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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 NTRS2000

Long Life Nickel Electrodes for Nickel-Hydrogen Cells: Fiber Substrates Nickel Electrodes

Samples of nickel fiber mat electrodes were investigated over a wide range of fiber diameters, electrode thickness, porosity and active material loading levels. Thickness' were 0.040, 0.060 and 0.080 inches for the plaque: fiber diameters were primarily 2, 4, and 8 micron and porosity was 85, 90, and 95%. Capacities of 3.5 in. diameter electrodes were determined in the flooded condition with both 26 and 31% potassium hydroxide solution. These capacity tests indicated that the highest capacities per unit weight were obtained at the 90% porosity level with a 4 micron diameter fiber plaque. It appeared that the thinner electrodes had somewhat better performance, consistent with sintered electrode history. Limited testing with two-positive-electrode boiler plate cells was also carried out. Considerable difficulty with constructing the cells was encountered with short circuits the major problem. Nevertheless, four cells were tested. The cell with 95% porosity electrodes failed during conditioning cycling due to high voltage during charge. Discharge showed that this cell had lost nearly all of its capacity. The other three cells after 20 conditioning cycles showed capacities consistent with the flooded capacities of the electrodes. Positive electrodes made from fiber substrates may well show a weight advantage of standard sintered electrodes, but need considerably more work to prove this statement. A major problem to be investigated is the lower strength of the substrate compared to standard sintered electrodes. Problems with welding of leads were significant and implications that the electrodes would expand more than sintered electrodes need to be investigated. Loading levels were lower than had been expected based on sintered electrode experiences and the lower loading led to lower capacity values. However, lower loading causes less expansion and contraction during cycling so that stress on the substrate is reduced.

Rogers, Howard H.↗
NASA NTRS2003

Effects Of Environmental And Operational Stresses On RF MEMS Switch Technologies For Space Applications

Micro Electro Mechanical Systems (MEMS) have been heralded for their ability to provide tremendous advantages in electronic systems through increased electrical performance, reduced power consumption, and higher levels of device integration with a reduction of board real estate. RF MEMS switch technology offers advantages such as low insertion loss (0.1- 0.5 dB), wide bandwidth (1 GHz-100 GHz), and compatibility with many different process technologies (quartz, high resistivity Si, GaAs) which can replace the use of traditional electronic switches, such as GaAs FETS and PIN Diodes, in microwave systems for low signal power (x < 500 mW) applications. Although the electrical characteristics of RF MEMS switches far surpass any existing technologies, the unknown reliability, due to the lack of information concerning failure modes and mechanisms inherent to MEMS devices, create an obstacle to insertion of MEMS technology into high reliability applications. All MEMS devices are sensitive to moisture and contaminants, issues easily resolved by hermetic or near-hermetic packaging. Two well-known failure modes of RF MEMS switches are charging in the dielectric layer of capacitive membrane switches and contact interface stiction of metal-metal switches. Determining the integrity of MEMS devices when subjected to the shock, vibration, temperature extremes, and radiation of the space environment is necessary to facilitate integration into space systems. This paper will explore the effects of different environmental stresses, operational life cycling, temperature, mechanical shock, and vibration on the first commercially available RF MEMS switches to identify relevant failure modes and mechanisms inherent to these device and packaging schemes for space applications. This paper will also describe RF MEMS Switch technology under development at NASA GSFC.

Jah, Muzar↗
NASA NTRS2003

Behavior of HfB2-SiC Materials in Simulated Re-Entry Environments

The objectives of this research are to: 1) Investigate the oxidation/ablation behavior of HfB2/SiC materials in simulated re-entry environments; 2) Use the arc jet test results to define appropriate use environments for these materials for use in vehicle design. The parameters to be investigated include: surface temperature, stagnation pressure, duration, number of cycles, and thermal stresses.

