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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2026

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.

42 ENGINEERING↗
NASA NTRS2005

Torsion of Noncircular Composite Cylinders

The paper presents a brief overview of the predicted deformation and failure characteristics of noncircular composite cylinders subjected to torsion. Using a numerical analysis, elliptical cylinders with a minor-to-major diameter ratio of 0.7 are considered. Counterpart circular cylinders with the same circumference as the elliptical cylinders are included for comparison. The cylinders are constructed of a medium-modulus graphite-epoxy material in a quasi-isotropic lay-up. Imperfections generated from the buckling mode shapes are included in the initial cross-sectional geometry of the cylinders. Deformations until first fiber failure, as predicted using the maximum stress failure criterion and a material degradation scheme, are presented. For increasing levels of torsion, the deformations of the elliptical cylinders, in the form of wrinkling of the cylinder wall, occur primarily in the flatter regions of the cross section. By comparison the wrinkling deformations of the circular cylinders are more uniformly distributed around the circumference. Differences in the initial failure and damage progression and the overall torque vs. twist relationship between the elliptical and circular cylinders are presented. Despite differences in the response as the cylinders are being loaded, at first fiber failure the torque and twist for the elliptical and circular cylinders nearly coincide.

Rouse, Marshall↗
NASA NTRS1990

Freedom Station wall design using hydrodynamic modelling

The paper outlines selected outputs from an ongoing Marshall Space Flight Center/US Army Corps of Engineers parametric study of the effects of meteoroid/space debris impacts on Space Station Freedom module wall protection structures. The advantages and limitations of HULL hydrocode computer simulation are discussed, and examples of meteoroid/ debris impacts on various wall structural designs are presented. Trends in the terminal effects of particle sizes, velocities, shapes, and impact angles upon structural design parameters (wall and bumper thickness and spacing) are summarized and depicted through selected simulation runs. Throughout the paper, proposed structural modifications to the baseline module protection structure will be examined which are capable of mitigating damage from particle impacts.

Williamsen, Joel E.↗
NASA NTRS1993

Synchrotron/crystal sample preparation

The Center for Applied Optics (CAO) of the University of Alabama in Huntsville (UAH) prepared this final report entitled 'Synchrotron/Crystal Sample Preparation' in completion of contract NAS8-38609, Delivery Order No. 53. Hughes Danbury Optical Systems (HDOS) is manufacturing the Advanced X-ray Astrophysics Facility (AXAF) mirrors. These thin-walled, grazing incidence, Wolter Type-1 mirrors, varying in diameter from 1.2 to 0.68 meters, must be ground and polished using state-of-the-art techniques in order to prevent undue stress due to damage or the presence of crystals and inclusions. The effect of crystals on the polishing and grinding process must also be understood. This involves coating special samples of Zerodur and measuring the reflectivity of the coatings in a synchrotron system. In order to gain the understanding needed on the effect of the Zerodur crystals by the grinding and polishing process, UAH prepared glass samples by cutting, grinding, etching, and polishing as required to meet specifications for witness bars for synchrotron measurements and for investigations of crystals embedded in Zerodur. UAH then characterized these samples for subsurface damage and surface roughness and figure.

Johnson, R. Barry↗
DOE OSTI2022

Investigation of Cycle-to-Cycle Variations in Internal Combustion Engine Using Proper Orthogonal Decomposition

The understanding, modeling and control of the cycle-to-cycle variation (CCV) in the modern internal combustion engine (ICE) is a key scientific challenge to achieve stable engine operation. High CCV in the engine combustion chamber may contribute to partial burn, misfire and knock, which adversely affects the engine performance and may potentially damage the engine. The objective of the current study is to leverage high-fidelity numerical simulations to improve the understanding of the causes of CCV. Using the massively parallel code, Nek5000, multi-cycle, wall-resolved large-eddy simulations (LES) were performed for the General Motors (GM), Transparent Combustion Chamber (TCC-III) optical engine under motored operating conditions. Further, the large-scale structures of the in-cylinder flow were investigated using a triple proper orthogonal decomposition (POD) technique to explore the characteristics of different parts of the flow and their contributions to CCV. The kinetic energy of the subset of flow structures were determined and correlated between the intake and compression strokes. The insights from the analysis of the large-scale flow structures will be used to assist the development of improved engine designs with reduced CCV and enhance the engine performance.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Damage Accumulations Predictions for Boiler Components Via Microstructurally Informed Material Models

