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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Elevated temperature crack growth

Alloy 718 crack growth experiments were conducted to assess the ability of the selected path-independent (P-I) integrals to describe the elevated temperature crack growth behavior. These tests were performed on single edge notch (SEN) specimens under displacement control with multiple extensometers to monitor the specimen and crack mouth opening displacement (CMOD). The displacements in these tests were sufficiently high to induce bulk cyclic inelastic deformation of the specimen. Under these conditions, the linear elastic fracture mechanics (LEFM) parameter K does not correlate the crack growth data. The experimentally measured displacement gradients at the end of specimen gage length were used as the boundary conditions in elastic-plastic finite element method (FEM) analyses. These analyses were performed with a node release approach using CYANIDE, a GEAE FEM code, which included a gap element which is capable of efficiently simulating crack closure. Excellent correlation was obtained between the experimentally measured and predicted variation of stress and CMOD with crack length and the stress-CMOD loops for Alloy 718 tests conducted at 538 C. This confirmed the accuracy of the FEM crack growth simulation approach. The experimentally measured crack growth rate data correlated well the selected P-I integrals. These investigations have produced significant progress in developing P-I integrals as non-linear fracture mechanics parameters. The results suggest that this methodology has the potential of accurately describing elevated temperature crack growth behavior under the combined influence of thermal cycling and bulk elastic-inelastic deformation states.

Kim, K. S.↗
NASA NTRS2004

Development and Testing of Ceramic Thermal Barrier Coatings

Ceramic thermal barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. Durability of the coating systems remains a critical issue with the ever-increasing temperature requirements. Thermal conductivity increase and coating degradation due to sintering and phase changes are known to be detrimental to coating performance. There is a need to characterize the coating behavior and temperature limits, in order to potentially take full advantage of the current coating capability, and also accurately assess the benefit gained from advanced coating development. In this study, thermal conductivity behavior and cyclic durability of plasma-sprayed ZrO2-8wt%Y2O3 thermal barrier coatings were evaluated under laser heat-flux simulated high temperature, large thermal gradient and thermal cycling conditions. The coating degradation and failure processes were assessed by real-time monitoring of the coating thermal conductivity under the test conditions. The ceramic coating crack propagation driving forces and resulting failure modes will be discussed in light of high temperature mechanical fatigue and fracture testing results.

Zhu, Dongming↗
DOE OSTI2023

Utah FORGE: Triaxial Direct Shear Results

This submission contains a report and associated data from triaxial direct shear tests conducted by Los Alamos National Laboratory. The samples used were sourced from 16A(78)-32 well core. The primary objectives of this test were to determine the shear strength in both intact and residual states, evaluate dilation against displacement, assess permeability in relation to displacement, time, and normal stress, understand the relationship between aperture and normal stress, and monitor the effluent chemistry as a function of time.

15 GEOTHERMAL ENERGY↗
NASA NTRS1977

Signature analysis of acoustic emission from graphite/epoxy composites

Acoustic emissions were monitored for crack extension across and parallel to the fibers in a single ply and multiply laminates of graphite epoxy composites. Spectrum analysis was performed on the transient signal to ascertain if the fracture mode can be characterized by a particular spectral pattern. The specimens were loaded to failure quasistatically in a tensile machine. Visual observations were made via either an optical microscope or a television camera. The results indicate that several types of characteristics in the time and frequency domain correspond to different types of failure.

Russell, S. S.↗
DOE OSTI2024

Numerically Testing Conceptual Models of the Utah FORGE Reservoir Using July 2023 Circulation Test Data