Ellerby, Don↗
NASA NTRS2007

Hubble Space Telescope Battery Capacity Update

Orbital battery performance for the Hubble Space Telescope is discussed and battery life is predicted which supports decision to replace orbital batteries by 2009-2010 timeframe. Ground characterization testing of cells from the replacement battery build is discussed, with comparison of data from battery capacity characterization with cell studies of Cycle Life and 60% Stress Test at the Naval Weapons Surface Center (NWSC)-Crane, and cell Cycle Life testing at the Marshal Space Flight Center (MSFC). The contents of this presentation includes an update to the performance of the on-orbit batteries, as well as a discussion of the HST Service Mission 4 (SM4) batteries manufactured in 1996 and activated in 2000, and a second set of SM4 backup replacement batteries which began manufacture Jan 11, 2007, with delivery scheduled for July 2008.

Hollandsworth, Roger↗
NASA NTRS2005

Frozen-Plug Technique for Liquid-Oxygen Plumbing

A frozen-plug technique has been conceived as a means of temporarily blocking the flow of liquid oxygen or its vapor through a tube or pipe. The technique makes it possible to perform maintenance, repair, or other work on downstream parts of the cryogenic system in which the oxygen is used, without having to empty an upstream liquid-oxygen reservoir and, hence, without wasting the stored liquid oxygen and without subjecting the reservoir to the stresses of thermal cycling.

McCaskey, C. E. "Mac"↗
NASA NTRS2012

Laser Machining of Melt Infiltrated Ceramic Matrix Composite

As interest grows in considering the use of ceramic matrix composites for critical components, the effects of different machining techniques, and the resulting machined surfaces, on strength need to be understood. This work presents the characterization of a Melt Infiltrated SiC/SiC composite material system machined by different methods. While a range of machining approaches were initially considered, only diamond grinding and laser machining were investigated on a series of tensile coupons. The coupons were tested for residual tensile strength, after a stressed steam exposure cycle. The data clearly differentiated the laser machined coupons as having better capability for the samples tested. These results, along with micro-structural characterization, will be presented.

Jarmon, D. C.↗
NASA NTRS2012

Failure Analysis of T-38 Aircraft Burst Hydraulic Aileron Return Line

During maintenance troubleshooting for fluctuating hydraulic pressures, a technician found that a right hand aileron return line, on the flight hydraulic side, was ruptured (Fig. 1, 2). This tubing is part of the Hydraulic Flight Control Aileron Return Reducer to Aileron Manifold and is suspected to be original to the T-38 Talon trainer aircraft. Ailerons are small hinged sections on the outboard portion of a wing used to generate rolling motion thereby banking the aircraft. The ailerons work by changing the effective shape of the airfoil of the outer portion of the wing [1]. The drawing, Northrop P/N 3-43033-55 (6/1960), specifies that the line is made from 0.375 inch OD, aluminum 5052-0 tubing with a 0.049 inch wall thickness. WW-T-787 requires the tube shall be seamless and uniform in quality and temper [2]. The test pressure for this line is 3000 psi, and the operational pressure for this line is estimated to be between 45 psi and 1500 psi based on dynamic loading during flight. Examination of the fracture surface found evidence of arrest bands originating on the inner diameter (Fig 3). Ductile dimples are observed on the tube fractures (Fig. 4). The etched cross-section revealed thinning and work-hardening in the burst region (Fig. 5). The wall thickness just outside the work-hardened fracture region measured 0.035". Barlow's Formula: P = 2St/D, where P is burst pressure, S is allowable stress, t is wall thickness and D is the outer diameter of tube. Using the ultimate tensile strength of 28 ksi and a measured wall thickness of 0.035 inches at burst, P = 5.2 ksi (burst pressure). Using the yield of 13 ksi (YS) for aluminum 5052-0, plastic deformation will happen at P = 2.4 ksi suggesting plastic deformation occurred at a proof pressure of 3.0 ksi. Conclusion: The burst resulted from high stress, low-cycle fatigue. Evidence of arrest bands originating on the inner diameter. Fracture is predominately shear dimples, characteristic of high load ductile fractures (Fig 6). Section wall reduction in the burst region. Plastic deformation and thinning of the out-of-specification tube wall likely happened during the initial proof testing years ago. Metallography of tubing away from rupture site confirmed tubing was seamless. Based on the tube microstructure, it is likely that the initial wall thickness was about 30 % thinner than the requirement of 0.049 inches. Fracture initiated on the ID and progressed to the OD (shear lip). The tube is made of the correct material of 5052-0 aluminum as verified using Optical Emission Spectroscopy (Table 2). The tubing hardness tested 77 HV100 (77 HRE). This hardness is slightly above the requirement for 70 HRE maximum for aluminum 5052-0 in AMS 2658C [3].

