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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Identifying the Accuracy of Surface Roughness for Metal Additive Manufacturing Parts Captured with Computed Tomography Scanning

Conventional surface roughness measurement techniques require direct access to internal surfaces, often necessitating destructive sectioning of test articles. Computed tomography (CT) offers a non-destructive alternative for internal surface characterization, but its application in metrology remains unstandardized and sensitive to machine resolution and operator technique. This study investigates the feasibility of using CT scanning to quantify areal surface roughness in metal AM heat exchanger tubes with three distinct internal geometries: ribbed, discrete W, and featureless. CT-derived surface parameters were extracted using custom Python scripts and compared to measurements obtained from a focus variation microscope calibrated against a known standard. Results show that CT-based roughness measurements closely matched microscope values for the discrete W specimen, deviations between CT and microscope measurements were minimal—less than 1 µm—indicating reliable reconstruction. In contrast, the ribbed and featureless specimens, with lower roughness values showed greater discrepancies. The findings suggest that CT scanning can be a viable non-destructive metrology tool for AM parts with surface roughness above approximately 8 µm. For smoother surfaces, current CT capabilities may not provide sufficient accuracy, highlighting the need for resolution-aware workflows and further standardization in CT-based surface metrology.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Evaluation of Progressive Failure Analysis and Modeling of Impact Damage in Composite Pressure Vessels

NASA White Sands Test Facility (WSTF) is leading an evaluation effort in advanced destructive and nondestructive testing of composite pressure vessels and structures. WSTF is using progressive finite element analysis methods for test design and for confirmation of composite pressure vessel performance. Using composite finite element analysis models and failure theories tested in the World-Wide Failure Exercise, WSTF is able to estimate the static strength of composite pressure vessels. Additionally, test and evaluation on composites that have been impact damaged is in progress so that models can be developed to estimate damage tolerance and the degradation in static strength.

Sanchez, Christopher M.↗
DOE OSTI2020

Sister Rod Destructive Examinations (FY20) Appendix E: Mechanical Testing

This report documents work performed under the Spent Fuel and Waste Disposition’s Spent Fuel and Waste Science and Technology program for the US Department of Energy (DOE) Office of Nuclear Energy (NE). This work was performed to fulfill Level 2 Milestone M2SF-21OR010201032, “ORNL High Burnup Confirmatory Demo Sibling Rod Testing Results,” within work package SF-21OR01020103 and is an update to the work reported in M2SF-19ORO010201026 and M2SF-19OR010201028.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Quantitative Non-Destructive Evaluation of Fatigue Damage Based on Multi-Sensor Fusion

Based on sensor fusion and machine learning, this project developed a novel non-destructive evaluation (NDE) methodology, which consists of a remaining useful life (RUL) prediction framework and regression models for predicting residual stress and full width at half maximum (FWHM). A series of fatigue testing experiments were conducted using 5052-H32 aluminum alloy specimens. All specimens were measured using linear ultrasonic (LU) and nonlinear ultrasonic (NLU) testing methods non-destructively. Machine learning models were developed to use LU and NLU measurements to predict loading condition, fatigue level, residual stress, and FWHM. It was demonstrated that the developed methodology could distinguish new and fatigue specimens with an accuracy of 97.53%. Also, the prediction errors for residual stress and FWHM were as low as 4.73% and 1.62%, respectively. An interactive database was created to publicly share the data generated from the project. It is envisioned that the developed NDE technology will equip manufacturers with a responsive screening system for incoming used metallic components, and potentially lead to a significant increase in using used metallic components for remanufacturing.

42 ENGINEERING↗
NASA NTRS2013

Common Practice Lightning Strike Protection Characterization Technique to Quantify Damage Mechanisms on Composite Substrates

