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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Reliability analysis of single crystal NiAl turbine blades

As part of a co-operative agreement with General Electric Aircraft Engines (GEAE), NASA LeRC is modifying and validating the Ceramic Analysis and Reliability Evaluation of Structures algorithm for use in design of components made of high strength NiAl based intermetallic materials. NiAl single crystal alloys are being actively investigated by GEAE as a replacement for Ni-based single crystal superalloys for use in high pressure turbine blades and vanes. The driving force for this research lies in the numerous property advantages offered by NiAl alloys over their superalloy counterparts. These include a reduction of density by as much as a third without significantly sacrificing strength, higher melting point, greater thermal conductivity, better oxidation resistance, and a better response to thermal barrier coatings. The current drawback to high strength NiAl single crystals is their limited ductility. Consequently, significant efforts including the work agreement with GEAE are underway to develop testing and design methodologies for these materials. The approach to validation and component analysis involves the following steps: determination of the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; measurement of the failure strength envelope of the material; coding of statistically based reliability models; verification of the code and model; and modeling of turbine blades and vanes for rig testing.

Salem, Jonathan↗
NASA NTRS2003

Multiaxial Temperature- and Time-Dependent Failure Model

A temperature- and time-dependent mathematical model predicts the conditions for failure of a material subjected to multiaxial stress. The model was initially applied to a filled epoxy below its glass-transition temperature, and is expected to be applicable to other materials, at least below their glass-transition temperatures. The model is justified simply by the fact that it closely approximates the experimentally observed failure behavior of this material: The multiaxiality of the model has been confirmed (see figure) and the model has been shown to be applicable at temperatures from -20 to 115 F (-29 to 46 C) and to predict tensile failures of constant-load and constant-load-rate specimens with failure times ranging from minutes to months..

Richardson, David↗
NASA NTRS1996

The Yeh-Stratton Criterion for Stress Concentrations on Fiber -Reinforced Composite Materials

The Yeh-Stratton criterion developed from a yielding criterion is modified to a generalized failure criterion and applied to fiber-reinforced composites with a central crack or a circular cutout under tensile loadings. The purpose of a material failure criterion is to establish a theoretical margin of safety and to be validated by experiments. It is necessary to obtain the crack tip stress field before a failure criterion of composite materials is applied. However, the crack tip stress field is complicated since there are numerous factors that influence the crack tip stress distribution. The understanding of the factors that contribute to crack tip stress field is of critical importance in analyzing composite laminates.

Yeh, Hsieng-Yang↗
NASA NTRS1996

Craft Stick Beams

The objective of this exercise is to provide a phenomenological 'hands-on' experience that shows how geometry can affect the load carrying capacity of a material used in construction, how different materials have different failure characteristics, and how construction affects the performance of a composite material. This will be accomplished by building beams of a single material and composite beams of a mixture of materials (popsicle sticks, fiberboard sheets, and tongue depressors); testing these layered beams to determine how and where they fail; and based on the failure analysis, designing a layered beam that will fail in a predicted manner. The students will learn the effects of lamination, adhesion, and geometry in layered beam construction on beam strength and failure location.

Karplus, Alan K.↗
DOE OSTI2026

A simple wire-coil resistive heater for high temperature radial x-ray diffraction in a diamond anvil cell

Diamond anvil cells are commonly used at synchrotron x-ray diffraction beamlines to study structural and thermoelastic properties of materials at high pressures. In a radial geometry, where the x-ray probe is oriented perpendicular to the axis of force, the deformation and strength of materials can be measured in situ. Because the anelastic and failure properties of materials depend strongly on temperature, many applications would benefit from the ability to measure high pressure radial diffraction in elevated and accurately controlled thermal environments. Previous work to introduce high temperature to radial diamond anvil cells has been largely limited to laser heating, with relatively scant efforts to resistively heat the sample. Here, we report a relatively straightforward adaptation of a simple wire coil heater, with in situ high-temperature radial diffraction performed on tungsten carbide up to 573 K at beamline 12.2.2 of the Advanced Light Source. In conclusion, the results demonstrate that the differential stress supported by WC decreases with increasing temperature: the differential stress on the basal (001) and pyramidal (101) planes decreased 6.6% and 5.5%, respectively, while the (100) plane only saw a 2.7% decrease, in agreement with previous studies.