The goal of the project was to model material behavior and degradation during cyclic plasticity— with and without hold time—for nickel-based superalloys used in USC (ultra-super-critical) and A-USC (advanced-ultra-super-critical) boiler components. The study provided physically informed models, capturing the microstructural changes taking place in the industrial components under cyclic loading and long duration stress (up to 300,000 hours) and high temperature exposure (1100°F/593°C to 1400°F/760°C). The major developments were: 1) Qualitative and quantitative understanding of microstructure evolution (gamma prime precipitates), deformation (dislocation density), and damage mechanisms of Haynes ® 282 alloy. 2) Qualitative understanding of microstructural features generating local strain variations. 3) A continuum damage mechanics model (CDM) for Haynes ® 282 alloy at 1100°F to 1400°F capturing cyclic behavior with and without hold time. 4) Structural analysis for creep and LCF life predictions of an USC thick-wall Grade 91 superheater steel header and understanding life sensitivity to wall thickness of an AUSC Haynes ® 282 header.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1972

A thermocouple thermode for small animals

Thermode composed of two thin-walled stainless steel hypodermic needles and cooper-constantan thermocouple or small thermistor to indicate temperature at point of perfusion is used to measure brain temperature in animals. Because of relatively small size of thermode, structural damage to brain is minimized.

Williams, B. A.↗
DOE OSTI2025

Thermomechanical Modeling and Analysis of a High-Temperature Light Trapping Planar Cavity Receiver

Solar energy harnessed through concentrating solar power (CSP) systems offers a promising path to sustainable energy production, with the efficiency and longevity of these systems relying on key components like solar receivers. This study analyzes the thermomechanical behavior of an innovative enclosed light-trapping solar receiver optimized for particle heating applications. The receiver utilizes sheet metal alloys to form enclosed cavities that reflect and trap incoming solar flux, as well as enclosed channels that contain fluidized particle beds absorbing solar heat. Finite element analysis (FEA) is applied to predict the receiver's thermomechanical performance under extreme solar flux conditions. Temperature distributions from a thermal model simulating a multi-panel assembly at steady state are input into the FEA thermomechanical model for stress analysis. A key aspect of the analysis focuses on evaluating creep-fatigue damage, with a design target of achieving a 30- year service life. Various stress relief techniques are also proposed to extend the receiver's service life. The results highlight the significant impact of the particle-to-wall heat transfer coefficients (HTCs), ranging from 800 W/m2*K to 1400 W/m2*K. The 800 W/m2*K case shows a maximum von Mises stress of 164 MPa, while the 1400 W/m2*K case reduces it to 150 MPa. The creep life increases from 4,000 hrs in the 800 W/m2*K case to over 100,000 hrs in the 1400 W/m2*K case with Inconel 740H used, indicating that higher HTCs reduce stress and extend lifespan. This research advances the design of high-efficiency, low-stress solar receivers for particle-based thermal energy storage in CSP and industrial heating applications.

concentrating solar power↗
NASA NTRS1990

Creep and creep rupture of strongly reinforced metallic composites

A creep and creep damage theory is presented for metallic composites with strong fibers. Application is to reinforced structures in which the fiber orientation may vary throughout but a distinct fiber direction can be identified locally (local transverse isotropy). The creep deformation model follows earlier work and is based on a flow potential function that depends on invariants reflecting stress and the material symmetry. As the focus is on the interaction of creep and damage, primary creep is ignored. The creep rupture model is an extension of continuum damage mechanics and includes an isochronous damage function that depends on invariants specifying the local maximum transverse tension and the maximum longitudinal shear stress. It is posited that at high temperature and low stress, appropriate to engineering practice, these stress components damage the fiber/matrix interface through diffusion controlled void growth, eventually causing creep rupture. Experiments are outlined for characterizing a composite through creep rupture tests under transverse tension and longitudinal shear. Application is made to a thin-walled pressure vessel with reinforcing fibers at an arbitrary helical angle. The results illustrate the usefulness of the model as a means of achieving optimal designs of composite structures where creep and creep rupture are life limiting.