To support FAA certification airworthiness standards, composite substrates are subjected to lightning direct-effect electrical waveforms to determine performance characteristics of the lightning strike protection (LSP) conductive layers used to protect composite substrates. Test results collected from independent LSP studies are often incomparable due to variability in test procedures & applied practices at different organizations, which impairs performance correlations between different LSP data sets. Under a NASA supported contract, The Boeing Company developed technical procedures and documentation as guidance in order to facilitate a test method for conducting universal common practice lightning strike protection test procedures. The procedures obtain conformity in future lightning strike protection evaluations to allow meaningful performance correlations across data sets. This universal common practice guidance provides the manufacturing specifications to fabricate carbon fiber reinforced plastic (CFRP) test panels, including finish, grounding configuration, and acceptable methods for pretest nondestructive inspection (NDI) and posttest destructive inspection. The test operations guidance elaborates on the provisions contained in SAE ARP5416 to address inconsistencies in the generation of damage protection performance data, so as to provide for maximum achievable correlation across capable lab facilities. In addition, the guidance details a direct effects test bed design to aid in quantification of the multi-physical phenomena surrounding a lightning direct attachment supporting validation data requirements for the development of predictive computational modeling. The lightning test bed is designed to accommodate a repeatable installation procedure to secure the test panel and eliminate test installation uncertainty. It also facilitates a means to capture the electrical waveform parameters in 2 dimensions, along with the mechanical displacement and thermal heating parameters which occur during lightning attachment. Following guidance defined in the universal common practice LSP test documents, protected and unprotected CFRP panels were evaluated at 20, 40 and 100KAmps. This report presents analyzed data demonstrating the scientific usefulness of the common practice approach. Descriptions of the common practice CFRP test articles, LSP test bed fixture, and monitoring techniques to capture the electrical, mechanical and thermal parameters during lightning attachment are presented here. Two methods of measuring the electrical currents were evaluated, inductive current probes and a newly developed fiberoptic sensor. Two mechanical displacement methods were also examined, optical laser measurement sensors and a digital imaging correlation camera system. Recommendations are provided to help users implement the common practice test approach and obtain LSP test characterizations comparable across data sets.

Szatkowski, George N.↗
NASA NTRS1994

Significant issues in proof testing: A critical appraisal

Issues which impact on the interpretation and quantification of proof test benefits are reviewed. The importance of each issue in contributing to the extra quality assurance conferred by proof testing components is discussed, particularly with respect to the application of advanced fracture mechanics concepts to enhance the flaw screening capability of a proof test analysis. Items covered include the role in proof testing of elastic-plastic fracture mechanics, ductile instability analysis, deterministic versus probabilistic analysis, single versus multiple cycle proof testing, and non-destructive examination (NDE). The effects of proof testing on subsequent service life are reviewed, particularly with regard to stress redistribution and changes in fracture behavior resulting from the overload. The importance of proof test conditions are also addressed, covering aspects related to test temperature, simulation of service environments, test media and the application of real-time NDE. The role of each issue in a proof test methodology is assessed with respect to its ability to: promote proof test practice to a state-of-the-art; aid optimization of proof test design; and increase awareness and understanding of outstanding issues.

Chell, G. G.↗
NASA NTRS2004

COTS Ceramic Chip Capacitors: An Evaluation of the Parts and Assurance Methodologies

Commercial-Off-The-Shelf (COTS) multilayer ceramic chip capacitors (MLCCs) are continually evolving to reduce physical size and increase volumetric efficiency. Designers of high reliability aerospace and military systems are attracted to these attributes of COTS MLCCs and would like to take advantage of them while maintaining the high standards for long-term reliable operation they are accustomed io when selecting military qualified established reliability (MIL-ER) MLCCs. However, MIL-ER MLCCs are not available in the full range of small chip sizes with high capacitance as found in today's COTS MLCCs. The objectives for this evaluation were to assess the long-term performance of small case size COTS MLCCs and to identify effective, lower-cost product assurance methodologies. Fifteen (15) lots of COTS X7R dielectric MLCCs from four (4) different manufacturers and two (2) MIL-ER BX dielectric MLCCs from two (2) of the same manufacturers were evaluated. Both 0805 and 0402 chip sizes were included. Several voltage ratings were tested ranging from a high of 50 volts to a low of 6.3 volts. The evaluation consisted of a comprehensive screening and qualification test program based upon MIL-PRF-55681 (i.e., voltage conditioning, thermal shock, moisture resistance, 2000-hour life test, etc.). In addition, several lot characterization tests were performed including Destructive Physical Analysis (DPA), Highly Accelerated Life Test (HALT) and Dielectric Voltage Breakdown Strength. The data analysis included a comparison of the 2000-hour life test results (used as a metric for long-term performance) relative to the screening and characterization test results. Results of this analysis indicate that the long-term life performance of COTS MLCCs is variable -- some lots perform well, some lots perform poorly. DPA and HALT were found to be promising lot characterization tests to identify substandard COTS MLCC lots prior to conducting more expensive screening and qualification tests. The results indicate that lot- specific screening and qualification are still recommended for high reliability applications. One significant and concerning observation is that MIL- type voltage conditioning (100 hours at twice rated voltage, 125 C) was not an effective screen in removing infant mortality parts for the particular lots of COTS MLCCs evaluated.