Diamond anvil cells↗
NASA NTRS2007

Spherical Cryogenic Hydrogen Tank Preliminary Design Trade Studies

A structural analysis, sizing optimization, and weight prediction study was performed by Collier Research Corporation and NASA Glenn on a spherical cryogenic hydrogen tank. The tank consisted of an inner and outer wall separated by a vacuum for thermal insulation purposes. HyperSizer (Collier Research and Development Corporation), a commercial automated structural analysis and sizing software package was used to design the lightest feasible tank for a given overall size and thermomechanical loading environment. Weight trade studies were completed for different panel concepts and metallic and composite material systems. Extensive failure analyses were performed for each combination of dimensional variables, materials, and layups to establish the structural integrity of tank designs. Detailed stress and strain fields were computed from operational temperature changes and pressure loads. The inner tank wall is sized by the resulting biaxial tensile stresses which cause it to be strength driven, and leads to an optimum panel concept that need not be stiffened. Conversely, the outer tank wall is sized by a biaxial compressive stress field, induced by the pressure differential between atmospheric pressure and the vacuum between the tanks, thereby causing the design to be stability driven and thus stiffened to prevent buckling. Induced thermal stresses become a major sizing driver when a composite or hybrid composite/metallic material systems are used for the inner tank wall for purposes such as liners to contain the fuel and reduce hydrogen permeation.

Arnold, Steven M.↗
NASA NTRS1976

On the thermoelastic analysis of solar cell arrays and related material properties

Accurate prediction of failure of solar cell arrays requires accuracy in the computation of thermally induced stresses. This was accomplished by using the finite element technique. Improved procedures for stress calculation were introduced together with failure criteria capable of describing a wide range of ductile and brittle material behavior. The stress distribution and associated failure mechanisms in the N-interconnect junction of two solar cell designs were then studied. In such stress and failure analysis, it is essential to know the thermomechanical properties of the materials involved. Measurements were made of properties of materials suitable for the design of lightweight arrays: microsheet-0211 glass material for the solar cell filter, and Kapton-H, Kapton F, Teflon, Tedlar, and Mica Ply PG-402 for lightweight substrates. The temperature-dependence of the thermal coefficient of expansion for these materials was determined together with other properties such as the elastic moduli, Poisson's ratio, and the stress-strain behavior up to failure.

Salama, M. A.↗
NASA NTRS2019

Regolith Particle Erosion of Material in Aerospace Environments

This paper studies the effect of exposing thermal control S13GP:6N/LO-I white paint, Kapton flex cable, fiber optic cable, HEPA filter, and M55J graphite composite to high-velocity regolith environment that spacecraft landing on Mars are commonly exposed to. Due to the similarity between the Mars 2020 Rover design and Mars Science Laboratory design, it is expected that the Mars 2020 rover will be exposed to a similar high-speed regolith environment that the Mars Science Laboratory was exposed to. This environment is replicated to test the survivability of susceptible materials. The testing is performed at the University of Dayton Research Institute in Dayton, Ohio. The experiments expose different materials to basaltic–like particles ranging in size from approximately 40 μm to 2 cm, at velocities ranging from 19 m/s to 250 m/s, with varied particle fluxes (measured in mg/cm2). Depending on the size of the particle used, the particles can either embed in or erode the material. Posttest analysis shows that all materials tested will survive the expected environment observed during the Mars 2020 landing event. Some materials are tested to failure in order to better characterize material response. Materials that fail in some test scenarios include the paint, fiber optic cable, and the graphite composite. After being exposed to regolith, the α/ε ratio of the paint increased by ~37% due to particles embedding in the paint. Darkening of the paint can negatively affect thermal control of the rover. With high particle mass fluxes, the paint eventually degraded enough to expose the aluminum substrate. When impacted by a 1.5 cm particle traveling at 20 m/s, the fiber optic cable did not sever, but the impact did cause the cable to deform enough to crack the glass, which resulted in a significant increase in attenuation, rendering the cable unable to transmit data. The graphite composite also failed when exposed to high particle fluxes. All of the observed failures occurred for test cases above the expected landing environment with significant margin. Tests performed beyond the requirements help characterize how well these materials will survive in even more extreme environments for future missions.

