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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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Information is given in viewgraph form on the nickel hydrogen common pressure vessel (CPV) 2.5V twin stack cell designs. Information given includes an energy analysis, a CPV design comparison, a summary of CPV characterization testing, a comparison of discharge voltage among designs, and life test performance summaries.
A two-dimensional and time-dependent thermal model of a multicell common pressure vessel (CPV) nickel-hydrogen battery was developed. A finite element solver called PDE/Protran was used to solve this model. The model was used to investigate the effects of various design parameters on the temperature profile within the cell. The results were used to help find a design that will yield an acceptable temperature gradient inside a multicell CPV nickel-hydrogen battery. Steady-state and unsteady-state cases with a constant heat generation rate and a time-dependent heat generation rate were solved.
Eddy current testing (ET) was used to scan bare metallic liners used in the fabrication of composite overwrapped pressure vessels (COPVs) for flaws which could result in premature failure of the vessel. The main goal of the project was to make improvements in the areas of scan signal to noise ratio, sensitivity of flaw detection, and estimation of flaw dimensions. Scan settings were optimized resulting in an increased signal to noise ratio. Previously undiscovered flaw indications were observed and investigated. Threshold criteria were determined for the system software's flaw report and estimation of flaw dimensions were brought to an acceptable level of accuracy. Computer algorithms were written to import data for filtering and a numerical derivative filtering algorithm was evaluated.
In coordination with the Office of Safety and Mission Assurance and the respective Center Pressure System Managers (PSMs), the NASA Engineering and Safety Center (NESC) was requested to formulate a consensus draft proposal for the development of additional testing and analysis methods to establish the technical validity, and any limitation thereof, for the continued safe operation of facility non-code layered pressure vessels. The PSMs from each NASA Center were asked to participate as part of the assessment team by providing, collecting, and reviewing data regarding current operations of these vessels. This document contains the appendices to the main report.
The Engineering Guide presents curves and general equations for safelife design of lightweight glass fiber reinforced (GFR) metal pressure vessels operating under anticipated Space Shuttle service conditions. The high composite vessel weight efficiency is shown to be relatively insensitive to shape, providing increased flexibility to designers establishing spacecraft configurations. Spheres, oblate speroids, and cylinders constructed of GFR Inconel X-750, 2219-T62 aluminum, and cryoformed 301 stainless steel are covered; design parameters and performance efficiencies for each configuration are compared at ambient and cryogenic temperature for an operating pressure range of 690 to 2760 N/sq cm (1000 to 4000 psi). Design variables are presented as a function of metal shell operating to sizing (proof) stress ratios for use with fracture mechanics data generated under a separate task of this program.
Buckling, fiber and resin thermal resistance, and hydrostatic tests of glass fiber reinforced spherical pressure vessels and liners
Dual-pump Coherent anti-Stokes Raman scattering (CARS) measurements have been performed in a heated pressure vessel at NASA Langley Research Center. Each measurement, consisting of 500 single shot spectra, was recorded at a fixed location in dry air at various pressures and temperatures, in a range of 0.03-55×10(exp 5) Pa and 300-1373 K, where the temperature was varied using an electric heater. The maximum output power of the electric heater limited the combinations of pressures and temperatures that could be obtained. Charts of CARS signal versus temperature (at constant pressure) and signal versus pressure (at constant temperature) are presented and fit with an empirical model to validate the range of capability of the dual-pump CARS technique; averaged spectra at different conditions of pressure and temperature are also shown.
Method provides quantitative estimation of critical vessel wall and crack parameters that must not be exceeded to ensure against failure of pressurized vessels.
We discuss the concept of an integrated, fiber-optic/microelectronic distributed sensor system that can monitor composite material pressure vessels for Air Force space systems to provide assessments of the overall health and integrity of the vessel throughout its entire operating history from birth to end of life. The fiber optic component would include either a semiconductor light emitting diode or diode laser and a multiplexed fiber optic sensing network incorporating Bragg grating sensors capable of detecting internal temperature and strain. The microelectronic components include a power source, a pulsed laser driver, time domain data acquisition hardware, a microprocessor, a data storage device, and a communication interface. The sensing system would be incorporated within the composite during its manufacture. The microelectronic data acquisition and logging system would record the environmental conditions to which the vessel has been subjected to during its storage and transit, e.g., the history of thermal excursions, pressure loading data, the occurrence of mechanical impacts, the presence of changing internal strain due to aging, delamination, material decomposition, etc. Data would be maintained din non-volatile memory for subsequent readout through a microcomputer interface.