Brusse, Jay A.↗
DOE OSTI2021

UV-Fluorescence Imaging of Silicon PV Modules After Outdoor Aging and Accelerated Stress Testing

Fast, non-destructive, outdoor-compatible methods for photovoltaic module characterization are essential for monitoring module quality without disrupting energy production. UV-fluorescence (UVF) imaging of the encapsulant layer can be used for crack detection in the field. We show that UVF patterns vary widely between modules and types of applied stress. We propose that combining accelerated stress testing (e.g. thermal cycling and damp heat) with field investigations can help build understanding of different types of UVF, which are formed and subsequently quenched at varying rates. Ultimately, such understanding could enable estimating when cracks were formed.

41 EE - Solar Energy Technologies Office (EE-4S)↗
NASA NTRS2016

Single-Event Effect Testing of the Linear Technology LTC6103HMS8#PBF Current Sense Amplifier

The LTC6103HMS8#PBF (henceforth abbreviated as LTC6103) current sense amplifier from Linear Technology was tested for both destructive and non-destructive single-event effects (SEE) using the heavy-ion cyclotron accelerator beam at Lawrence Berkeley National Laboratory (LBNL) Berkeley Accelerator Effects (BASE) facility. During testing, the input voltages and output currents were monitored to detect single event latch-up (SEL) and single-event transients (SETs).

single-event effects (SEE)↗
DOE OSTI2020

Testing of UV Oxidation Process for Acetonitrile Destruction

The Hanford Site Effluent Treatment Facility (ETF) currently treats aqueous waste streams that include condensates from the 242-A evaporator, leachate from the Environmental Restoration Disposal Facility (ERDF), as well as laboratory wastes and, in the future, will treat liquid effluents from the Hanford Waste Treatment and Immobilization Plant (WTP) and Integrated Disposal Facility (IDF) leachate. Liquid effluents from the WTP will have significant concentrations of acetonitrile. Acetonitrile is formed by reaction of nitrates and sugar in the WTP low activity waste (LAW) melters and is prevalent in the submerged bed scrubber (SBS) and wet electrostatic precipitator (WESP) liquid effluents from WTP off-gas treatment. When these liquids are concentrated in the WTP Effluent Management Facility (EMF) evaporator in the direct feed low activity waste (DFLAW) flow-sheet, testing has shown that the majority of the acetonitrile partitions to the evaporator condensate. Since the evaporator condensate is directed to the ETF, this creates a potential issue with the ETF waste acceptance criteria and, specifically, the ETF Delisting Modification treatability envelope limits. Consequently, there is a need to assess possible mitigation approaches, one of which involves identification and assessment of potential treatment processes to destroy the acetonitrile, which is the subject of the present report.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1965

Force controlled solenoid drives microweld tester

Solenoid-driven device tests the integrity of a microweld joint between an electronic component lead wire and a wire ribbon by applying tension stress to the joint. Variable measured force is provided when either destructive or nondestructive testing is performed.

