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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

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NASA NTRS1990

Splat-quench solidification of freely falling liquid-metal drops by impact on a planar substrate

Results are presented of a study of the splat-quench solidification of small, freely falling liquid drops of the alloy Nitronic 40W, which were allowed to impact on a solid, planar, horizontal substrate. The principal variable was the substrate material, with substrates of copper, alumina and fused quartz being used. The shapes of the solidified splats were correlated with a simplified model for the energetics of the splatting process and with the thermal conductivity of the substrate. The measured results are qualitatively in agreement with theoretical predictions, and suggestions are offered for a more comprehensive model of splat-quench solidification. A relationship between sessile droplet diameter and parent wire diameter is also presented and discussed.

Collings, E. W.↗

NASA NTRS1992

Optimal design of geodesically stiffened composite cylindrical shells

An optimization system based on the finite element code Computations Structural Mechanics (CSM) Testbed and the optimization program, Automated Design Synthesis (ADS), is described. The optimization system can be used to obtain minimum-weight designs of composite stiffened structures. Ply thickness, ply orientations, and stiffener heights can be used as design variables. Buckling, displacement, and material failure constraints can be imposed on the design. The system is used to conduct a design study of geodesically stiffened shells. For comparison purposes, optimal designs of unstiffened shells and shells stiffened by rings and stingers are also obtained. Trends in the design of geodesically stiffened shells are identified. An approach to include local stress concentrations during the design optimization process is then presented. The method is based on a global/local analysis technique. It employs spline interpolation functions to determine displacements and rotations from a global model which are used as 'boundary conditions' for the local model. The organization of the strategy in the context of an optimization process is described. The method is validated with an example.

Gendron, G.↗

NASA NTRS1992

Page turning system

A device for holding reading materials for use by readers without arm mobility is presented. The device is adapted to hold the reading materials in position for reading with the pages displayed to enable turning by use of a rubber tipped stick that is held in the mouth and has a pair of rectangular frames. The frames are for holding and positioning the reading materials opened in reading posture with the pages displayed at a substantially unobstructed sighting position for reading. The pair of rectangular frames are connected to one another by a hinge so the angle between the frames may be varied thereby varying the inclination of the reading material. A pair of bent spring mounted wires for holding opposing pages of the reading material open for reading without substantial visual interference of the pages is mounted to the base. The wires are also adjustable to the thickness of the reading material and have a variable friction adjustment. This enables the force of the wires against the pages to be varied and permits the reader to manipulate the pages with the stick.

Kerley, James J.↗

NASA NTRS1992

Optimal design of geodesically stiffened composite cylindrical shells

An optimization system based on general-purpose finite element code CSM Testbed and optimization program ADS is described. The system can be used to obtain minimum-mass designs of composite shell structures with complex stiffening arrangements. Ply thicknesses, ply orientations, and stiffener heights can be used as design variables. Buckling, displacement, and material failure constraints can be imposed on the design. The system is used to conduct a preliminary design study of geodesically stiffened shells. For comparison purposes, optimal designs of unstiffened shells, and ring and longitudinal stringer stiffened shells are also studied. Trends in the design of geodesically stiffened shells are identified. Features that enhance the capabilities and efficiency of the design system are described.

Gendron, G.↗

NASA NTRS1992

Variable frequency pulsed phase-locked loop method for measuring material nonlinearity

The design of a pressure vessel with an isothermal volume to measure changes in the natural velocities of material continuously over a wide temperature range is reported. Highly sensitive pulsed phase-locked loop technology is used to measure the natural velocity of fatigued aluminum 2024-T4 as a function of pressure at different temperatures. Second derivative variations with respect to pressure and temperature are found to exhibit order-of-magnitude changes at a gauge pressure near 950 kPa at room temperature. This indicates a significant change in certain combinations of second-order and higher-order elastic constants at relatively low pressures. Fractional frequency change as a function of applied pressure for aluminum 2024-T4 with fatigue damage is illustrated.

