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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Analytical Round Robin for Elastic-Plastic Analysis of Surface Cracked Plates, Phase II Results

The second phase of an analytical round robin for the elastic-plastic analysis of surface cracks in flat plates was conducted under the auspices of ASTM Interlaboratory Study 732. The interlaboratory study (ILS) had 10 participants with a broad range of expertise and experience, and experimental results from a surface crack tension test in 4142 steel plate loaded well into the elastic-plastic regime provided the basis for the study. The participants were asked to evaluate a surface crack tension test according to the version of the surface crack initiation toughness testing standard published at the time of the ILS, E2899-13. Data were provided to each participant that represent the fundamental information that would be provided by a mechanical test laboratory prior to evaluating the test result. Overall, the participant’s test analysis results were in good agreement and constructive feedback was received that has resulted in an improved published version of the standard E2899-15.

Allen, P. A.↗
NASA NTRS2008

Full-field Strain Methods for Investigating Failure Mechanisms in Triaxial Braided Composites

Composite materials made with triaxial braid architecture and large tow size carbon fibers are beginning to be used in many applications, including composite aircraft and engine structures. Recent advancements in braiding technology have led to commercially viable manufacturing approaches for making large structures with complex shape. Although the large unit cell size of these materials is an advantage for manufacturing efficiency, the fiber architecture presents some challenges for materials characterization, design, and analysis. In some cases, the static load capability of structures made using these materials has been higher than expected based on material strength properties measured using standard coupon tests. A potential problem with using standard tests methods for these materials is that the unit cell size can be an unacceptably large fraction of the specimen dimensions. More detailed investigation of deformation and failure processes in large unit cell size triaxial braid composites is needed to evaluate the applicability of standard test methods for these materials and to develop alternative testing approaches. In recent years, commercial equipment has become available that enables digital image correlation to be used on a more routine basis for investigation of full field 3D deformation in materials and structures. In this paper, some new techniques that have been developed to investigate local deformation and failure using digital image correlation techniques are presented. The methods were used to measure both local and global strains during standard straight-sided coupon tensile tests on composite materials made with 12 and 24 k yarns and a 0/+60/-60 triaxial braid architecture. Local deformation and failure within fiber bundles was observed, and this local failure had a significant effect on global stiffness and strength. The matrix material had a large effect on local damage initiation for the two matrix materials used in this investigation. Premature failure in regions of the unit cell near the edge of the straight-sided specimens was observed for transverse tensile tests in which the braid axial fibers were perpendicular to the specimen axis and the bias fibers terminated on the cut edges in the specimen gage section. This edge effect is one factor that could contribute to a measured strength that is lower than the actual material strength in a structure without edge effects.

Littell, Justin D.↗
NASA NTRS1996

Instrumented Materials Testing

This presentation starts with an introduction to the need for materials testing. Classic failures (such as brittle ship hull fractures) are discussed before fundamental discoveries in fracture analysis (Griffith, Westergaard, and Irwin). Next standard tests are identified, followed by a look at brittle versus ductile failure. Griffith's result (the composite paradigm) that smaller composite specimens are stronger because they have smaller flaws, is covered. This leads into composite tests. And finally, stress waves are shown as an example that will initiate damage.

Mackin, Thomas J.↗
NASA NTRS2017

ECLSS Universal Waste Management System (UWMS) Metal Materials Compatibility Study- Electrochemical and Crevice Corrosion Evaluation

Electrochemical and crevice corrosion laboratory test results are presented for three noble metal candidates with possible application on the Universal Waste Management System (UWMS) in support of the Environmental Control and Life Support System (ECLSS) aboard the International Space Station (ISS). The three metal candidates, which included Inconel 625, Hastelloy C276 and Titanium 6Al-4V, were evaluated in two solutions representative of the acidic pretreatment formulations utilized during processing of waste liquids within the ECLSS. Final test results and data analysis indicated that the passive layer on all three metals provides excellent corrosion protection in both solutions under standard test conditions.

