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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Cost-Benefit Analysis for Alternatives to Aliphatic Isocyanate Polyurethanes

NASA and Air Force Space Command (AFSPC) have similar missions and therefore similar facilities and structures in similar environments. The standard practice for protecting metallic substrates in atmospheric environments is the application of an applied coating system. The most common topcoats used in coating systems are polyurethanes that contain isocyanates. Isocyanates are classified as potential human carcinogens and are known to cause cancer in animals. The primary objective of this effort was to demonstrate and validate alternatives to aliphatic isocyanate polyurethanes resulting in one or more isocyanate-free coatings qualified for use at AFSPC and NASA installations participating in this project. This Cost-Benefit Analysis (CBA) quantifies the estimated capital and process costs of coating alternatives and cost savings relative to the current coatings. The estimates in this CBA are to be used for assessing the relative merits of the selected alternatives. The actual economic effects at any specific facility will depend on the alternative material or technology implemented, the number of actual applications converted, future workloads, and other factors . The participants initially considered eighteen (18) alternative coatings as described in the Potential Alternatives Report entitled Potential Alternatives Report for Validation of Alternatives to Aliphatic Isocyanate Polyurethanes, prepared by ITB. Of those, 8 alternatives were selected for testing in accordance with the Joint Test Protocol entitled Joint Test Protocol for Validation of Alternatives to Aliphatic Isocyanate Polyurethanes, and the Field Test Plan entitled Field Evaluations Test Plan for Validation of Alternatives 10 Aliphatic Isocyanate Polyurethanes, both of which were prepared by ITB. A joint Test Report entitled Joint Test Report for Validation of Alternatives to Aliphatic Isocyanate Polyurethanes, prepared by ITB, documents the results of the laboratory and field testing, as well as any test modifications made during the execution of the testing. The coatings selected for evaluation in this CBA are shown in the table below. Only one control coating system is considered in this analysis. These coatings were either downselected for Phase II or performed well enough to be included in the Qualified Products List in the NASA technical standard NASA-STD-5008, Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment.

Lewis, Pattie↗
DOE OSTI2020

In Situ and Post-Mortem Characterizations of Ultrasonic Spot Welded AZ31B and Coated Dual Phase 590 Steel Joints

Ultrasonic spot welding using different welding conditions was applied to join dissimilar metals of galvanized DP590 steel and AZ31B magnesium sheets. In situ high-speed imaging, digital image correlation, and infrared thermography were utilized to quantitatively study the interfacial relative motion, surface indentation, and heat generation across the joint faying interface and the sheet/sonotrode interfaces under the welding condition of moderate welding power and short welding time. For welds made with high power and long welding time, lap shear tensile tests as well as fatigue tests were carried out. Different fracture modes were observed after the lap shear tensile tests and fatigue tests performed under different peak loads. Post-weld cross-sectional analysis with scanning electron microscopy coupled with energy dispersive X-Ray spectroscopy revealed the variation of morphology and chemical composition at the joint interface for welds made with different welding conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Acid Dissolution Behavior of Ferritic FeCrAl Tubes Candidates for Nuclear Fuel Cladding

The international materials community is engaged in finding safer alternatives to zirconium alloys for the cladding of fuel in light water reactors. One solution is to replace the zirconium cladding using ferritic iron-chromium-aluminum (FeCrAl) alloys, which offer extraordinary resistance to high-temperature reaction with air or steam due to the formation of a protective alumina layer on the external surface. It is important to characterize the behavior of FeCrAl not only during accident conditions but in the entire fuel cycle, which may include reprocessing of the used fuel after it is removed from the power reactors. The reprocessing may involve the dissolution of the fuel rods in mineral acids. Little or nothing is known on the dissolution of FeCrAl alloys in common mineral acids, therefore the objective of this research was to study the dissolution of typical cladding tubing having two compositions of FeCrAl (APMT and C26M) in three acids (H 2 SO 4 , HNO 3 , and HCl) as a function of the temperature using both standard ASTM immersion tests as well as electrochemical tests. The dissolution behavior of the FeCrAl alloys is compared to the dissolution capability of other traditional nuclear materials such as austenitic stainless steels (304SS and 316SS) and austenitic nickel alloys (Alloy 600 and Hastelloy C-276). Results show that both C26M and APMT have a higher dissolution capability in the studied mineral acids, which will be beneficial for reprocessing procedures.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Apollo experience report environmental acceptance testing