Martinez, J. E.↗
NASA NTRS2014

Low-Cost Radiator for Fission Power Thermal Control

NASA Glenn Research Center (GRC) is developing fission power system technology for future Lunar surface power applications. The systems are envisioned in the 10 to 100kW(sub e) range and have an anticipated design life of 8 to 15 years with no maintenance. NASA GRC is currently setting up a 55 kW(sub e) non-nuclear system ground test in thermal-vacuum to validate technologies required to transfer reactor heat, convert the heat into electricity, reject waste heat, process the electrical output, and demonstrate overall system performance. Reducing the radiator mass, size, and cost is essential to the success of the program. To meet these goals, Advanced Cooling Technologies, Inc. (ACT) and Vanguard Space Technologies, Inc. (VST) are developing a single facesheet radiator with heat pipes directly bonded to the facesheet. The facesheet material is a graphite fiber reinforced composite (GFRC) and the heat pipes are titanium/water. By directly bonding a single facesheet to the heat pipes, several heavy and expensive components can be eliminated from the traditional radiator design such as, POC(TradeMark) foam saddles, aluminum honeycomb, and a second facesheet. A two-heat pipe radiator prototype, based on the single facesheet direct-bond concept, was fabricated and tested to verify the ability of the direct-bond joint to withstand coefficient of thermal expansion (CTE) induced stresses during thermal cycling. The thermal gradients along the bonds were measured before and after thermal cycle tests to determine if the performance degraded. Overall, the results indicated that the initial uniformity of the adhesive was poor along one of the heat pipes. However, both direct bond joints showed no measureable amount of degradation after being thermally cycled at both moderate and aggressive conditions.

Bonding↗
NASA NTRS2016

Effects of Hindlimb Unloading and Ionizing Radiation on Murine Gene Expression in Skin and Bone

Long duration spaceflight causes a negative calcium balance and reduces bone density in astronauts. The underlying mechanisms of spaceflight-induced bone loss and the possible influences of both microgravity and radiation are not fully understood although emerging evidence suggests that these two factors may interact to result in increased bone loss. Previously, gene expression analysis of hair follicles from astronauts, as well as skin from space-flown mice, revealed changes in the expression of genes related to DNA damage and oxidative stress responses. These results resemble the responses of bone to spaceflight-like radiation and simulated weightlessness by hindlimb unloading (HU). Hence in this study, we initiated studies to determine whether skin can be used to predict the responses of bone to simulated microgravity and radiation. We examined oxidative stress and growth arrest pathways in mouse skin and long bones by measuring gene expression levels via quantitative polymerase chain reaction (qPCR). To investigate the effects of irradiation andor HU on gene expression, we used skin and femora (cortical shaft) from the following treatment groups: control (normally loaded, sham-irradiated) (CT), hindlimb unloading (HU), 56Fe radiation (IR) and both HU+IR. Animals were euthanized 11 days post-IR, and results were analyzed by 1-way ANOVA. In skin samples, Cdkn1a was decreased to the same extent in HU and HU+IR (47 of CT). In addition, HU reduced FoxO3 expression (46 of CT) and IR increased Gadd45g expression 135 compared CT in skin. But in bone, HU increased FoxO3 expression 31 compared the level of CT. These results suggest that radiation and simulated weightlessness regulated simliar oxidative stress and cell cycle arrest genes in both skin and bone, although the time course and direction of changes may differ. This research may lead to the development of a relatively simple diagnostic tool for bone loss with the advantage that hair follicles and skin are relatively easy to acquire from subjects.