Lee, R. E.↗
NASA NTRS2017

Environmental Testbed Development to Evaluate Power Distribution Materials in Electrified Aircraft (EA)

NASA is pursuing the development of electrified propulsion (EP) technologies to improve air transportation in terms of efficiency, affordability, and sustainability. The power requirements are expected to reach 20 megawatts for large EP commercial airliners. A key challenge is transmission and distribution of the high voltage (20 kilovolts) needed for some EP systems. This is a challenge because the risk of electrical failure in aircraft at high altitude (low pressure) due to corona discharge and other forms of partial discharge increases significantly when voltages exceed 327 V. Corona discharge is a form of partial discharge in which gaseous molecules are ionized by strong electric fields. Corona discharge leads to aging in power transmission lines. Aging is a leading cause of electrical failure in electrical insulation materials. In particular, aging from electrical, vibrational, and thermal stresses decrease the performance life of insulation materials. There are currently no test standards or equipment that can effectively age materials under high altitude, voltage and frequency conditions. This poster proposes a design for a test system including an environmental chamber that can simulate the environment of future EP systems for material and component aging tests.

Materials Test chamber Design↗
NASA NTRS1973

Operational frequency stability of rubidium and cesium frequency standards

The frequency stabilities under operational conditions of several commercially available rubidium and cesium frequency standards were determined from experimental data for frequency averaging times from 10 to the 7th power s and are presented in table and graph form. For frequency averaging times between 10 to the 5th power and 10 to the 7th power s, the rubidium standards tested have a stability of between 10 to the minus 12th power and 5 x 10 to the minus 12th power, while the cesium standards have a stability of between 2 x 10 to the minus 13th power and 5 x 10 to the minus 13th power.

Lavery, J. E.↗
NASA NTRS1990

Behavior of surface and corner cracks subjected to tensile and bending loads in Ti-6Al-4V alloy

The behavior of part-through flaws with regard to failure under monotonic loading and their growth under fatigue loading was studied experimentally and analytically. Comparisons are made of experimental values of toughness obtained using surface and corner cracked specimens with those obtained using standard test specimens, and also experimental growth cycles were compared with numerical predictions using the NASA/FLAGRO computer program. Tests were conducted on various types of surface and corner cracks under tensile and bending loads. Room temperature lab air provided the test environment. The material used in this study was the Ti-6Al-4V alloy in the solution treated and aged (STA) and stress relieved condition. Detailed tabulation of the fracture toughness data and results of life prediction using the NASA/FLAGRO program are presented. Fatigue crack growth rates for the part-through cracked specimens are compared with a base curve fitted from the data obtained using standard specimens. The fatigue loading used in the crack growth testing was constant-amplitude sinusoidal type.

Forman, Royce G.↗
NASA NTRS1992

Behavior of surface and corner cracks subjected to tensile and bending loads in a Ti-6Al-4V alloy

The behavior of part-through flaws with regard to failure under monotonic loading and their growth under fatigue loading was investigated experimentally and analytically. The objective of this paper is to present comparisons of experimental values of toughness obtained using surface- and corner-cracked specimens with those obtained using standard test specimens, and also to compare experimental growth cycles with numerical predictions using the NASA/FLAGRO computer program. Tests were conducted on various types of surface and corner cracks under tensile and bending loads. Room temperature laboratory air provided the test environment. The material used in this investigation was the Ti-6Al-4V alloy in the solution treated and aged (STA) and stress-relieved condition. Detailed tabulation of the fracture toughness data and results of life prediction using the NASA/FLAGRO program are presented. Fatigue crack growth rates for the part-through-cracked specimens are compared with a base curve fitted from the data obtained using standard specimens. The fatigue loading used in the crack growth testing was of constant-amplitude sinusoidal type.

Forman, Royce G.↗
NASA NTRS2003

Promoted Ignition and Burning Tests of Stainless Steel in Flowing and Nonflowing Oxygen