Environmental acceptance testing was used extensively to screen selected spacecraft hardware for workmanship defects and manufacturing flaws. The minimum acceptance levels and durations and methods for their establishment are described. Component selection and test monitoring, as well as test implementation requirements, are included. Apollo spacecraft environmental acceptance test results are summarized, and recommendations for future programs are presented.

Laubach, C. H. M.↗
NASA NTRS1995

Static stability of the Space Station solar array FASTMast structure

The combined loads test of the 3-Bay FASTMast marks the end of the Lewis Research Center (LeRC) effort to characterize the behavior of the principal Space Station solar array support structure. The primary objective of this test and analysis effort was to develop a method to predict structural stability failure modes under flight-like applied loads. Included at the beginning of this report is a brief historical perspective of the hardware design development and FASTMast structural stability problem evolution. Once an understanding of the solution process has been established, test and analysis details are presented and related to the postulated failure theories. The combined load test series subjected the structure to a combination of transverse, moment, and torsion loads similar to that expected in the service environment. Nonlinear finite element (FE) models were developed and large displacement analyses were performed to support the test effort and failure mode predictions. Details of the test configuration as well as test and analysis results are presented. The results were then critiqued to establish valid and successful support of the failure mode assessments. Finally, study conclusions are drawn and recommendations for safe operation of the FASTMast structure are presented for consideration.

Shaker, John F.↗
NASA NTRS1996

Scuffing Characteristics of High-Load Rolling/Sliding Contacts Operating in Liquid Oxygen: Effects of Materials and Surface Roughness

This research reports on an experimental study of the effects of materials and surface roughness on the scuffing characteristics of rolling/sliding contacts cooled and lubricated with liquid oxygen. Experiments were carried out under heavy loading with a Hertzian pressure in the range of 2.0 GPa to 3.0 GPa and with a high rolling velocity of up to 48 m/s. For contacts between AISI 440 C stainless-steel elements, the results showed that the scuffing behavior of the system was fairly consistent under a wide range of rolling velocity. Scuffing commenced at a small slide-to-roll ratio of around 0.02, and the scuffing behavior of the contact was not sensitive to surface roughness for the test-sample RMS roughness ranging from 0.02 microns to 0.10 microns. For contacts between 440 C and Si3N4 elements, on the other hand, the scuffing behavior of the system was not very consistent and somewhat unpredictable. The results were sensitive to surface roughness particularly that of the Si3N4 test sample. With well polished test samples, consistent results were obtained; the level of traction was lower than that with a 440 C toroid and scuffing did not take place up to a slide-to-roll ratio of near 0.03. The results strongly suggest that significant hydrodynamic effect can be generated by liquid oxygen under heavy loading and high velocity conditions. The results also suggest that the hydrodynamic action is likely generated by the conventional viscous mechanism as it can be largely destroyed by a narrow circumferential surface scratch running through the central region of the contact.

Chang, L.↗
NASA NTRS2004

NEXIS Reservoir Cathode 2000 Hour Life Test

The current design of the Nuclear Electric Xenon Ion System (NEXIS) employs a reservoir cathode as both the discharge and neutralizer cathode to meet the 10 yr thruster design life. The main difference between a reservoir cathode and a conventional discharge cathode is the source material (barium-containing compound) is contained within a reservoir instead of in an impregnated insert in the hollow tube. However, reservoir cathodes do not have much life test history associated with them. In order to demonstrate the feasibility of using a reservoir cathode as an integral part of the NEXIS ion thruster, a 2000 hr life test was performed. Several proof-of-concept (POC) reservoir cathodes were built early in the NEXIS program to conduct performance testing as well as life tests. One of the POC cathodes was sent to Marshall Space Flight Center (MSFC) where it was tested for 2000 hrs in a vacuum chamber. The cathode was operated at the NEXIS design point of 25 A discharge current and a xenon flow rate of 5.5 sccm during the 2000 hr test. The cathode performance parameters, including discharge current, discharge voltage, keeper current; keeper voltage, and flow rate were monitored throughout test. Also, the temperature upstream of cathode heater, the temperature downstream of the cathode heater, and the temperature of the orifice plate were monitored throughout the life of the test. The results of the 2000 hr test will be described in this paper. Included in the results will be time history of discharge current, discharge voltage, and flow rate. Also, a time history of the cathode temperature will be provided.