Source record↗
NASA NTRS2013

Status of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test as of 50,000 h and 900 kg Throughput

The NASA's Evolutionary Xenon Thruster (NEXT) project is developing the next-generation solar electric propulsion ion propulsion system with significant enhancements beyond the state-of-the-art NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) ion propulsion system in order to provide future NASA science missions with enhanced propulsion capabilities. As part of a comprehensive thruster service life assessment, the NEXT Long-Duration Test (LDT) was initiated in June 2005 to demonstrate throughput capability and validate thruster service life modeling. The NEXT LDT exceeded its original qualification throughput requirement of 450 kg in December 2009. To date, the NEXT LDT has set records for electric propulsion lifetime and has demonstrated 50,170 hours of operation, processed 902 kg of propellant, and delivered 34.9 MN-s of total impulse. The NEXT thruster design mitigated several life-limiting mechanisms encountered in the NSTAR design, dramatically increasing service life capability. Various component erosion rates compare favorably to the pretest predictions based upon semi-empirical ion thruster models. The NEXT LDT either met or exceeded all of its original goals regarding lifetime demonstration, performance and wear characterization, and modeling validation. In light of recent budget constraints and to focus on development of other components of the NEXT ion propulsion system, a voluntary termination procedure for the NEXT LDT began in April 2013. As part of this termination procedure, a comprehensive post-test performance characterization was conducted across all operating conditions of the NEXT throttle table. These measurements were found to be consistent with prior data that show minimal degradation of performance over the thruster's 50 kh lifetime. Repair of various diagnostics within the test facility is presently planned while keeping the thruster under high vacuum conditions. These diagnostics will provide additional critical information on the current state of the thruster, in regards to performance and wear, prior to destructive post-test analyses performed on the thruster under atmosphere conditions.

Life test↗
NASA NTRS2015

Status of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test as of 50,000 h and 900 kg Throughput

The NASA's Evolutionary Xenon Thruster (NEXT) project is developing the next-generation solar electric propulsion ion propulsion system with significant enhancements beyond the state-of-the-art NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) ion propulsion system in order to provide future NASA science missions with enhanced propulsion capabilities. As part of a comprehensive thruster service life assessment, the NEXT Long-Duration Test (LDT) was initiated in June 2005 to demonstrate throughput capability and validate thruster service life modeling. The NEXT LDT exceeded its original qualification throughput requirement of 450 kg in December 2009. To date, the NEXT LDT has set records for electric propulsion lifetime and has demonstrated 50,170 h of operation, processed 902 kg of propellant, and delivered 34.9 MN-s of total impulse. The NEXT thruster design mitigated several life-limiting mechanisms encountered in the NSTAR design, dramatically increasing service life capability. Various component erosion rates compare favorably to the pretest predictions based upon semi-empirical ion thruster models. The NEXT LDT either met or exceeded all of its original goals regarding lifetime demonstration, performance and wear characterization, and modeling validation. In light of recent budget constraints and to focus on development of other components of the NEXT ion propulsion system, a voluntary termination procedure for the NEXT LDT began in April 2013. As part of this termination procedure, a comprehensive post-test performance characterization was conducted across all operating conditions of the NEXT throttle table. These measurements were found to be consistent with prior data that show minimal degradation of performance over the thruster's 50 kh lifetime. Repair of various diagnostics within the test facility is presently planned while keeping the thruster under high vacuum conditions. These diagnostics will provide additional critical information on the current state of the thruster, in regards to performance and wear, prior to destructive post-test analyses performed on the thruster under atmosphere conditions.

Ion thruster↗
NASA NTRS1986

Nondestructive evaluation of adhesive bond strength using the stress wave factor technique

Acousto-ultrasonic nondestructive evaluation has been conducted to evaluate the adhesive bond strength between rubber and steel plates using the stress wave factor (SWF) measurement technique. Specimens with different bond strength were manufactured and tested using the SWF technique. Two approaches were used to define the SWF. One approach defines the SWF as the signal energy and the other approach defines the SWF as the square root of the zero moment of the frequency spectrum of the received signal. The strength of the rubber-steel adhesive joint was then evaluated using the destructive peel strength test method. It was observed that in both approaches higher values of the SWF measurements correspond to higher values of the peel strength test data. Therefore, these results show that the stress wave factor technique has the potential of being used in quality assurance of the adhesive bond strength between rubber and steel substrates.