Yost, William T.↗

NASA NTRS1993

Detailed study of oxidation/wear mechanism in lox turbopump bearings

Wear of 440C angular contact ball bearings of the phase 2 high pressure oxygen turbopump (HPOTP) of the space shuttle main engine (SSME) has been studied by means of various advanced nondestructive techniques (NDT) and modeled with reference to all known material, design, and operation variables. Three modes dominating the wear scenario were found to be the adhesive/sheer peeling (ASP), oxidation, and abrasion. Bearing wear was modeled in terms of the three modes. Lacking a comprehensive theory of rolling contact wear to date, each mode is modeled after well-established theories of sliding wear, while sliding velocity and distance are related to microsliding in ball-to-ring contacts. Microsliding, stress, temperature, and other contact variables are evaluated with analytical software packages of SHABERTH(TM)/SINDA(TM) and ADORE(TM). Empirical constants for the models are derived from NIST experiments by applying the models to the NIST wear data. The bearing wear model so established precisely predicts quite well the average ball wear rate for the HPOTP bearings. The wear rate has been statistically determined for the entire population of flight and development bearings based on Rocketdyne records to date. Numerous illustrations are given.

Chase, T. J.↗

NASA NTRS1992

Local design optimization for composite transport fuselage crown panels

Composite transport fuselage crown panel design and manufacturing plans were optimized to have projected cost and weight savings of 18 and 45 percent, respectively. These savings are close to those quoted as overall NASA Advanced Composite Technology (ACT) program goals. Three local optimization tasks were found to influence the cost and weight of fuselage crown panels. The effects are summarized of each task and the task associated with a design cost model is described in detail. Studies were performed to evaluate the relationship between manufacturing cost and design details. A design tool was developed to aid in these studies. The development of the design tool included combining cost and performance constraints with a random search optimization algorithm. The resulting software was used in a series of optimization studies that evaluated the sensitivity of design variables, guidelines, criteria, and material selection on cost. The effect of blending adjacent design points in a full scale panel subjected to changing load distributions and local variations was shown to be important. Technical issues and directions for future work were identified.

Swanson, G. D.↗

NASA NTRS1992

Local design optimization for composite transport fuselage crown panels

Composite transport fuselage crown panel design and manufacturing plans were optimized to have projected cost and weight savings of 18 percent and 45 percent, respectively. These savings are close to those quoted as overall NASA ACT program goals. Three local optimization tasks were found to influence the cost and weight of fuselage crown panels. This paper summarizes the effect of each task and describes in detail the task associated with a design cost model. Studies were performed to evaluate the relationship between manufacturing cost and design details. A design tool was developed to aid in these investigations. The development of the design tool included combining cost and performance constraints with a random search optimization algorithm. The resulting software was used in a series of optimization studies that evaluated the sensitivity of design variables, guidelines, criteria, and material selection on cost. The effect of blending adjacent design points in a full scale panel subjected to changing load distributions and local variations was shown to be important. Technical issues and directions for future work were identified.

Swanson, G. D.↗

NASA NTRS1996

Effect of Processing Variables on the Microstructure and Mechanical Properties of Microporous Carbon Materials

Microporous carbon materials with different pore and strut sizes have been fabricated by the pyrolysis of furfuryl alcohol resin, triethylene glycol, and p-toluene sulfonic acid mixtures. The resulting materials were characterized by scanning electron microscopy and density measurements. The room temperature flexural strength and modulus of these materials decreases with increasing amount of acid curing agent.