Vaughn, Jason↗
NASA NTRS2009

Solder Joint Health Monitoring Testbed System

The density and pin count for Field Programmable Gate Arrays (FPGAs) has been increasing, and has exceeded current methods of solder joint inspection, making early detection of failures more problematic. These failures are a concern for both flight safety and maintenance in commercial aviation. Ridgetop Group, Inc. has developed a method for detecting solder joint failures in real time. The NASA Dryden Flight Research Center is developing a set of boards to test this method in ground environmental and accelerated testing as well as flight test on a Dryden F-15 or F-18 research aircraft. In addition to detecting intermittent and total solder joint failures, environmental data on the boards, such as temperature and vibration, will be collected and time-correlated to aircraft state data. This paper details the technical approach involved in the detection process, and describes the design process and products to date for Dryden s FPGA failure detection boards.

Delaney, Michael M.↗
NASA NTRS2007

Joint Test Report for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel

Headquarters National Aeronautics and Space Administration (NASA) chartered the NASA Acquisition Pollution Prevention (AP2) Office to coordinate agency activities affecting pollution prevention issues identified during system and component acquisition and sustainment processes. The primary objectives of the AP2 Office are to: (1) Reduce or eliminate the use of hazardous materials or hazardous processes at manufacturing, remanufacturing, and sustainment locations. (2) Avoid duplication of effort in actions required to reduce or eliminate hazardous materials through joint center cooperation and technology sharing. The objective of this project was to qualify candidate alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel applications at NASA facilities. This project compares the surface preparation/depainting performance of the proposed alternatives to existing surface preparation/depainting systems or standards. This Joint Test Report (JTR) contains the results of testing as per the outlines of the Joint Test Protocol (JTP), Joint Test Protocol for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel, and the Field Test Plan (FTP), Field Evaluations Test Plan for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel, for critical requirements and tests necessary to qualify alternatives for coating removal systems. These tests were derived from engineering, performance, and operational impact (supportability) requirements defined by a consensus of government and industry participants. This JTR documents the results of the testing as well as any test modifications made during the execution of the project. This JTR is made available as a reference for future pollution prevention endeavors by other NASA Centers, the Department of Defense and commercial users to minimize duplication of effort. The current coating removal processes identified herein are for polyurethane, epoxy and other paint systems applied by conventional wet-spray processes. A table summarizes the target hazardous materials, processes and materials, applications, affected programs, and candidate substrates.

Lewis, Pattie↗
NASA NTRS2011

Planning Image-Based Measurements in Wind Tunnels by Virtual Imaging

Virtual imaging is routinely used at NASA Ames Research Center to plan the placement of cameras and light sources for image-based measurements in production wind tunnel tests. Virtual imaging allows users to quickly and comprehensively model a given test situation, well before the test occurs, in order to verify that all optical testing requirements will be met. It allows optimization of the placement of cameras and light sources and leads to faster set-up times, thereby decreasing tunnel occupancy costs. This paper describes how virtual imaging was used to plan optical measurements for three tests in production wind tunnels at NASA Ames.