Dos Reis, Henrique L. M.↗
NASA NTRS2019

High Velocity Impact Performance of a Dual Layer Thermal Protection System for the Mars Sample Return Earth Entry Vehicle

The Mars Sample Return (MSR) Earth Entry Vehicle (EEV) is currently planned on being released from its Micro-Meteorite/Orbital Debri (MM/OD) shielding housing about two days before the Earth entry phase. This leaves the EEV exposed to incoming MM/OD impacts, potentially damaging the heat shield and compromising its Entry, Decent, and Landing (EDL) integrity. Currently, two materials are proposed to comprise the MSR-EEV heat shield, a dual layer material Heat-shield for Extreme Entry Environment Technology (HEEET) and Phenolic Impregnated Carbon Ablator (PICA). PICA has been well characterized for OD class impacts, ~7km/s high mass impacts, from previous testing done in the Orion program, but hasn't under-gone extensive MM impact testing. HEEET is a rela-tively new material with minimal prior testing in re-gards to High Velocity Impacts (HVI). In order to in-form selectability of a material, it is crucial to under-stand the material performance when faced with an HVI, directly affecting mission success probability.The current measure of a Thermal Protection Sys-tem's (TPS) performance against an HVI is evaluating a thermally sized material against its derived Balistic Limit Equation (BLE). A BLE is generated empirically from multiple shots of HVI testing, and is used as a first order method in evaluating TPS's performance against the expected MM/OD environment. This method has proved useful for previous uniform densi-ty TPS materials, but has never been validated against a dual layer recession material such as HEEET. Testing in the MSR program for FY19 has a re-quirement to assess the effects of a dual layer TPS by testing various thicknesses of HEEET's Recession Layer, seen in Figure 1. From this data, BLE's will be derived for the individual thickness ratio samples, as well as the material as a whole to evaluate if a heritage form of the BLE can capture the complex physics associated with a dual layer system. Crater morpholo-gy will also be assessed with post-test Non-Destructive Evaluation (NDE) methods such as CT scanning to visualize if a BLE can well predict the associated pene-tration depths, since a BLE assumes full disinigration of the impacting particle and is generally only used to size a spherical crater ? disregarding any shrapenel effects from a high density impactor.To inform this analysis, expected MM environ-ments from the Meteoroid Engineering Model (MEM) and analytical equations for mass flux of incoming MM were evaluated against the notional MSR-EEV trajectory [1]. Using those dispersions, a monte-carlo was run to determine the most probable particle pa-rameters, as well as the riskiest in terms of full bondline penetration. From these probabilities, a test matrix was designed to test against bounding cases for the various parameters of the BLE: projectile density, projectile mass, projectile velocity, and the impact angle.This presentation will discuss the performance of the dual layer TPS material HEEET against a wide range of impact kinetic energies and densitites, as well as the comparison of HEEET to PICA in terms of MM/OD performance and selectability criteria.

Libben, B. J.↗
NASA NTRS2014

Buckling of a Longitudinally Jointed Curved Composite Panel Arc Segment for Next Generation of Composite Heavy Lift Launch Vehicles: Verification Testing Analysis

In this work, an all-bonded out-of-autoclave (OoA) curved longitudinal composite joint concept, intended for use in the next generation of composite heavy lift launch vehicles, was evaluated and verified through finite element (FE) analysis, fabrication, testing, and post-test inspection. The joint was used to connect two curved, segmented, honeycomb sandwich panels representative of a Space Launch System (SLS) fairing design. The overall size of the resultant panel was 1.37 m by 0.74 m (54 in by 29 in), of which the joint comprised a 10.2 cm (4 in) wide longitudinal strip at the center. NASTRAN and ABAQUS were used to perform linear and non-linear analyses of the buckling and strength performance of the jointed panel. Geometric non-uniformities (i.e., surface contour imperfections) were measured and incorporated into the FE model and analysis. In addition, a sensitivity study of the specimens end condition showed that bonding face-sheet doublers to the panel's end, coupled with some stress relief features at corner-edges, can significantly reduce the stress concentrations near the load application points. Ultimately, the jointed panel was subjected to a compressive load. Load application was interrupted at the onset of buckling (at 356 kN 80 kips). A post-test non-destructive evaluation (NDE) showed that, as designed, buckling occurred without introducing any damage into the panel or the joint. The jointed panel was further capable of tolerating an impact damage to the same buckling load with no evidence of damage propagation. The OoA cured all-composite joint shows promise as a low mass factory joint for segmented barrels.

mechanical/sub-structural testing↗