Abid, Mohamed↗
NASA NTRS1937

Torsion Tests of Tubes

This report presents the results of tests of 63 chromium-molybdenum steel tubes and 102 17st aluminum-alloy tubes of various sizes and lengths made to study the dependence of the torsional strength on both the dimensions of the tube and the physical properties of the tube material. Three types of failure are found to be important for sizes of tubes frequently used in aircraft construction: (1) failure by plastic shear, in which the tube material reached its yield strength before the critical torque was reached; (2) failure by elastic two-lobe buckling, which depended only on the elastic properties of the tube material and the dimensions of the tube; and (3) failure by a combination of (1) and (2) that is, by buckling taking place after some yielding of the tube material.

Stang, Ambrose H↗
DOE OSTI2024

Surrogate-assisted optimization under uncertainty for design for remanufacturing considering material price volatility

Remanufacturing is a well-established end-of-life (EOL) strategy that promises significant savings in energy and carbon emissions. However, the current design practices are not remanufacturing-inclusive, i.e., the majority of products are designed for a single life cycle. As a result, potential products that can sustain multiple life cycles are deprived of additional benefits of being designed for remanufacturing, such as reduced material usage, lower cost, and improved environmental impact. Moreover, the uncertainty in design, material selection, and economics are not considered to produce remanufacturable designs. Accordingly, this research proposes a design for remanufacturing (DfRem) framework that accounts for design uncertainty and material price volatility. The framework systematically explores the design space, performs design optimization under uncertainty, followed by topology optimization to provide additional mass savings, and finally, a price volatility analysis for plausible design material choices. The candidate designs are evaluated based on their design mass, material price volatility, failure mode characteristics, carbon footprint, and embodied energy impacts. The proposed framework's utility is demonstrated via the use of an engine cylinder head case study subjected to thermo-mechanical loads along with fatigue and wear failure. Considering grey cast iron and aluminum alloy as the design material choices, it was found that the cast iron design reduced the initial design mass by 6% as opposed to a 5% decrease for aluminum. On the other hand, about 8% area of the cast iron design failed due to fatigue, compared to 3% for aluminum. Here, we further observed that although the aluminum design provided better mechanical performance than the cast iron design, this material was more expensive and volatile in price.

36 MATERIALS SCIENCE↗
NASA NTRS2008

Spacecraft Materials in the Space Flight Environment: International Space Station - May 2002 to May 2007

The performance of ISS spacecraft materials and systems on prolonged exposure to the low-Earth orbit (LEO) space flight is reported in this paper. In-flight data, flight crew observations, and the results of ground-based test and analysis directly supporting programmatic and operational decision-making are presented. The space flight environments definitions (both natural and induced) used for ISS design, material selection, and verification testing are shown, in most cases, to be more severe than the actual flight environment accounting for the outstanding performance of ISS as a long mission duration spacecraft. No significant ISS material or system failures have been attributed to spacecraft-environments interactions. Nonetheless, ISS materials and systems performance data is contributing to our understanding of spacecraft material interactions in the spaceflight environment so as to reduce cost and risk for future spaceflight projects and programs. Orbital inclination (51.6o) and altitude (nominally near 360 km) determine the set of natural environment factors affecting the functional life of materials and systems on ISS. ISS operates in an electrically conducting environment (the F2 region of Earth s ionosphere) with well-defined fluxes of atomic oxygen, other charged and neutral ionospheric plasma species, solar UV, VUV, and x-ray radiation as well as galactic cosmic rays, trapped radiation, and solar cosmic rays (1-4). The LEO micrometeoroid and orbital debris environment is an especially important determinant of spacecraft design and operations (5, 6). The magnitude of several environmental factors varies dramatically with latitude and longitude as ISS orbits the Earth (1-4). The high latitude orbital environment also exposes ISS to higher fluences of trapped energetic electrons, auroral electrons, solar cosmic rays, and galactic cosmic rays (1-4) than would be the case in lower inclination orbits, largely as a result of the overall shape and magnitude of the geomagnetic field (1-4). As a result, ISS exposure to many environmental factors can vary dramatically along a particular orbital ground track, and from one ground track to the next, during any 24-hour period.