Kushner, Laura Kathryn↗
NASA NTRS2011

Demonstration/Validation of Environmentally-Preferable Coatings for Launch Facilities

Kennedy Space Center (KSC) is responsible for a number of facilities/structures with metallic structural and non-structural components in a highly corrosive environment. Metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the application of an applied coating system. Applied coating systems work via a variety of methods (barrier, galvanic and/or inhibitor) and adhere to the substrate through a combination of chemical and physical bonds. Maintenance at KSC and other NASA Centers is governed by NASA-STD-50088 (Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment) which establishes practices for the protective coating of ground support equipment and related facilities used by or for NASA programs and projects. The Standard is for the design of non-flight hardware used to support the operations of receiving, transportation, handling, assembly, inspection, test, checkout, service, and launch of space vehicles and payloads at NASA launch, landing, or retrieval sites. These criteria and practices contained within the Standard may be used for items used at the manufacturing, development, and test sites upstream of the launch, landing, or retrieval sites. The objective of this effort is to demonstrate and validate environmentally-preferable alternatives in accordance with NASA-STD-50088 and KSC requirements which can then be added to the Approved Products List. This Test Protocol contains the critical requirements and tests necessary to qualify alternatives for structural steel applications. These tests were derived from engineering, performance, and operational impact (supportability) requirements defined by a consensus of KSC participants. A Test Report will document the results of the testing as well as any test modifications made during the execution of the testing. Users of this Test Protocol should check the project's Test Report for additional test details or minor modifications that may have been necessary in the execution of the testing. The technical stakeholders will have agreed upon test procedures modifications documented in the Test Report.

Lewis, Pattie↗
NASA NTRS2019

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this research are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior.

Hipot testing↗
NASA NTRSDate not supplied

Propulsion Component Test Capabilities at MSFC’s Test Stand 115

Marshall Space Flight Center’s Test Stand 115 (TS115) is a propulsion component test facility in operation since its original activation in 1964 for testing small to medium size liquid rocket engine components including injectors, channel-cooled chambers, nozzles, passively-cooled metallic and composite nozzle extensions, valves, turbomachinery, and igniters. TS115 is a "blowdown" type facility, using high pressure tankage and components to provide liquid, gaseous, and cryogenic fluid delivery at specified pressures and flowrates. The facility consists of an open steel test stand structure, a mechanical hardware preparation shop, an electrical support equipment building, a control room, and a centralized data system room. In general, the facility infrastructure is rated to 3,000 psig. TS115 can accommodate thrust levels up to 10,000 lbf in the horizontal position. The facility is actively used for various internal NASA test programs as well as test campaigns for external customers from other government agencies, commercial industry partners, and academia. The available fluid systems, electrical power and instrumentation capabilities, facility controls and data acquisition systems, test program support capabilities, and available test rig configurations for external customer use are discussed in this paper.

Tal Wammen↗
NASA NTRSDate not supplied

Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering↗
DOE OSTI2020

Mechanical Characterization of Fe-Co-2V (Hiperco): Fatigue/Monotonic Testing Hardness Testing and Fractography

Fe-Co-2V is a popular metallic alloy used in electromagnetic applications. However, there is a lack of mechanical fatigue characterization of this alloy in the literature. In this work, Fe-Co-2V specimens with rectangular cross-sections were carefully prepared in accordance with standards. They were measured for surface roughness and then subjected to quasi-static monotonic testing, as well as fatigue testing at both 0.5 Hz and 1 Hz frequencies. Both Rockwell hardness and Vickers micro- hardness testing were performed. Additionally, scanning electron microscopy imaging of the fractured surfaces was done. The quasi-static testing revealed a flat yield region characteristic of Laders bands. Here, the fatigue results did not show significant differences or sensitivity to change in frequency, although the fatigue life was higher on average for the 0.5 Hz. However, the fatigue results differed from published work at 0.33 Hz. The fractography revealed purely brittle fracture, with clear chevron marks and fracture initiation always starting at the surface. Lastly, it was identified that the C, D, and F Rockwell hardness scales were appropriate for testing this material and that the grain size necessitated the use of the upper end of indentation force for Vickers micro-hardness testing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Single-Bar SMT Testing on Alloy 617 using Software Controls

INL has performed simplified model testing using a variable in the software control program to compare with the testing performed at ORNL, which uses hardware to modify the control signal. The INL tests compared well with the ORNL tests, showing similar stress and strain values, as well as similarly shaped hysteresis loops. This demonstrates that possibility of performing simplified model testing without any hardware modifications.

36 MATERIALS SCIENCE↗