The Industry-Sponsored Metals Combustion Test Program 96-1 was coordinated through Wendell Hull & Associates, Inc. on behalf of several contributing companies, and all design and testing was performed at the NASA White Sands Test Facility. Phase I of this test program studied the threshold pressure for self-sustained burning of various types and sizes of stain less steel rods in nonflowing oxygen, as observed in Standard Test Method for Determining the Combustion Behavior of Metallic Materials in Oxygen-Enriched Atmospheres (ASTM G 124-95). Phase II studied the ignition and propagation of burning of 316L stainless steel rods and pipe in flowing gaseous oxygen. The test sample configurations were chosen to replicate previous promoted ignition and burning tests as well as to represent geometries and cross-sectional thicknesses common in industrial piping applications. The gas pressw'es and velocities for the test matrix were selected to generally compare with CGA G-4.4 guidelines for the use of stain less steel in oxygen service. This paper summarizes the results from the Phase I nonflowing oxygen tests and presents in detail the results of the Phase II flowing oxygen tests. The maximum sample burn-length is shown as a function of test pressure in Phase 1 and also as a function of gas velocity in Phase IT. These results indicate that flowing oxygen, under the given test conditions, significantly affects maximum sample burn length as compared to nonflowing oxygen. Supplementary flowing oxygen test data on stainless steel rods from a follow-up test program are consistent with these results and are presented herein.

Forsyth, Elliot T.↗
NASA NTRS2022

Europa Clipper Payload Verification and Validation: Test and Analysis Program Design

NASA’s Europa Clipper mission – which is planned to launch in the mid-2020s – is designed to investigate the habitability of the jovian moon Europa with a state-of-the-art suite of over 10 sensors and instruments. Now past its project critical design review, Europa Clipper is starting the execution of its verification and validation (V&V) program. The payload V&V function in particular is responsible for designing and coordinating a thorough test and analysis program that will confirm the proper functioning and performance of our payload instruments. Given the large number of instruments to manage, we have developed a suite of standardized tests and analyses that are designed to cover all of the common interfaces across instruments, while allowing for flexibility to support the unique needs of individual instruments. This suite of activities, coordinated and/or performed by the payload team, forms the bulk of our payload verification and validation campaign. This paper provides a detailed summary of the full set of V&V activities in that suite, covering the four categories of activities: analysis of lower-level evidence, analysis via simulation, testing in the system testbeds, and testing in assembly, test, and launch operations (ATLO). We will describe the purpose of each activity type, how the activities are developed, and the review process for each type of activity. We then define the complete list of activities written for each instrument and how subtleties specific to certain instruments are managed. The discussion will provide a comprehensive understanding of the activities in the payload V&V purview and how various interfaces with different levels of the project are managed. This paper also describes key metrics the payload team uses to track V&V progress and some insights into the teaming design and division of labor we use to ensure consistency and completeness across the entire payload suite. Finally, the paper will offer a snapshot of the status of the Payload V&V program prior to instrument delivery and offer insights into the upcoming phase of instrument delivery and the start of ATLO.

Lee, Dennis↗
NASA NTRS2003

AWS Figure of Merit (FOM) Developed Parameters from Static, Transonic Model Tests

This paper provides an approach to answer the question of whether one can rely solely on static data taken during a transonic model test to provide the certainty needed that a new aircraft will or will not have Abrupt Wing Stall (AWS) events during its flight operations. By comparing traditional- and alternate-static-Figures of Merit (FOMs) with the Free-To-Roll (FTR) response data, a rational basis for assessing the merits of using standard testing techniques for the prediction of AWS events has been established. Using the FTR response data as a standard, since these results compare well with flight, the conclusion from this study is that neither traditional nor alternate FOMs can be trusted to provide an indication as to whether a configuration will or will not have AWS tendencies. Even though these FOMs may flag features which have a high degree of correlation with the FTR response data, there are as many or more of these FOM flagged features which do not correlate. Thus, one needs to use the FTR rig to assess AWS tendencies on new configurations.

Lamar, J. E.↗
NASA NTRS1996

Separator Materials Used in Secondary Alkaline Batteries Characterized and Evaluated