Golden, John↗
NASA NTRS2009

Environmental Effects on ISS Materials Aging (1998 to 2008)

The performance of ISS spacecraft materials and systems on prolonged exposure to the low- Earth orbit (LEO) space flight are reported in this paper. In-flight data, flight crew observations, and the results of ground-based test and analysis directly supporting programmatic and operational decision-making are described. The space flight environments definitions (both natural and induced) used for ISS design, material selection, and verification testing are shown, in most cases, to be more severe than the actual flight environment accounting, in part, for the outstanding performance of ISS as a long mission duration spacecraft. No significant ISS material or system failures have been attributed to spacecraft-environments interactions. Nonetheless, ISS materials and systems performance data is contributing to our understanding of spacecraft material interactions with the spaceflight environment so as to reduce cost and risk for future spaceflight projects and programs. Orbital inclination (51.6 deg) and altitude (nominally near 360 km) determine the set of natural environment factors affecting the functional life of materials and systems on ISS. ISS operates in an electrically conducting environment (the F2 region of Earth s ionosphere) with well-defined fluxes of atomic oxygen, other charged and neutral ionospheric plasma species, solar UV, VUV, and x-ray radiation as well as galactic cosmic rays, trapped radiation, and solar cosmic rays. The LEO micrometeoroid and orbital debris environment is an especially important determinant of spacecraft design and operations. The magnitude of several environmental factors varies dramatically with latitude and longitude as ISS orbits the Earth. The high latitude orbital environment also exposes ISS to higher fluences of trapped energetic electrons, auroral electrons, solar cosmic rays, and galactic cosmic rays than would be the case in lower inclination orbits, largely as a result of the overall shape and magnitude of the geomagnetic field. As a result, ISS exposure to many environmental factors can vary dramatically along a particular orbital ground track, and from one ground track to the next, during any 24-hour period. The induced environment results from ISS interactions with the natural environment as well as environmental factors produced by ISS itself and visiting vehicles fleet. Examples include ram-wake effects, hypergolic thruster plume impingement, materials out-gassing, venting and dumping of fluids, and specific photovoltaic (PV) power system interactions with the ionospheric plasma (7-11). Vehicle size (L) and velocity (V), combined with the magnitude and direction of the geomagnetic field (B) produce operationally significant magnetic induction voltages (VxB.L) in ISS conducting structure during flight through high latitudes (> +45deg) during each orbit. Finally, an induced ionizing radiation environment is produced by cosmic ray interaction with the relatively thick ISS structure and shielding materials. The intent of this review article is, therefore, to provide a summary of selected aspects and elements of the ISS vehicle with regard to LEO space environment effects, associated with the much larger and more complicated vehicle that ISS has become since 1998, but also with an eye towards performance life extension to the year 2016 and beyond.

Alred, John↗
NASA NTRS1957

Effect of Fiber Orientation on Ball Failures Under Rolling-contact Conditions

The rolling-contact fatigue spin rig was used to test bails of a bearing steel at maximum Hertz stresses of 600,000 to 750,000 psi. The effect of fiber orientation was observed with the ball track restricted to passing directly over the poles, coincident with the equator, or randomly around the ball. The polar areas were found to be weaker in fatigue than the nonpolar areas. This resulted in a much greater portion of the failures occurring in the polar areas than would be expected from a homogeneous material. The early failures are discussed.