Terada, Masahiro↗
NASA NTRS1979

Low-cost directionally-solidified turbine blades, volume 2

An endothermically heated technology was used to manufacture low cost, directionally solidified, uncooled nickel-alloy blades for the TFE731-3 turbofan engine. The MAR-M 247 and MER-M 100+Hf blades were finish processed through heat treatment, machining, and coating operations prior to 150 hour engine tests consisting of the following sequences: (1) 50 hours of simulated cruise cycling (high fatigue evaluation); (2) 50 hours at the maximum continuous power rating (stress rupture endurance (low cycle fatigue). None of the blades visually showed any detrimental effects from the test. This was verified by post test metallurgical evaluation. The specific fuel consumption was reduced by 2.4% with the uncooled blades.

Dennis, R. E.↗
NASA NTRS1985

Joint design for improved fatigue life of diffusion-bonded box-stiffened panels

Simple photoelastic models were used to identify a cross-section geometry that would eliminate the severe stress concentrations at the bond line between box stiffeners diffusion bonded to a panel skin. Experimental fatigue-test data from titanium test specimens quantified the allowable stress in terms of cycle life for various joint geometries. It is shown that the effect of stress concentration is reduced and an acceptable fatigue life is achieved.

Davis, R. C.↗
NASA NTRS1994

Prediction of fatique crack growth under flight-simulation loading with the modified CORPUS model

The CORPUS (Computation Of Retarded Propagation Under Spectrum loading) crack growth prediction model for variable-amplitude loading, as introduced by De Koning, was based on crack closure. It includes a multiple-overload effect and a transition from plane strain to plane stress. In the modified CORPUS model an underload affected zone (ULZ) is introduced, which is significant for flight-simulation loading in view of the once per flight compressive ground load. The ULZ is associated with reversed plastic deformation induced by the underloads after crack closure has already occurred. Predictions of the crack growth fatigue life are presented for a large variety of flight-simulation test series on 2024-T3 sheet specimens in order to reveal the effects of a number of variables: the design stress level, the gust spectrum severity, the truncation level (clipping), omission of small cycles, and the ground stress level. Tests with different load sequences are also included. The trends of the effects induced by the variables are correctly predicted. The quantitative agreement between the predictions and the test results is also satisfactory.

Padmadinata, U. H.↗
NASA NTRS1976

Environmental Effects on Graphite-Epoxy Fatigue Properties

Effects of torsional and flexural fatigue on the long-time Integrity of advanced graphite-epoxy structural composites have been investigated. Torsional fatigue tests were run at stress ratios of R = 0 (zero to maximum, repeated) and R = -1 (zero mean stress) on unidirectional, angleply, and woven graphite fiber materials in air and water at room temperature and at 74 C. Flexural fatigue tests (four-point bending) with R = -1 were run in air and water at room temperature, and with R = 0 in air. Results show that, in torsional cycling, both water environment and higher test temperature contribute to significant degradation of torsional stiffness. The degradation of stiffness from torsional stress cycling was observed to be much greater with R = -1 than with simple R = 0 cycling. The effect of environment also is greater in the fully reversed cycling. Flexural fatigue results on +/- 30 deg material show a large fatigue effect, with fatigue limits of less than 50% and 30% of the static failure strength for specimens tested under stress ratios of R = 0 and R = -1, respectively. Compliance measurements indicate that the final failures are preceded by damage initiation and accumulation, which begins at about 1% of the specimen life.