Over the past several years, many new data sets have become available regarding the characterization of the Utah FORGE reservoir. These include, but are not limited to, the stimulation of Well 16A, the drilling and completion of Well 16B, and interwell circulation confirmatory testing. As part of the characterization efforts, conceptual models of the reservoir are re-examined as new data become available. As part of the planning for FORGE activities, numerical models are often used to predict the reservoir response to the planned testing. Stochastic methods are often employed to bound uncertainty and allow for evaluation of comprehensive ranges of key reservoir parameters. For the most recent interwell circulation confirmatory testing (July 2023), a priori numerical model predictions did bound the observed behavior (Xinj et al., 2023), but key deviations from expected behavior prompted the FORGE team to reevaluate our conceptual model of the reservoir. In early October 2023, key members of the development, testing, and monitoring teams met for 2 days to review newly collected data and discuss ‘interesting’ or ‘key’ observations. From these discussions, 15 Key Observations were documented, with several significant ones being that the discrete fracture network developed from the 16A stimulation data may not be appropriate and that the early time pressure data obtained during the summer 2023 reservoir testing were best described using radial solutions. In July 2023, two campaigns of interwell confirmatory testing were conducted, the first set of tests occurred on July 4-5 and the second set on July 18-19. The second set of circulation tests conducted at the Utah FORGE site between the injection well 16A(78)-32 and production well 16B(78)-32 on July 18 and 19, 2023 are used to calibrate material properties in a thermal-hydraulic-mechanical (THM) simulation of the discrete fracture network connecting the wells. The spatially and temporally varying reservoir properties are calibrated to match the time dependent pressure and production profiles from the circulation tests. In future work, this calibrated model will be coupled to the native state THM model of the FORGE reservoir to predict surface deformation and strains resulting from pumping schedules.

58 GEOSCIENCES↗
DOE OSTI2024

Numerically Testing Conceptual Models of the Utah FORGE Reservoir Using July 2024 Circulation Test Data

Over the past several years, many new data sets have become available regarding the characterization of the Utah FORGE reservoir. These include, but are not limited to, the stimulation of Well 16A, the drilling and completion of Well 16B, and interwell circulation confirmatory testing. As part of the characterization efforts, conceptual models of the reservoir are re-examined as new data become available. As part of the planning for FORGE activities, numerical models are often used to predict the reservoir response to the planned testing. Stochastic methods are often employed to bound uncertainty and allow for evaluation of comprehensive ranges of key reservoir parameters. For the most recent interwell circulation confirmatory testing (July 2023), a priori numerical model predictions did bound the observed behavior (Xinj et al., 2023), but key deviations from expected behavior prompted the FORGE team to reevaluate our conceptual model of the reservoir. In early October 2023, key members of the development, testing, and monitoring teams met for 2 days to review newly collected data and discuss ‘interesting’ or ‘key’ observations. From these discussions, 15 Key Observations were documented, with several significant ones being that the discrete fracture network developed from the 16A stimulation data may not be appropriate and that the early time pressure data obtained during the summer 2023 reservoir testing were best described using radial solutions. In July 2023, two campaigns of interwell confirmatory testing were conducted, the first set of tests occurred on July 4-5 and the second set on July 18-19. The second set of circulation tests conducted at the Utah FORGE site between the injection well 16A(78)-32 and production well 16B(78)-32 on July 18 and 19, 2023 are used to calibrate material properties in a thermal-hydraulic-mechanical (THM) simulation of the discrete fracture network connecting the wells. The spatially and temporally varying reservoir properties are calibrated to match the time dependent pressure and production profiles from the circulation tests. In future work, this calibrated model will be coupled to the native state THM model of the FORGE reservoir to predict surface deformation and strains resulting from pumping schedules.

15 GEOTHERMAL ENERGY↗
NASA NTRS2015

Correlation of Electrical Resistance to CMC Stress-Strain and Fracture Behavior Under High Heat-Flux Thermal and Stress Gradients

Because SiCSiC ceramic matrix composites (CMCs) are under consideration for use as turbine engine hot-section components in extreme environments, it becomes necessary to investigate their performance and damage morphologies under complex loading and environmental conditions. Monitoring of electrical resistance (ER) has been shown as an effective tool for detecting damage accumulation of woven melt-infiltrated SiCSiC CMCs. However, ER change under complicated thermo-mechanical loading is not well understood. In this study a systematic approach is taken to determine the capabilities of ER as a relevant non-destructive evaluation technique for high heat-flux testing, including thermal gradients and localized stress concentrations. Room temperature and high temperature, laser-based tensile tests were conducted in which stress-dependent damage locations were determined using modal acoustic emission (AE) monitoring and compared to full-field strain mapping using digital image correlation (DIC). This information is then compared with the results of in-situ ER monitoring, post-test ER inspection and fractography in order to correlate ER response to convoluted loading conditions and damage evolution.