Robinson, D. N.↗
NASA NTRS2000

Formation of Leading-Edge Pinholes in the Space Shuttle Wings Investigated

The space shuttle wing leading edge and nose cap are composed of a carbon/carbon composite that is protected by silicon carbide. The coefficient of thermal expansion mismatch leads to cracks in the silicon carbide. The outer coating of the silicon carbide is a sodium-silicate-based glass that becomes fluid at the shuttles high reentry temperatures and fills these cracks. Small pinholes roughly 0.1 mm in diameter have been observed on these materials after 12 or more flights. These pinholes have been investigated by researchers at the NASA Johnson Space Center, Rockwell International, the Boeing Company, Lockheed Martin Corporation, and the NASA Glenn Research Center at Lewis Field to determine the possible sources and the extent of damage. A typical pinhole is illustrated in the photomicrographs. These pinholes are found primarily on the wing leading edges and not on the nose cap, which is covered when the orbiter is on the launch pad. The pinholes are generally associated with a bead of zincrich glass. Examination of the orbiter and launch structure indicates that weathering paint on the launch structure leads to deposits of zinc-containing paint flakes on the wing leading edge. These may become embedded in the crevices of the wing leading edge and form the observed zinc-rich glass. Laboratory experiments indicate that zinc oxide reacts vigorously with the glass coating on the silicon carbide. Thus, it is likely that this is the reaction that leads to pinhole formation (Christensen, S.V.: Reinforced Carbon/Carbon Pin Hole Formation Through Zinc Oxide Attack. Rockwell International Internal Letter, RDW 96 057, May 1996). Cross-sectional examination of pinholes suggests that they are enlarged thermal expansion mismatch cracks. This is illustrated in the photomicrographs. A careful microstructural analysis indicates that the pinhole walls consist of layers of zinc-containing glass. Thus, pinholes are likely formed by zinc oxide particles lodging in crevices and forming a corrosive zinc-rich glass that enlarges existing cracks. Having established the likely source of the pinholes, we next needed to model the damage. Our concern was that if a pinhole went through the silicon carbide to the carbon/carbon substrate, oxygen would have a clear path to oxidize the carbon at high temperatures. This possibility was examined with studies in a laboratory furnace. An ultrasonic drill was used to make artificial pinholes in a sample of protected carbon/carbon. After exposure, the specimens were weighed and cross-sectioned to quantify the extent of oxidation below the pinhole. The results at higher temperatures showed good agreement with a simple diffusion-control model. This model is based on the two-step oxidation of carbon to carbon monoxide and carbon dioxide. The fluxes are illustrated in the final figure. The model indicates a strong dependence on pinhole diameter. For smaller diameters and short times, the oxidation of carbon is very limited.

Jacobson, Nathan S.↗
NASA NTRS2001

Physical and biological studies with protons and HZE particles in a NASA supported research center in radiation health

NASA has established and supports a specialized center for research and training (NSCORT) to specifically address the potential deleterious effects of HZE particles on human health. The NSCORT in radiation health is a joint effort between Lawrence Berkeley National Laboratory (LBNL) and Colorado State University (CSU). The overall scope of research encompasses a broad range of subjects from microdosimetric studies to cellular and tissue responses to initial damage produced by highly energetic protons and heavy charged particles of the type found in galactic cosmic rays (GCR) spectrum. The objectives of the microdosimetry studies are to determine the response of Tissue Equivalent Proportional Counter (TEPC) to cosmic rays using ground based accelerators. This includes evaluation of energy loss due to the escape of high-energy delta rays and increased energy deposition due to the enhanced delta ray production in the wall of the detector. In this report major results are presented for 56Fe at 1000, 740, 600 and 400 MeV/nucleon. An assessment of DNA repair and early development of related chromosomal changes is extremely important to our overall understanding of enhanced biological effectiveness of high LET particle radiation. Results are presented with respect to the fidelity of the rejoining of double strand breaks and the implications of misrejoining. The relationship between molecular and cytogenetic measurements is presented by studying damage processing in highly heterochromatic supernumerary (correction of sypernumerary) X chromosomes and the active X-chromosome. One of the important consequences of cell's inability to handle DNA damage can be evaluated through mutation studies. Part of our goal is the assessment of potential radioprotectors to reduce the mutation yield following HZE exposures, and some promising results are presented on one compound. A second goal is the integration of DNA repair and mutation studies. Results are presented on a direct comparison of initial double strand breaks induction, the time course and fidelity of double strand break rejoining, cell killing and mutation induction in the same human model system. In order to understand the carcinogenic potential of protons and HZE particles, the role of damaged microenvironment in this process must be understood. In this project it has been postulated that radiation affects the microenvironment, which then modifies cell interactions in a manner conducive to neoplastic progression. Both TGF-beta and FGF-2 are important components of microenvironment. A recent result on the assessment of the role of FGF-2 and its cross-talk with TGF-beta as a function of radiation quality is presented. Theoretical modeling has so far played a central role in analyzing and integrating experimental data on repair and mutation studies and predicting new phenomena. The integrated NSCORT program also provides a broad training experience for students and postdoctoral fellows in space radiation health.

