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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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NASA NTRS2004

High-Performance SiC/SiC Ceramic Composite Systems Developed for 1315 C (2400 F) Engine Components

As structural materials for hot-section components in advanced aerospace and land-based gas turbine engines, silicon carbide (SiC) ceramic matrix composites reinforced by high performance SiC fibers offer a variety of performance advantages over current bill-of-materials, such as nickel-based superalloys. These advantages are based on the SiC/SiC composites displaying higher temperature capability for a given structural load, lower density (approximately 30- to 50-percent metal density), and lower thermal expansion. These properties should, in turn, result in many important engine benefits, such as reduced component cooling air requirements, simpler component design, reduced support structure weight, improved fuel efficiency, reduced emissions, higher blade frequencies, reduced blade clearances, and higher thrust. Under the NASA Ultra-Efficient Engine Technology (UEET) Project, much progress has been made at the NASA Glenn Research Center in identifying and optimizing two highperformance SiC/SiC composite systems. The table compares typical properties of oxide/oxide panels and SiC/SiC panels formed by the random stacking of balanced 0 degrees/90 degrees fabric pieces reinforced by the indicated fiber types. The Glenn SiC/SiC systems A and B (shaded area of the table) were reinforced by the Sylramic-iBN SiC fiber, which was produced at Glenn by thermal treatment of the commercial Sylramic SiC fiber (Dow Corning, Midland, MI; ref. 2). The treatment process (1) removes boron from the Sylramic fiber, thereby improving fiber creep, rupture, and oxidation resistance and (2) allows the boron to react with nitrogen to form a thin in situ grown BN coating on the fiber surface, thereby providing an oxidation-resistant buffer layer between contacting fibers in the fabric and the final composite. The fabric stacks for all SiC/SiC panels were provided to GE Power Systems Composites for chemical vapor infiltration of Glenn designed BN fiber coatings and conventional SiC matrices. Composite panels with system B were heat treated at Glenn, and the pores that remained open were filled by silicon melt infiltration (MI). Panels with system A and the other SiC/SiC systems were not heat treated, and remaining open pores in these systems were filled with SiC slurry and silicon MI.

DiCarlo, James A.↗

NASA NTRS1989

Issues in CSI analysis for large scale systems

Future spacecraft such as the International Space Station result in flexible models with hundreds, or perhaps thousands of modes in a frequency range where the potential for control/structure interaction exists. This provides the analyst with a formidable model reduction problem at both the component and the system level. Approaches to normal modes as a structural representation, applicability of alternate structural representations and algorithms for selecting important modal degrees of freedom at both the component and the system level are discussed. Practical implementation of these techniques on a large scale model of the Space Station are presented.

Blelloch, Paul↗

NASA NTRS1990

Design of a scientific probe for obtaining Mars surface material

The objective is to return a 1 Kg Martian soil sample from the surface of Mars to a mothership in a 60 km Mars orbit. Given here is information on the mission profile, the structural design and component placement, thermal control and guidance, propulsion systems, orbital mechanics, and specialized structures.

Baker, Miles↗

NASA NTRS1983

Process Yields Strong, Void-Free Laminates

Need for lightweight materials as structural components for future space transportation systems stimulated development of systematic method for manufacturing a polyimide/graphite composite. Laminates manufactured by process are void-free, exhibit excellent thermo-oxidative stability up to 315 degrees C (600 degrees F) and are 40 percent lighter than aluminum. Process is precise, repeatable, and ideally suited for researchers and small-lot producers of composite materials.

Bryant, L. E.↗

NASA NTRS1986

Measurement of Centaur/Orbiter multiple reaction forces in a full-scale test rig

A multiple component load cell for measuring load is described, and its capability and reliability are evaluated by utilizing it to measure the reaction forces between the Centaur and Centaur Support Structure. The system employs 11 six-component balances in a single test rig to react a combination of loads. The vehicle and balance loads, procedures for fabricating each balance, and the assembly of the balances are discussed. The calibration and testing of the balances are examined. It is noted that the multiple component load cell system is a cost-effective method for obtaining an accurate measurement of friction effects and primary loads.

Mole, Philip J.↗

NASA NTRS1987

Performance comparisons of maneuvering vehicles returning from orbit

In the present study of maneuvering reentry vehicles employing skipping and gliding flight paths, attention is given to aerodynamic heating pulses during longitudinal flight and lateral maneuvers. While skipping vehicles can achieve longer ranges than gliding ones, the deceleration loads can be an order of magnitude higher and involve heating rates 4-5 times higher, even for shallow entries, therefore requiring much heavier structural components and heavier thermal protection systems than gliders. A total lateral range of 8000 km is noted to be achievable by a gliding aerodynamic maneuver involving a 90-deg turn initiated at entry.