electrical resistance↗
DOE OSTI2026

Innovations in underground hydrogen storage with multiphysics simulations, optimization, and monitoring: A review

Underground Hydrogen Storage (UHS) is a promising solution for large-scale energy storage and a critical component in advancing low-carbon energy system. Ensuring the safety and efficiency of UHS necessitates a comprehensive understanding of multiphysical interactions driven by cyclic pore fluid pressure fluctuations and coupled physicochemical processes. Here, this review examines the key geomechanical responses in UHS, including rock property variations under cyclic loading, fracture evolution and propagation, reservoir stress sensitivity, and fault stability. It also explores the impact of geochemical and microbial reactions on geomechanical characteristics. We provide an in-depth analysis of Thermal-Hydraulic-Mechanical-Chemical (THMC) coupled numerical simulations, highlighting their potential for future multi-scale modeling. Limitations of current machine learning (ML) approaches in addressing UHS challenges are highlighted, emphasizing the need for innovative ML-based methodologies. Operational strategies for hydrogen injection and production are reviewed, focusing on safety, efficiency, and economic viability. The necessity for multi-objective optimization (MOO) to balance storage efficiency, risk mitigation, and cost-effectiveness is also discussed. Current monitoring technologies are evaluated to ensure safe and efficient UHS operations. Finally, this review identifies critical knowledge gaps and underscores the importance of advancing geomechanical understanding under multiphysics-coupling. We highlight the need for ML-driven multiphysics theories, enhanced modeling techniques, and robust optimization strategies to improve UHS performance. This study serves as a comprehensive reference for future research and the large-scale implementation of UHS systems.

25 ENERGY STORAGE↗
DOE OSTI2024

4D Electrical Resistivity Imaging of Stress Perturbations Induced During High–Pressure Shear Stimulation Tests

Fluid flow through fractured media is typically governed by the distribution of fracture apertures, which are in turn governed by stress. Consequently, understanding subsurface stress is critical for understanding and predicting subsurface fluid flow. Although laboratory–scale studies have established a sensitive relationship between effective stress and bulk electrical conductivity in crystalline rock, that relationship has not been extensively leveraged to monitor stress evolution at the field scale using electrical or electromagnetic geophysical monitoring approaches. In this paper we demonstrate the use time–lapse 3–dimensional (4D) electrical resistivity tomography to image perturbations in the stress field generated by pressurized borehole packers deployed during shear–stimulation attempts in a 1.25 km deep metamorphic crystalline rock formation.

58 GEOSCIENCES↗
NASA NTRSDate not supplied

Repurposing Drilling Control Diagnostics for Subsurface Edge Detection and Boundary Advisement During Planetary Drilling

Informed decision-making during lunar drilling and sampling missions will require data monitoring tools and specialized ground data systems. Accurate and updated situational awareness, with ongoing data monitoring, is critical for timely responses by to incoming science data. Traverse plans and scheduled activities may need to be flexibly changed in order to react to unexpected data or situations. Unlike (for example) Mars missions, the relative lightspeed closeness of the Moon allows for near-real-time ground processing of incoming mission and instrument data. An Apollo-class lunar regolith drill will in a sense “travel” a meter or two vertically at a given subsurface characterization site. As the drill penetrates into lunar regolith, it is likely to encounter a range of material densities, orientations, fracture toughness, and (perhaps) ice percentages. Lunar drill telemetry can provide science teams with a valuable first look into the subsurface structure, the regolith bulk properties, and constituents at each drilled site. Real-time AI-based recognition and reaction to downhole situations has been developed for automated deeper drilling on Mars and beyond. We can leverage the same knowledge bases and pattern-matching as areal-time interpreter of the subsurface, a situational awareness tool during drilling operations. We recently (Sept. 2019) demonstrated this AI drilling monitoring and analysis capability, in control of in-situ drilling and sampling operations, mounted on a KREX-2 rover in Chile’s Atacama Desert. Terrestrial automated drilling log analyses in oil exploration have used similar machine learning techniques in classifying and identifying features in drilling logs –but these typically are designed assuming a drilling fluid influencing downhole measurements and data (permeability, resistivity). Drilling models and existing AI software designed to detect and respond to drilling faults and hard materials can be repurposed, for near-real-time (ground-based) interpretation of drilling telemetry –a potentially valuable advisory tool for strata boundaries and changes in drilling parameters. On the Moon, this approach could be used to study the structure and to some extent the composition of lunar regolith vs. borehole depth, based on recognizable variations in fracture hardness, drilling energy and penetration rates while actively drilling. Since the early 2000s, a series of increasingly-capable real-time drilling telemetry interpretation and characterization software tools have been developed. These subsurface models and software tools have monitored the real-time drilling data received, and automatically identified changes in drill behavior (e.g., encountering a harder target layer, bit inclusions, drill choking due to infall downhole, and others) correlating these with subsurface structures and features. We discuss the mappings between drill borehole parameters, faults or events detected, and modeled changes in rock layer boundaries, in examples drawn from field testing at analog sites in an Arctic impact crater, Rio Tinto, and Chile’s Atacama Desert. These demonstrate how subsurface structural boundaries led to fault detections and responses by the software.