NASA Discipline Radiation Health↗
DOE OSTI2021

Magnetic-Confinement Fusion—Plasma Theory: Tokamak Magnetohydrodynamic Equilibrium and Stability

Magnetohydrodynamics (MHD) provides a useful model to describe the crucial plasma macroscopic equilibrium and stability behaviors in toroidal tokamak devices by considering the plasma as a conducting fluid interacting with a surrounding confining electromagnetic field. MHD is the most basic plasma model, incorporating most large-scale phenomena, including plasma equilibrium and all major instabilities. MHD equations are obtained by taking moments of the Boltzmann equations for different plasma species. They provide a set of comprehensive physics constrains to compute and optimize the equilibrium plasma shape and pressure and current profiles that are critical to its stability and performance. In the ideal case, the equations have special properties that lead to efficient numerical calculation schemes, the most important of which is the ideal MHD energy principle for linear stability against small departures from equilibrium. In a tokamak plasma, equilibrium pressure is mostly destabilizing for MHD modes, whereas equilibrium current is also often a major driving force. Plasma resistivity creates new freedom for a MHD instability to grow, but there are also cases where the plasma resistivity plays a stabilizing role. Equilibrium toroidal flow and/or flow shear can affect MHD instabilities. Principal MHD instabilities include the internal kink mode, sawtooth, fishbone, external kink, resistive wall mode, resistive interchange, tearing and neoclassical tearing modes (NTMs), locked modes, toroidal Alfven eigenmodes (TAEs), and edge localized modes (ELMs). Fast-growing MHD instabilities can lead to an abrupt plasma disruption and termination that can potentially damage the device plasma facing components (PFCs) and in-vessel structures. Furthermore, an important MHD application is to develop robust techniques to mitigate and control MHD instabilities.

Dispersive pellet injection↗
DOE OSTI2023

Design, fabrication, and testing of a water-cooled tungsten-foam high-heat flux plasma-facing module

Here, we present a comprehensive study detailing the design, fabrication and testing a new modular “finger” component, featuring a hexagonal tungsten foam armor tile bonded to the top surface of the water-cooled finger unit. The mechanical, thermal, and particle transport properties of the tungsten foam armor were determined for a wide range of porosity and cell size, and then combined in an equivalent solid material with “effective” properties suitable for large-scale simulations. A series of 3-D multiphysics simulations for coupled thermal and mechanical behavior of the “finger” module are used to optimize the design before fabrication. The simulation results show that, for the expected experimental conditions, a safe range of heat flux and foam porosity is possible for both water-cooling and helium-cooling. Based on these multiphysics simulations, an optimum finger cooling module has been fabricated at Ultramet, Inc. A series of experiments were designed to study the thermomechanical performance of the “finger” unit under steady-state and transient thermal loading at surface heat flux up to 16 MW/m 2 in the High Energy Flux Test facility (HEFTY) at UCLA. Testing conditions included low-power, steady-state plasma exposure at 6 MW/m 2 , followed by severe high heat flux cycles at 16 MW/m 2 . Results of these tests are explained through comparisons with multiphysics simulations. To eliminate the effects of thermomechanical damage carried out on a module on its thermo-mechanical response on a subsequent test, three different yet identically designed and fabricated finger modules were tested. The results show that the current design is capable of cooling the walls of fusion devices at surface heat flux up to 6 MW/m 2 without failure, and that the failure heat flux limit is below 16 MW/m 2 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2011

Demonstration of a Particle Impact Monitoring System for Crewed Space Exploration Modules

When micrometeorite or debris impacts occur on a space habitat, crew members need to be quickly informed of the likely extent of damage, and be directed to the impact location for possible repairs. The goal of the Habitat Particle Impact Monitoring System (HIMS) is to develop a fully automated, end-to-end particle impact detection system for crewed space exploration modules, both in space and on the surfaces of Solar System bodies. The HIMS uses multiple thin film piezo-polymer vibration sensors to detect impacts on a surface, and computer processing of the acoustical signals to characterize the impacts. Development and demonstration of the HIMS is proceeding in concert with NASA's Habitat Demonstration Unit (HDU) Project. The HDU Project is designed to develop and test various technologies, configurations, and operational concepts for exploration habitats. This paper describes the HIMS development, initial testing, and HDU integration efforts. Initial tests of the system on the HDU were conducted at NASA?s 2010 Desert Research and Technologies Studies (Desert-RATS). Four sensor locations were assigned near the corners of a rectangular pattern. To study the influence of wall thickness, three sets of four sensors were installed at different layer depths: on the interior of the PEM wall, on the exterior of the same wall, and on the exterior of a layer of foam insulation applied to the exterior wall. Once the system was activated, particle impacts were periodically applied by firing a pneumatic pellet gun at the exterior wall section. Impact signals from the sensors were recognized by a data acquisition system when they occurred, and recorded on a computer for later analysis. Preliminary analysis of the results found that the HIMS system located the point of impact to within 8 cm, provided a measure of the impact energy / damage produced, and was insensitive to other acoustic events. Based on this success, a fully automated version of this system will be completed and demonstrated as part of a crew "Caution/Warning" system at the 2011 Desert-RATS, along with a crew response procedure.