Singh, M.↗

NASA NTRS2002

Process Cost Modeling for Multi-Disciplinary Design Optimization

For early design concepts, the conventional approach to cost is normally some kind of parametric weight-based cost model. There is now ample evidence that this approach can be misleading and inaccurate. By the nature of its development, a parametric cost model requires historical data and is valid only if the new design is analogous to those for which the model was derived. Advanced aerospace vehicles have no historical production data and are nowhere near the vehicles of the past. Using an existing weight-based cost model would only lead to errors and distortions of the true production cost. This report outlines the development of a process-based cost model in which the physical elements of the vehicle are costed according to a first-order dynamics model. This theoretical cost model, first advocated by early work at MIT, has been expanded to cover the basic structures of an advanced aerospace vehicle. Elemental costs based on the geometry of the design can be summed up to provide an overall estimation of the total production cost for a design configuration. This capability to directly link any design configuration to realistic cost estimation is a key requirement for high payoff MDO problems. Another important consideration in this report is the handling of part or product complexity. Here the concept of cost modulus is introduced to take into account variability due to different materials, sizes, shapes, precision of fabrication, and equipment requirements. The most important implication of the development of the proposed process-based cost model is that different design configurations can now be quickly related to their cost estimates in a seamless calculation process easily implemented on any spreadsheet tool. In successive sections, the report addresses the issues of cost modeling as follows. First, an introduction is presented to provide the background for the research work. Next, a quick review of cost estimation techniques is made with the intention to highlight their inappropriateness for what is really needed at the conceptual phase of the design process. The First-Order Process Velocity Cost Model (FOPV) is discussed at length in the next section. This is followed by an application of the FOPV cost model to a generic wing. For designs that have no precedence as far as acquisition costs are concerned, cost data derived from the FOPV cost model may not be accurate enough because of new requirements for shape complexity, material, equipment and precision/tolerance. The concept of Cost Modulus is introduced at this point to compensate for these new burdens on the basic processes. This is treated in section 5. The cost of a design must be conveniently linked to its CAD representation. The interfacing of CAD models and spreadsheets containing the cost equations is the subject of the next section, section 6. The last section of the report is a summary of the progress made so far, and the anticipated research work to be achieved in the future.

Bao, Han P.↗

NASA NTRS2002

Predicting Production Costs for Advanced Aerospace Vehicles

Bao, Han P.↗

NASA NTRS2007

Titan's Surface from Cassini RADAR SAR and High Resolution Radiometry Data of the First Five Flybys

The first five Titan flybys with Cassini's Synthetic Aperture RADAR (SAR) and radiometer are examined with emphasis on the calibration and interpretation of the high-resolution radiometry data acquired during the SAR mode (SAR-radiometry). Maps of the 2-cm wavelength brightness temperature are obtained coincident with the SAR swath imaging, with spatial resolution approaching 6 km. A preliminary calibration shows that brightness temperature in these maps varies from 64 to 89 K. Surface features and physical properties derived from the SAR-radiometry maps and SAR imaging are strongly correlated; in general, we find that surface features with high radar reflectivity are associated with radiometrically cold regions, while surface features with low radar reflectivity correlate with radiometrically warm regions. We examined scatterplots of the normalized radar cross-section sigma(exp o) versus brightness temperature, finding differing signatures that characterize various terrains and surface features. Implications for the physical and compositional properties of these features are discussed. The results indicate that volume scattering is important in many areas of Titan's surface, particularly Xanadu, while other areas exhibit complex brightness temperature variations consistent with variable slopes or surface material and compositional properties.

Titan↗

NASA NTRS2024

Plasma Produced Gaseous Species for Food, Seed, and Equipment Sanitization

Researchers at KSC have shown that plasma produced gaseous species have shown greater than 5.89 log reduction of inoculated coupons and sanitization (greater than 3 log reduction) of produce and 3D printed materials, though with more variable results. The results were obtained using a recirculating plasma system, with 1 L of air, 1 mL of H 2 O, and less than 500 W of power being the only consumable commodities. The work is versatile and enabling for future missions since the air and the produced gases can be reused or recycled on board the spacecraft.

Kenneth Engeling↗

NASA NTRS2026

Thermoplastic Matrix Composite Design for Cryotanks Using Multiscale Modeling and Bayesian Optimization

Designing lightweight, robust cryogenic storage tanks is critical for future launch vehicles, in-space propellant storage, and hydrogen powered aircraft. This work presents a multiscale modeling and Bayesian optimization framework for the design of thermoplastic matrix composite cryotanks. Molecular dynamics simulations are first used to determine temperature-dependent constituent properties for candidate thermoplastic matrices, which are homogenized to the lamina scale using NASA’s Multiscale Analysis Tool (NASMAT). These lamina properties, in combination with laminate family generation rules, are evaluated in HyperX structural optimization software to identify stacking sequences that meet all cryogenic load requirements. A Bayesian optimization framework is applied, with HyperX in the loop (via the HyperX API) to efficiently search across material and laminate design variables, yielding an optimized cryotank configuration with significant reductions in design cycle time compared to exhaustive search approaches.