drilling advisor↗
NASA NTRS1974

The use of the ion probe mass spectrometer in the measurement of hydrogen concentration gradients in Monel K 500

The ion probe mass spectrometer was used to measure hydrogen concentration gradients in cathodically charged Monel K 500. Initial work with the ion probe involved the calibration of the instrument and the establishment of a suitable experimental procedure for this application. Samples of Monel K 500 were cathodically charged in a weak sulfuric acid solution. By varying the current density, different levels of hydrogen were introduced into the samples. Hydrogen concentration gradients were taken by ion sputtering on the surface of these samples and monitoring the behavior of the hydrogen mass peak as a function of time. An attempt was made to determine the relative amounts of hydrogen in the bulk and grain boundaries by analyzing a fresh fracture surface with a higher proportion of grain boundary area. It was found that substantially more hydrogen was detected in the grain boundaries than in the bulk, confirming the predictions of previous workers. A sputter rate determination was made in order to establish the rate of erosion.

Truhan, J. J., Jr.↗
NASA NTRS1985

Cracked rotor demonstration

The purpose of this demonstration is to observe the behavior of a rotor with a single crack. This will be presented in oscilloscope orbits, 2X POLAR PLOTS, and spectrum cascade diagrams. Crack detection must be observed in all three formats and monitored over a period of time or start-ups. The change in the 2X behavior pattern provides an early warning that a crack potentially exists and that it is likely propagating toward total rotor fracture.

Bosmans, R. F.↗
NASA NTRS2002

Ion Milling of Sapphire

The ion figuring system at the Marshall Space Flight Center has been successfully used for at least three previous investigations into the ion milling of metals. The research was directed toward improving the surface quality of X-ray directing optics. These studies were performed on surfaces that were already hand polished to an excellent surface quality and were intended to remove the residual unwanted figure left by those techniques. The ion milling was typically carried out on test surfaces or mandrels that were several centimeters in width and length. The good thermal conductivity of the metal samples allowed the ion beam to be directed onto the sample for an indefinite period of time. This is not true of sapphire or most electrical insulators and problems have arisen in recent attempts to ion mill thin samples of sapphire. The failure and fracture of the material was likely due to thermal stresses and the relatively low thermal conductivity of sapphire (compared to most metals), These assumed stresses actually provided the key as to how they might be monitored. A thermal gradient in the sapphire sample will induce an effective index of refraction change and because of the shape constraint and the crystal structure and simple thermal expansion, this index change will be nonuniform across the sample. In all but simple cubic crystal structures, this leads to a spatially nonuniform optical retardance induced on any polarized optical beam traversing the sample, and it is this retardance that can be monitored using standard polarimetric procedures.

Don A. Gregory↗
NASA NTRS2011

Detecting Damage in Ceramic Matrix Composites Using Electrical Resistance

The majority of damage in SiC/SiC ceramic matrix composites subjected to monotonic tensile loads is in the form of distributed matrix cracks. These cracks initiate near stress concentrations, such as 90 deg fiber tows or large matrix pores and continue to accumulate with additional stress until matrix crack saturation is achieved. Such damage is difficult to detect with conventional nondestructive evaluation techniques (immersion ultrasonics, x-ray, etc.). Monitoring a specimen.s electrical resistance change provides an indirect approach for monitoring matrix crack density. Sylramic-iBN fiber- reinforced SiC composites with a melt infiltrated (MI) matrix were tensile tested at room temperature. Results showed an increase in resistance of more than 500% prior to fracture, which can be detected either in situ or post-damage. A relationship between resistance change and matrix crack density was also determined.