Tauber, Michael E.↗

NASA NTRS1988

Validation of the NESSUS probabilistic finite element analysis computer program

A computer program, NESSUS, is being developed as part of a NASA-sponsored project to develop probabilistic structural analysis methods for propulsion system components. This paper describes the process of validating the NESSUS code, as it has been developed to date, and presents numerical results comparing NESSUS and exact solutions for a set of selected problems.

Wu, Y.-T.↗

NASA NTRS1992

A probabilistic approach to the evaluation of fatigue damage in a space propulsion system injector element

The fatigue damage of a space propulsion system component is computed using probabilistic structural analysis methods. The analysis takes into account the variations in static and dynamic loads, the uncertainty in structural damping, and the scatter in material fatigue resistance. The key elements of the probabilistic approach include: (1) a numerical engine model for describing the global component interface loads consistent with engine balance, (2) models for computing the local mode boundary conditions on the component, (3) a static structural analysis model that captures the strains at a damage critical location as a function of engine performance variables, (4) a finite element model for assessment of the random amplitude stress response due to random base and pressure excitations with uncertain power and correlation length, and (5) advanced first order reliability methods for computing the probabilities associated with the fatigue damage.

Rajagopal, K. R.↗

NASA NTRS1992

Assigning Damping Parameters To Component Dynamical Modes

Damping parameters found by solving nonlinear optimization problem. Paper discusses assignment of matrices of damping parameters to mathematical models of vibrations and rotations of interconnected flexible components of large, flexible structure. Such models truncated at component level to reduce amount of computation necessary to simulate dynamics of structure numerically at both component and system levels.

Lee, Allan Y.↗

NASA NTRS1991

New approximation of frequency response for structural synthesis and parameter identification

This paper presents two approaches that will improve the accuracy of explicit approximations of frequency responses. They are important components of structural design optimization and system identification. The first is a product form approximation that improves approximated frequency responses near resonant conditions. This approach is applicable to both design optimization and system identification problems. The second is aimed at improving the computed sensitivity coefficients that are used to solve system identification problems.

Miura, Hirokazu↗

NASA NTRS1994

Weight minimization of structural components for launch in space shuttle

Minimizing the weight of structural components of the space station launched into orbit in a space shuttle can save cost, reduce the number of space shuttle missions, and facilitate on-orbit fabrication. Traditional manual design of such components, although feasible, cannot represent a minimum weight condition. At NASA Lewis Research Center, a design capability called CometBoards (Comparative Evaluation Test Bed of Optimization and Analysis Routines for the Design of Structures) has been developed especially for the design optimization of such flight components. Two components of the space station - a spacer structure and a support system - illustrate the capability of CometBoards. These components are designed for loads and behavior constraints that arise from a variety of flight accelerations and maneuvers. The optimization process using CometBoards reduced the weights of the components by one third from those obtained with traditional manual design. This paper presents a brief overview of the design code CometBoards and a description of the space station components, their design environments, behavior limitations, and attributes of their optimum designs.

Patnaik, Surya N.↗

NASA NTRS2009

Improved Fabrication of Ceramic Matrix Composite/Foam Core Integrated Structures

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heatflux environments (150 W/cm2) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same pick location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cm3 in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Hurwitz, Frances I.↗

NASA NTRS2009

Inert Welding/Brazing Gas Filters and Dryers

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heat-flux environments (150 W/sq cm) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading-edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same "pick" location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cu cm in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Goudy, Jerry↗

NASA NTRS2012

Disturbance Accommodating Adaptive Control with Application to Wind Turbines

Adaptive control techniques are well suited to applications that have unknown modeling parameters and poorly known operating conditions. Many physical systems experience external disturbances that are persistent or continually recurring. Flexible structures and systems with compliance between components often form a class of systems that fail to meet standard requirements for adaptive control. For these classes of systems, a residual mode filter can restore the ability of the adaptive controller to perform in a stable manner. New theory will be presented that enables adaptive control with accommodation of persistent disturbances using residual mode filters. After a short introduction to some of the control challenges of large utility-scale wind turbines, this theory will be applied to a high-fidelity simulation of a wind turbine.