Opiela, J. N.↗
DOE OSTI2024

Operando XPS for Plasma Process Monitoring: A Case Study on the Hydrogenation of Copper Oxide Confined under h-BN

Here, we demonstrate that ambient pressure x-ray photoelectron spectroscopy (APXPS) can be used for in situ studies of dynamic changes in surface chemistry in a plasma environment. This opens a new and vast application space for XPS and greatly complements modern spectroscopy techniques to probe plasma-solid/liquid interactions relevant to process monitoring in the semiconductor industry, bio-medical plasma applications and plasma remediation technologies. Hexagonal boron nitride (h-BN) grown on Cu was used in this study as a well-defined model system for plasma process monitoring and because of its unique chemical, optical and electrical properties that make it a prospective material for advanced electronics. To better understand the stability and surface chemistry of h-BN during plasma assisted processing, we track in real time the plasma-induced chemical state changes of B, N and the underlying Cu substrate using APXPS equipped with an AC discharge plasma source operating at 13 Pa. Residual gas analysis (RGA) mass-spectra were concurrently collected during plasma-XPS to track reaction products formed during plasma exposure. A clear reduction of Cu x O is seen, while an h-BN layer remains intact, suggesting hydrogen radical (H • ) species can attack the exposed and h-BN covered Cu oxide patches and partially reduce the underlying substrate without significantly damaging the overlaying h-BN, which is of practical importance for development of h-BN encapsulated devices and interfaces. In addition to demonstration of plasma-XPS capabilities we discuss the observed challenges (e.g., parasitic plasma-chamber walls reactions and charging effects) and propose potential solutions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2011

Radiation Protection Using Single-Wall Carbon Nanotube Derivatives

This invention is a means of radiation protection, or cellular oxidative stress mitigation, via a sequence of quenching radical species using nano-engineered scaffolds, specifically single-wall carbon nanotubes (SWNTs) and their derivatives. The material can be used as a means of radiation protection by reducing the number of free radicals within, or nearby, organelles, cells, tissue, organs, or living organisms, thereby reducing the risk of damage to DNA and other cellular components (i.e., RNA, mitochondria, membranes, etc.) that can lead to chronic and/or acute pathologies, including but not limited to cancer, cardiovascular disease, immuno-suppression, and disorders of the central nervous system. In addition, this innovation could be used as a prophylactic or antidote for accidental radiation exposure, during high-altitude or space travel where exposure to radiation is anticipated, or to protect from exposure from deliberate terrorist or wartime use of radiation- containing weapons.

Tour, James M.↗
NASA NTRS1971

An experimental study of the strength and stability of thin monocoque shells with reinforced and unreinforced rectangular cutouts

Axial compression tests were run on eleven thin-walled aluminum cylinders having rectangular cutouts. Various types of reinforcement were used around the cutouts, and some tests were run with no reinforcement. The test results are compared with the cylinder buckling loads prior to installation of the cutouts (obtained without damaging the cylinder by using a buckle-capture technique), and correlated with computer-predicted failure loads. The latter were based on the use of the STAGS computer program. For thin cylinders such as these, the test and computer-based analysis shows that for small to moderate size cutouts, reinforcement of the cutout is of no benefit unless the cylinder is of extremely high (geometrical) quality. For cylinder quality and cutout size where reinforcement is beneficial, the relative merits of the various reinforcement configurations are discussed, and an empirical basis for design is proposed.

Holmes, A. M. C.↗
NASA NTRS2005

Lifing of Engine Components

The successful development of advanced aerospace engines depends greatly on the capabilities of high performance materials and structures. Advanced materials, such as nickel based single crystal alloys, metal foam, advanced copper alloys, and ceramics matrix composites, have been engineered to provide higher engine temperature and stress capabilities. Thermal barrier coatings have been developed to improve component durability and fuel efficiency, by reducing the substrate hot wall metal temperature and protecting against oxidation and blanching. However, these coatings are prone to oxidation and delamination failures. In order to implement the use of these materials in advanced engines, it is necessary to understand and model the evolution of damage of the metal substrate as well as the coating under actual engine conditions. The models and the understanding of material behavior are utilized in the development of a life prediction methodology for hot section components. The research activities were focused on determining the stress and strain fields in an engine environment under combined thermo-mechanical loads to develop life prediction methodologies consistent with the observed damage formation of the coating and the substrates.

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