MATERIALS, PROPERTIES - FATIGUE↗
NASA NTRS2010

Testing and Failure Mechanisms of Ice Phase Change Material Heat Exchangers

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM s have over evaporators in this scenario is that they do not use a consumable. The use of water as a PCM rather than the more traditional paraffin wax has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. A number of ice PCM heat exchangers were fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion were investigated. This paper presents the results of testing that occurred from March through September of 2010 and builds on testing that occurred during the previous year.

Leimkuehler, Thomas O.↗
NASA NTRS2011

Testing and Failure Mechanisms of Ice Phase Change Material Heat Exchangers

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as specific spacecraft orientations in Low Earth Orbit (LEO) and low beta angle Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM s have over evaporators in this scenario is that they do not use a consumable. The use of water as a PCM rather than the more traditional paraffin wax has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. A number of ice PCM heat exchangers were fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion were investigated. This paper presents the results of testing that occurred from March through September of 2010 and builds on testing that occurred during the previous year.

Leimkuehler, Thomas O.↗
NASA NTRS2005

Failure Analysis of Discrete Damaged Tailored Extension-Shear-Coupled Stiffened Composite Panels

The results of an analytical and experimental investigation of the failure of composite is tiffener panels with extension-shear coupling are presented. This tailored concept, when used in the cover skins of a tiltrotor aircraft wing has the potential for increasing the aeroelastic stability margins and improving the aircraft productivity. The extension-shear coupling is achieved by using unbalanced 45 plies in the skin. The failure analysis of two tailored panel configurations that have the center stringer and adjacent skin severed is presented. Finite element analysis of the damaged panels was conducted using STAGS (STructural Analysis of General Shells) general purpose finite element program that includes a progressive failure capability for laminated composite structures that is based on point-stress analysis, traditional failure criteria, and ply discounting for material degradation. The progressive failure predicted the path of the failure and maximum load capability. There is less than 12 percent difference between the predicted failure load and experimental failure load. There is a good match of the panel stiffness and strength between the progressive failure analysis and the experimental results. The results indicate that the tailored concept would be feasible to use in the wing skin of a tiltrotor aircraft.

Baker, Donald J.↗
NASA NTRSDate not supplied

TPS Certification by Analysis: Model-Driven Characterization of Properties and Failure in Woven Thermal Protection Systems

Woven, ablative thermal protection system (TPS) materials provide a robust option for aggressive (re)entries and thus have been baselined for the upcoming Mars Sample Return (MSR) mission's Earth Entry System (EES). The reliability requirements for MSR-EES necessitate understanding of material property variability, which could be significant given the complex structure and anisotropic nature of properties in TPS weaves, as well as the response to potential impact with micrometeoroids or orbital debris during the EES re-entry. The TPS Certification by Analysis effort within the Entry Systems Modeling project seeks to provide computational models and analyses that support the certification against such material-based risks. For the present talk, focus will be given to the characterization of baseline woven TPS material properties and mechanical failure limits, which entails (1) use of computational techniques (e.g., machine learning) to interpret computed tomography images of the weave to generate representative structural models and (2) application of multiscale material modeling approaches to characterize thermomechanical and failure properties.

thermal protection systems↗
NASA NTRSDate not supplied

TPS Certification by Analysis: Model-Driven Characterization of Properties and Failure in Woven Thermal Protection Systems

Woven, ablative thermal protection system (TPS) materials provide a robust option for aggressive (re)entries and thus have been baselined for the upcoming Mars Sample Return (MSR) mission’s Earth Entry System (EES). The reliability requirements for MSR-EES necessitate understanding of material property variability, which could be significant given the complex structure and anisotropic nature of properties in TPS weaves, as well as the response to potential impact with micrometeoroids or orbital debris during the EES re-entry. The TPS Certification by Analysis effort within the Entry Systems Modeling project seeks to provide computational models and analyses that support the certification against such material-based risks. For the present talk, focus will be given to the characterization of baseline woven TPS material properties and mechanical failure limits, which entails (1) use of computational techniques (e.g., machine learning) to interpret computed tomography images of the weave to generate representative structural models and (2) application of multiscale material modeling approaches to characterize thermomechanical and failure properties.

Justin B. Haskins↗