Stress wave analysis and crack opening displacement to monitor subcritical crack growth for grade B alloy steel pressure vessels
Stress corrosion cracking of Ti alloys in nitrogen tetroxide and methyl alcohol environments in Apollo spacecraft pressure vessels
A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Agency's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar(TradeMark) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar(TradeMark) filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However, due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to the experimental investigation reported in [1] and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel's residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.
A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Administration's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to a previously reported experimental investigation and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel s residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.
In conjunction with a recent NASA Engineering and Safety Center (NESC) investigation of flight worthiness of Kevlar Overwrapped Composite Pressure Vessels (COPVs) on board the Orbiter, two stress rupture life prediction models were proposed independently by Phoenix and by Glaser. In this paper, the use of these models to determine the system reliability of 24 COPVs currently in service on board the Orbiter is discussed. The models are briefly described, compared to each other, and model parameters and parameter uncertainties are also reviewed to understand confidence in reliability estimation as well as the sensitivities of these parameters in influencing overall predicted reliability levels. Differences and similarities in the various models will be compared via stress rupture reliability curves (stress ratio vs. lifetime plots). Also outlined will be the differences in the underlying model premises, and predictive outcomes. Sources of error and sensitivities in the models will be examined and discussed based on sensitivity analysis and confidence interval determination. Confidence interval results and their implications will be discussed for the models by Phoenix and Glaser.
This slide presentation reviews some of the issues concerning the aging of the materials in a Composite Overwrapped Pressure Vessels (COPV). The basic composition of the COPV is a Boss, a composite overwrap, and a metallic liner. The lifetime of a COPV is affected by the age of the overwrap, the cyclic fatigue of the metallic liner, and stress rupture life, a sudden and catastrophic failure of the overwrap while holding at a stress level below the ultimate strength for an extended time. There is information about the coupon tests that were performed, and a test on a flight COPV.
Titanium alloy (Ti-6-4) is currently being proposed for the manufacturing of pressure vessels (PV) for storage of compressed helium gas, which are mounted inside the ARES I's liquid hydrogen (LH2) tank. At cryogenic temperature, titanium alloys usually have the highest strength-to-weight ratio property and have been considered as the metallic materials of choice for lightweight PV operating in LH2 environment. Titanium PV s are also considered as heritage hardware because they have been used by NASA for the Saturn IV-B rocket s LH2 tank in the mid 1960 s. However, hydrogen embrittlement is possible if Ti-6-4 alloy is exposed to gaseous hydrogen at certain pressure and temperature during the LH2 tank filling and draining operations on the launch pad, and during the J2X engine burn period for the ARES I s upper stage. Additionally, the fracture toughness and ductility properties of Ti-6-4 are significantly decreased at cryogenic temperature. These factors do not necessary preclude the use of titanium PV in hydrogen or at cryogenic applications; however, their synergistic effects and the material damage tolerance must be accounted for in the mission life assessment for PV s, which are considered as fracture critical hardware. In this paper, an overview of the risk assessment for Ti-6-4 alloy, strategy to control hydrogen embrittlement and brief metallic material trade study for PV operating in LH2 tank will be presented.
Low cost automated and manual welding techniques for pressure vessels made of HY-150 steel plates
Over 7000 low-earth-orbit (LEO) cycles were demonstrated on a full-size aerospace common pressure vessel (CPV) prototype. The battery demonstrated the capability of the basic CPV design to meet the life and reliability requirements of aerospace missions. Subsequent design modifications have been employed to address the shortcomings of the original design and several new prototypes have been fabricated. These include a 12-cell 125 amp-hour geosynchronous earth-orbit (GEO) battery and a 22-cell 10.5 amp-hour LEO battery. Cells for an 80-cell battery intended to demonstrate the high voltage capability of the CPV design have also been fabricated. In addition, assembly of a 20-cell aircraft starting battery prototype is in progress, and testing of a group of 12-volt, 160 amp-hour terrestrial batteries is continuing.