establish the mechanical load-displacement behavior of a single interlayer FGM at room temperature, 800 and 1000 K. Room temperature bend strength of the FGM was 3-4 times that of the base NiAl. At elevated temperatures, composite fracture occurred in a gradual, noncatastrophic mode involving NiAl retardation of a succession of cracks originating in the alumina face.

Miller, D. P.↗
DOE OSTI2022

Benchmarking Solid-State Batteries Containing Sulfide Separators: Effects of Electrode Composition and Stack Pressure

Integrating sulfide separators into solid-state batteries (SSBs) containing high energy cathodes typically requires one or more materials and engineering solutions including: (i) applying interfacial coatings to mitigate electrolyte decomposition, (ii) applying high stack pressures to form robust solid-solid contacts, and (iii) using alloying anodes to avoid Li dendrite formation. Despite the promise of these approaches, a lack of standardized testing protocols makes it difficult to directly compare results among different studies. To address this problem, the present work benchmarks the performance of SSBs containing β-Li 3 PS 4 (LPS) separators and composite cathodes. By systematically varying the anode/cathode composition and stack pressure, this work demonstrates that cathode design is a major bottleneck for solid-state cells cycled at low rates (<100 µA cm -2 ). Operando stack pressure measurements show that, while mechanical confinement generally promotes higher active material utilization and cycling stability, this strategy alone does not address interfacial reactivity between LPS and high voltage cathodes. Here, these results also demonstrate that stress evolution during cycling is dominated by volume changes at the Li metal anode. Finally, we show that FeS 2 cathodes with moderate operating voltages (<3 V vs Li/Li + ) exhibit superior cycling performance compared to high voltage cathodes by facilitating formation of stable cathode/electrolyte interfaces.

25 ENERGY STORAGE↗
NASA NTRS1973

Thermal fatigue behavior of T-111 and ASTAR 811C in ultrahigh vacuum

The thermal fatigue behavior of the tantalum alloys T-111 (Ta-8W-2Hf) and ASTAR 811C (Ta-8W-1Re-0.7Hf-0.025C) has been evaluated using completely reversed push-pull fatigue tests conducted in ultrahigh vacuum with independently programmed temperature and strain cycles. Test results showed that cycling of the test temperature simultaneously with the mechanical strain in most cases significantly reduced the cycles to failure of both alloys compared to isothermal testing. Notched specimens had reduced lives under isothermal conditions, but the presence of a notch or use of a 1-h holdtime provided only a small further decrease in life for the temperature cycled tests. Compressive stress at the maximum temperature produced longer lives than tensile stress. ASTAR 811C was more fatigue resistant than T-111 isothermally and did not have as great a decrease in life with thermal cycling. Results are analyzed by partition of plastic strains into creep and creep-independent components and considering where each component was active in the hysteresis cycle.

Sheffler, K. D.↗