Frost, Susan↗

NASA NTRS2001

Probabilistic Structural Analysis and Reliability Using NESSUS With Implemented Material Strength Degradation Model

This project included both research and education objectives. The goal of this project was to advance innovative research and education objectives in theoretical and computational probabilistic structural analysis, reliability, and life prediction for improved reliability and safety of structural components of aerospace and aircraft propulsion systems. Research and education partners included Glenn Research Center (GRC) and Southwest Research Institute (SwRI) along with the University of Texas at San Antonio (UTSA). SwRI enhanced the NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) code and provided consulting support for NESSUS-related activities at UTSA. NASA funding supported three undergraduate students, two graduate students, a summer course instructor and the Principal Investigator. Matching funds from UTSA provided for the purchase of additional equipment for the enhancement of the Advanced Interactive Computational SGI Lab established during the first year of this Partnership Award to conduct the probabilistic finite element summer courses. The research portion of this report presents the cumulation of work performed through the use of the probabilistic finite element program, NESSUS, Numerical Evaluation and Structures Under Stress, and an embedded Material Strength Degradation (MSD) model. Probabilistic structural analysis provided for quantification of uncertainties associated with the design, thus enabling increased system performance and reliability. The structure examined was a Space Shuttle Main Engine (SSME) fuel turbopump blade. The blade material analyzed was Inconel 718, since the MSD model was previously calibrated for this material. Reliability analysis encompassing the effects of high temperature and high cycle fatigue, yielded a reliability value of 0.99978 using a fully correlated random field for the blade thickness. The reliability did not change significantly for a change in distribution type except for a change in distribution from Gaussian to Weibull for the centrifugal load. The sensitivity factors determined to be most dominant were the centrifugal loading and the initial strength of the material. These two sensitivity factors were influenced most by a change in distribution type from Gaussian to Weibull. The education portion of this report describes short-term and long-term educational objectives. Such objectives serve to integrate research and education components of this project resulting in opportunities for ethnic minority students, principally Hispanic. The primary vehicle to facilitate such integration was the teaching of two probabilistic finite element method courses to undergraduate engineering students in the summers of 1998 and 1999.

Bast, Callie C.↗

NASA NTRS1999

Cryotank Skin/Stringer Bondline Analysis

The need for light weight structure for advanced launch systems have presented great challenges and led to the usage of composites materials in a variety of structural assemblies where joining of two or more components is imperative. Although joints can be mechanically bolted, adhesive bonding has always been a very desirable method for joining the composite components, particularly for the cryotank systems, to achieve maximum structural efficiency. This paper presents the analytical approach resulted from the conceptual development of the DC-Y composite cryotank, conducted under the NASA/Boeing NRA 8-12 Partnership, to support the continued progress of SSTO (Single-Stage-To-Orbit) concepts. One of the critical areas of design was identified as the bonded interface between the skin (tank wall) and stringer. The approach to analyze this critical area will be illustrated through the steps which were used to evaluate the structural integrity of the bondline. Detailed finite element models were developed and numerous coupon test data were also gathered as part of the approach. Future plan is to incorporate this approach as a building block in analyzing bondline for the cryotank systems of RLVs (Reusable Launch Vehicles).

Nguyen, Bao↗

NASA NTRS1990

Non-Destructive Testing Scanner

Bio-Imaging Research's technology that originated in an aerospace program has come full circle with a new aerospace adaptation called the Advanced Computed Tomography Inspection System, or ACTIS. The medical version of CT scans the human body for tumors or other abnormalities, the ACTIS system finds imperfections in aerospace structures and components, such as castings, assemblies, rocket motors and nozzles. ACTIS is described by its developer as the most versatile CT scanner available for non-destructive testing applications. ACTIS is a variable geometry system. ACTIS source and detectors can be moved closer together or farther apart to optimize the geometry for different sizes of test objects. The combination of variable geometry, three sources, and focusing detectors makes ACTIS cost effective for a broad range of applications. System can scan anything from very small turbine blades to large rocket assemblies.

Source record↗

NASA NTRS1991

Damping characterization in large structures

This research project has as its main goal the development of methods for selecting the damping characteristics of components of a large structure or multibody system, in such a way as to produce some desired system damping characteristics. The main need for such an analytical device is in the simulation of the dynamics of multibody systems consisting, at least partially, of flexible components. The reason for this need is that all existing simulation codes for multibody systems require component-by-component characterization of complex systems, whereas requirements (including damping) often appear at the overall system level. The main goal was met in large part by the development of a method that will in fact synthesize component damping matrices from a given system damping matrix. The restrictions to the method are that the desired system damping matrix must be diagonal (which is almost always the case) and that interbody connections must be by simple hinges. In addition to the technical outcome, this project contributed positively to the educational and research infrastructure of Tuskegee University - a Historically Black Institution.

Eke, Fidelis O.↗