Nickel-cadmium (Ni/Cd) and nickel-hydrogen (Ni/H2) secondary alkaline batteries are vital to aerospace applications. Battery performance and cycle life are significantly affected by the type of separators used in those batteries. A team from NASA Lewis Research Center's Electrochemical Technology Branch developed standardized testing procedures to characterize and evaluate new and existing separator materials to improve performance and cycle life of secondary alkaline batteries. Battery separators must function as good electronic insulators and as efficient electrolyte reservoirs. At present, new types of organic and inorganic separator materials are being developed for Ni/Cd and Ni/H2 batteries. The separator material previously used in the NASA standard Ni/Cd was Pellon 2505, a 100-percent nylon-6 polymer that must be treated with zinc chloride (ZnCl2) to bond the fibers. Because of stricter Environmental Protection Agency regulation of ZnCl2 emissions, the battery community has been searching for new separators to replace Pellon 2505. As of today, two candidate separator materials have been identified; however, neither of the two materials have performed as well as Pellon 2505. The separator test procedures that were devised at Lewis are being implemented to expedite the search for new battery separators. The new test procedures, which are being carried out in the Separator Laboratory at Lewis, have been designed to guarantee accurate evaluations of the properties that are critical for sustaining proper battery operation. These properties include physical and chemical stability, chemical purity, gas permeability, electrolyte retention and distribution, uniformity, porosity, and area resistivity. A manual containing a detailed description of 12 separator test procedures has been drafted and will be used by the battery community to evaluate candidate separator materials for specific applications. These standardized procedures will allow for consistent, uniform, and reliable results that will ensure that separator materials have the desired properties for long life and good performance in secondary alkaline cells.

Source record↗
NASA NTRSDate not supplied

Size Effects on Laser Powder Bed Fusion and Laser Powder Directed Energy Deposition GRCop-42 Alloy

Additive manufacturing (AM) plays a significant role in the fabrication of regeneratively cooled rocket engine combustion chambers, where internal channels are used to transport high pressure propellants to keep the engine from overheating. Cooling channels are designed with thin walls between the cooling and combustion sides, experiencing high thermal and mechanical stresses from large temperature gradients and internal pressures. Hence, selecting materials suited for this environment and maintaining a high-quality processing for this critical application is of utmost importance. GRCop-alloys (Cu-Cr-Nb) were developed as an ideal material for combustion chambers due to its high conductivity and high strength at temperature, being employed as a structural member for the hotwall with excellent heat transfer capabilities. GRCop-42 (Cu, 4 at% Cr, 2 at% Nb) has significantly matured using the Laser Powder Bed Fusion (L-PBF) process through microstructure, mechanical and thermophysical properties and evaluations using hot-fire testing. Additionally, Laser Powder Directed Energy Deposition (LP-DED) has demonstrated successful deposition and geometry samples using GRCop-42. While the maturation in properties has focused on bulk material properties from standard test specimens, these cannot be extrapolated to be used in thin walls, as different features (i.e., microstructure, porosity, and surface texture) have a greater effect on thin walls, especially on AM structures built using L-PBF and LP-DED. This presentation provides an overview of the effects introduced by reducing the thickness on the fabrication, microstructure, surface metrology and subsequent mechanical properties of GRCop-42 using L-PBF and LP-DED as well as future work planned for this research.

Gabriel Demeneghi↗
NASA NTRS1974

Testing for hydrogen environment embrittlement - Experimental variables

Hydrogen embrittlement is classified into three types: internal reversible hydrogen embrittlement, hydrogen reaction embrittlement, and hydrogen environment embrittlement. Characteristics of and materials embrittled by these types of hydrogen embrittlement are discussed. Hydrogen environment embrittlement is reviewed in detail. Factors involved in standardizing test methods for detecting the occurrence of and evaluating the severity of hydrogen environment embrittlement are considered. The effects of test technique, hydrogen pressure, gas purity, strain rate, stress concentration factor, and test temperature are discussed.

Gray, H. R.↗
NASA NTRS1999

Pre-Flight Testing of Spaceborne GPS Receivers Using a GPS Constellation Simulator

The NASA Goddard Space Flight Center (GSFC) Global Positioning System (GPS) test facility has been established within the GSFC Guidance Navigation and Control Center. The GPS test facility is currently housing the STR2760 GPS satellite 40-channel attitude simulator and an STR4760 12-channel navigation simulator. The facility also contains a few other Goddard resources such as an atomic time standard test bed, a rooftop antenna platform and a radome. It provides a new capability of high dynamics GPS simulations for space flight that is unique within the aerospace community. The GPS facility gives a significant advantage in the development and support of GPS based technologies for position, attitude and precise time determination on-board a spacecraft, sounding rocket or balloon. The GPS simulator system is configured in a transportable rack and is available for GPS applications' component development as well as for spacecraft subsystem and system level testing at spacecraft integration and test sites. The GPS facility has been operational since early 1996 and has been already utilized by a few successful flight projects carrying GPS experiments, such as USA Seastar satellite and the first Argentine satellite SAC-A. The experience in the SAC-A pre-flight testing using the STR2760 simulator is summarized as well as the comparison with preliminary analysis of the GPS data from SAC-A telemetry.