Sumsion, H. T.↗
NASA NTRS2017

Residual Stresses in a NiCrY-Coated Powder Metallurgy Disk Superalloy

Protective ductile coatings will be necessary to mitigate oxidation and corrosion attack on superalloy disks exposed to increasing operating temperatures in some turbine engine environments. However, such coatings must be resistant to harmful surface cracking during service. The objective of this study was to investigate how residual stresses evolve in such coatings. Cylindrical gage fatigue specimens of powder metallurgy-processed disk superalloy LSHR were coated with a NiCrY coating, shot peened, and then subjected to fatigue in air at room and high temperatures. The effects of shot peening and fatigue cycling on average residual stresses and other aspects of the coating were assessed. Shot peening did induce beneficial compressive residual stresses in the coating and substrate. However, these stresses became more tensile in the coating with subsequent heating and contributed to cracking of the coating in long intervals of cycling at 760 C. Substantial compressive residual stresses remained in the substrate adjacent to the coating, sufficient to suppress fatigue cracking. The coating continued to protect the substrate from hot corrosion pitting, even after fatigue cracks initiated in the coating.

superalloy↗
NASA NTRS2011

Simulating Thermal Cycling and Isothermal Deformation Response of Polycrystalline NiTi

A microstructure-based FEM model that couples crystal plasticity, crystallographic descriptions of the B2-B19' martensitic phase transformation, and anisotropic elasticity is used to simulate thermal cycling and isothermal deformation in polycrystalline NiTi (49.9at% Ni). The model inputs include anisotropic elastic properties, polycrystalline texture, DSC data, and a subset of isothermal deformation and load-biased thermal cycling data. A key experimental trend is captured.namely, the transformation strain during thermal cycling is predicted to reach a peak with increasing bias stress, due to the onset of plasticity at larger bias stress. Plasticity induces internal stress that affects both thermal cycling and isothermal deformation responses. Affected thermal cycling features include hysteretic width, two-way shape memory effect, and evolution of texture with increasing bias stress. Affected isothermal deformation features include increased hardening during loading and retained martensite after unloading. These trends are not captured by microstructural models that lack plasticity, nor are they all captured in a robust manner by phenomenological approaches. Despite this advance in microstructural modeling, quantitative differences exist, such as underprediction of open loop strain during thermal cycling.

Manchiraju, Sivom↗
NASA NTRS1990

High temperature inelastic deformation of the B1900 + Hf alloy under multiaxial loading - Theory and experiment

The multiaxial deformation behavior of the Ni-based alloy B1900 + Hf has been studied at elevated temperatures in the range of 649-982 C. Combined tension/torsion cyclic tests were performed on thin-wall tubular specimens under both in-phase and out-of-phase strain-controlled loading cycles. Both straining conditions resulted in stress loci of comparable magnitude, exhibiting no difference in cyclic hardening response. A phase angle was observed between the deviatoric stress and the incremental plastic strain vectors during 90-deg out-of-phase strain cycling, and nonproportional stress relaxation occurred under biaxial strain hold. The overall results have been used to assess the flow law, the hardening equations, and the applicability of the J2-based, elastic-viscoplastic model of Bodner-Partom (1979) for multiaxial loading conditions. The overall agreement between theory and experiment is good. Discrepancies are discussed in relation to micromechanical considerations.

Chan, K. S.↗
NASA NTRS1998

Room Temperature Tensile Behavior and Damage Accumulation of Hi-Nicalon Reinforced SiC Matrix Composites

Composites consisting of woven Hi-Nicalon fibers, BN interphases, and different SiC matrices were studied in tension at room temperature. Composites with SiC matrices processed by CVI and melt infiltration were compared. Monotonic and load/unload/reload tensile hysteresis experiments were performed. A modal acoustic emission (AE) analyzer was used to monitor damage accumulation during the tensile test. Post test polishing of the tensile gage sections was performed to determine the extent of cracking. The occurrence and location of cracking could easily be determined using modal AE. The loss of modulus could also effectively be determined from the change in the velocity of sound across the sample. Finally, the stresses where cracks appear to intersect the load-bearing fibers correspond with high temperature low cycle fatigue run out stresses for these materials.

Morscher, G. N.↗