thermoplastics↗

NASA NTRS2018

Plasticity and Damage Modeling of Stress Asymmetry and Dynamic Behavior of AFS Additive Manufactured Aluminum Alloy 2219

The Solid State Additive Manufacturing (AM) process referred as MELD that fabricated the samples in this study, provides a new path for repairing, coating, joining and additive manufacturing metals and metal matrix composites. This research will be the first application of a physics-based microstructure dependent internal state variable (ISV) plasticity and damage material model to capture the mechanical response of an AM Aluminum Alloy (AA) 2219 via the MELD process. In this research, a microstructure-based internal state variable (ISV) plasticity-damage model was used to capture the mechanical behavior of AFS 2219 aluminum alloy. Aeroprobe Corporation, creator and patent holder for the MELD process, fabricated the material by pushing a solid filler rod of AA2219-T861 material through a hollow rotating tool onto an AA2219 T851 plate substrate. As feedstock, solid or powder precursor metals are pushed through a nonconsumable rotating cylindrical tool. Herein, added layers are deposited and metallurgically bonded to substrate material or previously deposited layers by the heat generated from the rotating tool through plastic deformation of the filler material. Once a layer has been added, the tool height increases, and starts the deposition of the next layer. This process results in beneficial properties such as grain refinement, homogenization and reduced porosity (fully dense). This process will experience temperatures similar to those in the weld nugget zone (WNZ) in friction stir welding (FSW), ranging from 0.6-0.9 Tm, with Tm being the melting point of the material. MELD is highly scalable with AA deposition rates reaching over 1000 cm3/hr, which allows for MELD being used for repairs, coatings, and building components. A motivating factor driving the research for physics-based history dependent material modeling of MELD components is the ability to accurately capture the stress-state and strain rate dependence in the material caused by variations in material microstructure from the MELD processing of new or repaired components. The ISV model incorporates microstructural content and is consistent with continuum level kinematics, kinetics, and thermodynamics. These features allow the ISV model to capture large deformations at the structural scale using the kinematic and isotropic hardening, while microscale damage is obtained from the microstructural features. The benefits of the ISV model arise from the inclusion of structure-property relationships identified from microstructural characterization and experimentation. The Bauschinger effect (BE) is an important concept, vital in the accurate prediction of cyclic stress-strain response of ductile materials such as metals. The ISV model has been successfully used to capture the behavior and damage, and the BE of different aluminum alloys and steels. The ISV model uses kinematic and isotropic hardening to help capture deformations of the material at the macro scale. To understand this hardening relationship, calculating the kinematic and isotropic hardening relationship in the material is warranted for a high-fidelity model. Electron Backscattered Diffraction (EBSD) was used to characterize the as-fabricated microstructure, where a fully-dense equiaxed grain morphology with average grain size of 2.5 μm was observed. Microhardness mapping of the as-built structures, monotonic tension and compression experiments at both quasi-static (0.001/s) strain rates, tension-followed-by-compression and compression-followed-by-tension experiments were performed to obtain the set of plasticity and damage constants necessary to capture strain rate and stress state behavior of this additive material. To calibrate the plasticity-damage model, a single set of constants were determined to capture the different stress states the MELD AA2219. One set of the constants was determined from experimental true stress-strain curves for the tension and compression data. Additionally, microstructural information and data from the open literature were used as the other model constants. This research is a first of its kind for AFS AA2219, includes correlating the ISV model to the monotonic experimental results that capture the isotropic and kinematic plasticity mechanical response.