Kizhner, Semion↗
NASA NTRS2001

Verifying Data Integrity of Electronically Scanned Pressure Systems at the NASA Glenn Research Center

The proper operation of the Electronically Scanned Pressure (ESP) System critical to accomplish the following goals: acquisition of highly accurate pressure data for the development of aerospace and commercial aviation systems and continuous confirmation of data quality to avoid costly, unplanned, repeat wind tunnel or turbine testing. Standard automated setup and checkout routines are necessary to accomplish these goals. Data verification and integrity checks occur at three distinct stages, pretest pressure tubing and system checkouts, daily system validation and in-test confirmation of critical system parameters. This paper will give an overview of the existing hardware, software and methods used to validate data integrity.

Panek, Joseph W.↗
NASA NTRS2026

Influence of Processing Parameters on the Mechanical Properties of 3D Printed Borosilicate Particulate Reinforced Polymer Composites

Emerging composite materials are expanding the potential of additive manufacturing and enabling applications previously restricted by traditional manufacturing methods. The multi-phase nature of these composite materials combined with the complex in-ternal geometry of additively manufactured parts have enabled unique behavior, and potentially new applications. Additionally, these materials can be pyrolyzed to create dense metal, ceramic, and glass parts with geometries typically not achievable by tra-ditional processes. Additive manufacturing of borosilicate glass-based systems can open new applications in nuclear engineering, astronomy, and bone regrowth therapy. To elucidate the process-parameter relationship of borosilicate-polylactic acid (PLA) composites, mechanical testing was conducted and compared with a pure polylactic acid polymer baseline. Test specimens were fabricated by fused-filament fabrication with minimal post-processing. Yield strength, ultimate strength, and elastic modulus were calculated from stress-strain curves. Optical and scanning electron microscopy were conducted to observe the specimen microstructure before and after testing. The highest compressive yield strength for the composite was 28.22 MPa, and the highest compressive yield strength for PLA was 49.30 MPa. Print orientation was found to benefit the composite material but have a detrimental effect on the pure matrix material. An elastic modulus of 2.66 GPa was recorded for the borosilicate-PLA composite at 100% infill, 1 shell wall, and layer lines parallel to compression axis. Microscopy revealed that lower modulus composite specimens had the particulates re-distributed within the matrix. Tensile testing was done according to a polymer testing standard, which caused difficulties obtaining consistent fracture within the gauge length.

mechanical testing↗
NASA NTRS2003

An Overview of the NASA Aerospace Flight Battery Systems Program

The NASA Aerospace Flight Battery Systems Program is an agency-wide effort aimed at ensuring the quality, safety, reliability and performance of flight battery systems for NASA applications. The program provides for the validation of primary and secondary cell and battery level technology advances to ensure their availability and readiness for use in NASA missions. It serves to bridge the gap between the development of technology advances and the realization and incorporation of these advances into mission applications. The program is led by the Glenn Research Center and involves funded task activities at each of the NASA mission centers and JPL. The overall products are safe, reliable, high quality batteries for mission applications. The products are defined along three product lines: 1. Battery Systems Technology - Elements of this task area cover the systems aspects of battery operation and generally apply across chemistries. This includes the development of guidelines documents, the establishment and maintenance of a central battery database that serves a central repository for battery characterization and verification test data from tests performed under the support of this program, the NASA Battery Workshop, and general test facility support. 2. Secondary Battery Technology - l h s task area focuses on the validation of battery technology for nickel-cadmium, nickel-hydrogen, nickel-metal-hydride and lithium-ion secondary battery systems. Standardized test regimes are used to validate the quality of a cell lot or cell design for flight applications. In this area, efforts are now concentrated on the validation and verification of lithium-ion battery technology for aerospace applications. 3. Primary Battery Technology - The safety and reliability aspects for primary lithium battery systems that are used in manned operations on the Shuttle and International Space Station are addressed in the primary battery technology task area. An overview of the task areas supported under this program will be presented.

Manzo, Michelle A.↗