Smith, Craig E.↗
NASA NTRS2011

Detecting Cracks in Ceramic Matrix Composites by Electrical Resistance

The majority of damage in SiC/SiC ceramic matrix composites subjected to monotonic tensile loads is in the form of distributed matrix cracks. These cracks initiate near stress concentrations, such as 90o fiber tows or large matrix pores and continue to accumulate with additional stress until matrix crack saturation is achieved. Such damage is difficult to detect with conventional nondestructive evaluation techniques (immersion ultrasonics, x-ray, etc.). Monitoring a specimen.s electrical resistance change provides an indirect approach for monitoring matrix crack density. Sylramic-iBN fiber- reinforced SiC composites with a melt infiltrated (MI) matrix were tensile tested at room temperature. Results showed an increase in resistance of more than 500% prior to fracture, which can be detected either in situ or post-damage. A relationship between resistance change and matrix crack density was also determined.

Smith, Craig↗
DOE OSTI2021

DCIF Westerly Granite AE Stress Effect Test (Task 3-1)

Directional Cooling-Induced Fracturing (DCIF) experiments were conducted on rectangular Westerly granite blocks (width=depth=4.0", height=2.0"). Liquid nitrogen was poured in a small, 1"-diameter copper cup attached to the top of the sample, and the resulting acoustic emissions (AEs) and temperature changes on the surface of the sample were monitored. Several confining stresses were applied bi-axially to the sides of the samples so that the onset of AE activity and the stress applied to the sample were correlated. The obtained AEs were used to determine the microcracking source locations and amplitude, and the associated moment tensors. Included in this submission are the animations of the AE locations and graphics displaying the measured temperature-AE activity changes for different stresses.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Progress of Gas Injection EOR Surveillance in the Bakken Unconventional Play—Technical Review and Machine Learning Study

Although considerable laboratory and modeling activities were performed to investigate the enhanced oil recovery (EOR) mechanisms and potential in unconventional reservoirs, only limited research has been reported to investigate actual EOR implementations and their surveillance in fields. Eleven EOR pilot tests that used CO2, rich gas, surfactant, water, etc., have been conducted in the Bakken unconventional play since 2008. Gas injection was involved in eight of these pilots with huff ‘n’ puff, flooding, and injectivity operations. Surveillance data, including daily production/injection rates, bottomhole injection pressure, gas composition, well logs, and tracer testing, were collected from these tests to generate time-series plots or analytics that can inform operators of downhole conditions. A technical review showed that pressure buildup, conformance issues, and timely gas breakthrough detection were some of the main challenges because of the interconnected fractures between injection and offset wells. The latest operation of co-injecting gas, water, and surfactant through the same injection well showed that these challenges could be mitigated by careful EOR design and continuous reservoir monitoring. Reservoir simulation and machine learning were then conducted for operators to rapidly predict EOR performance and take control actions to improve EOR outcomes in unconventional reservoirs.

Energy & Fuels↗
NASA NTRS1994

A Review of Transmission Diagnostics Research at NASA Lewis Research Center

This paper presents a summary of the transmission diagnostics research work conducted at NASA Lewis Research Center over the last four years. In 1990, the Transmission Health and Usage Monitoring Research Team at NASA Lewis conducted a survey to determine the critical needs of the diagnostics community. Survey results indicated that experimental verification of gear and bearing fault detection methods, improved fault detection in planetary systems, and damage magnitude assessment and prognostics research were all critical to a highly reliable health and usage monitoring system. In response to this, a variety of transmission fault detection methods were applied to experimentally obtained fatigue data. Failure modes of the fatigue data include a variety of gear pitting failures, tooth wear, tooth fracture, and bearing spalling failures. Overall results indicate that, of the gear fault detection techniques, no one method can successfully detect all possible failure modes. The more successful methods need to be integrated into a single more reliable detection technique. A recently developed method, NA4, in addition to being one of the more successful gear fault detection methods, was also found to exhibit damage magnitude estimation capabilities.

Zakajsek, James J.↗