Rivera, O. G.↗

NASA NTRSDate not supplied

Spectral Characterization of Modern Spacecraft Materials

One of the observational parameters of interest in ground-based optical measurements is ascertaining material properties using broadband filter photometry and spectroscopy for orbiting targets. Broadband photometry can provide reflectance measurements that can aid in color-color indices and assess if objects can be classified into families or taxonomies. However, these reflectance properties can vary due to aspect angle, phase angle, and general degradation of the target’s exterior material. Spectral characterization can aid in material characterization utilizing known absorption bands and spectra signatures, but these signatures are affected by the same conditions described for remote observations. When utilizing ground-based measurements, it is well understood that material characterization is subject to variability due to space weathering and/or other external events (i.e., collision or explosion). The focus of this study is on space weathering effects on spacecraft materials in low Earth orbit. To better assess how materials are affected by the harsh space environment, specifically modern materials, a collection of materials was analyzed in both its pristine condition and after electron bombardment. This sample collection is part of an upcoming mission with the Materials International Space Station Experiment Flight Facility (MISSE-FF) that will be launched in 2022. These laboratory analyses on the samples will provide a ground truth to compare with the in-situ collected data. The data will also be stored in the NASA Johnson Space Center’s Spacecraft Materials Spectral Database that is available to U. S. citizens and maintained by the Orbital Debris Program Office. The following paper provides an overview of the materials investigated, laboratory and database overview, and spectral results for both pristine and post-electron exposed conditions. The spectral signature data highlights which materials are stable, or remain relatively unchanged, and which materials vary significantly due to exposure and material configuration (variations due to rotation of the sample on a flat surface). Initial results on changes in spectral directional reflectance of the materials as a function of incident illumination direction are also presented. This data also will benefit the space situational awareness community with spectral characterization of novel materials that can support their respective optical measurements focused on material identification.

Heather M Cowardin↗

NASA NTRSDate not supplied

Spectral Characterization of Modern Spacecraft Materials

One of the observational parameters of interest in ground-based optical measurements is ascertaining material properties using broadband filter photometry and spectroscopy for orbiting targets. Broadband photometry can provide reflectance measurements that can aid in producing color-color indices and assess if objects can be classified into families or taxonomies. However, these reflectance properties can vary due to aspect angle, phase angle, and general degradation of the target’s exterior material. Spectral characterization can aid in material characterization utilizing known absorption bands and spectral signatures, but these signatures are affected by the same conditions described for remote observations.When utilizing ground-based measurements, it is well understood that material characterization is subject to variability due to space weathering and/or other external events (i.e., collision or explosion). The focus of this study is on space weathering effects on spacecraft materials in low Earth orbit. To better assess how materials are affected by the harsh space environment, specifically modern materials, a collection of materials were analyzed in both their pristine condition and after electron bombardment. This sample collection is part of an upcoming mission with the Materials International Space Station Experiment Flight Facility (MISSE-FF) that will be launched in 2022. These laboratory analyses on the samples will provide a ground-truth to compare with the insitu collected data. The data will also be stored in the NASA Johnson Space Center’s Spacecraft Materials Spectral Database that is available to U.S. citizens and maintained by the Orbital Debris Program Office. The following paper provides an overview of the materials investigated, laboratory, and database overview, and spectral results for both pristine and post-electron exposed conditions. The spectral signature data highlights which materials are stable, or remain relatively unchanged, and which materials vary significantly due to exposure and material configuration (variations due to rotation of the sample on a flat surface).Initial results on changes in spectral directional reflectance of the materials as a function of incident illumination direction are also presented.This data also will benefit the space situational awareness community with spectral characterization of novel materials that can support their respective optical measurements focused on material identification.

Heather M. Cowardin↗

NASA NTRS1985

Measured acoustic properties of variable and low density bulk absorbers

Experimental data were taken to determine the acoustic absorbing properties of uniform low density and layered variable density samples using a bulk absober with a perforated plate facing to hold the material in place. In the layered variable density case, the bulk absorber was packed such that the lowest density layer began at the surface of the sample and progressed to higher density layers deeper inside. The samples were placed in a rectangular duct and measurements were taken using the two microphone method. The data were used to calculate specific acoustic impedances and normal incidence absorption coefficients. Results showed that for uniform density samples the absorption coefficient at low frequencies decreased with increasing density and resonances occurred in the absorption coefficient curve at lower densities. These results were confirmed by a model for uniform density bulk absorbers. Results from layered variable density samples showed that low frequency absorption was the highest when the lowest density possible was packed in the first layer near the exposed surface. The layers of increasing density within the sample had the effect of damping the resonances.

Dahl, M. D.↗