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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
NASA NTRS1995

Thermal spray processing

Thermal spray processing has been used for a number of years to cost-effecticely apply TBC's for a wide range of heat engine applications. In particular, bond coats are applied by plasma spray and HVOF techniques and partially-stabilized zirconia top coats are applied by plasma spray methods. Thermal spray involves melting and rapid transport of the molten particles to the substrate, where high-rate solidification and coating build-up occur. It is the very nature of this melt processing that leads to the unique layered microstructure, as well as the apparent imperfections, so readily identified with thermal spray. Modeling the process, process-induced residual stresses, and thermal conductivity will be discussed in light of a new understanding of porosity and its anisotropy. Microcracking can be understood using new approaches, allowing a fuller view of the processing-performance connection. Detailed electron microscopic, novel neutron diffraction and fracture analysis of the deposits can lead to a better understanding of how overall microstructure can be controlled to influence critical properties of the deposited TBC system.

Herman, H.↗
NASA NTRSDate not supplied

Establishing and Maintaining the Digital Thread of Additively Manufactured Materials and Applications

Additive Manufacturing (AM) and Integrated Computational Materials Engineering (ICME) are complementary enabling technologies for design and manufacturing of “fit-for-purpose” materials. Both technologies will impact rapid material design, reduction in cost- and time-to-market for new applications, and discovery and implementation of new materials. An ICME approach to design, however, requires experimentally validated material models at multiple length and time scales, an integrated framework that can connect analysis tools with one another to ensure the digital thread of an application is maintained, and the manufacturing (e.g., AM) capability to leverage processing-structure-property-performance (PSPP) relationships to achieve spatially varying material properties where desired. AM enables the implementation of the design of an optimized, spatially varying microstructure through careful selection of the processing parameters used during an additively manufactured build. In order to establish these PSPP relations, a large amount of data is necessary, and that data must be properly captured, analyzed and maintained in an information management system that can establish the required traceability between various aspects of the design process to ensure an application’s digital thread is maintained (from design to end of life). Such an information management system must be able to capture feedstock material pedigree, resulting microstructure from various build parameters, subsequent mechanical properties derived from testing, developed material models, and enable spatial variations in material assignment in an engineering application. Furthermore, the information management system should be easily integrated with traditionally engineered materials in a single, centralized platform to enable an ICME optimization tool to explore both types of manufacturing processes. At NASA GRC, a robust, 21st century materials information management system has been previously developed with a focus towards enabling ICME. In this work, GRC’s ICME schema is extended to accommodate additively manufactured materials, enabling storage of both traditionally and additively manufactured materials in the same construct. The methodology for properly capturing additively manufactured materials across the entire material lifecycle is presented, following the previously established database best practices, as a potential framework for establishing PSPP relationships for additively manufactured materials and applying them to engineering applications.

Data management↗
NASA NTRS2022

Coupling Carbon Oxidation and Surface Recession in Direct-Simulation Monte Carlo Code, SPARTA

Ablative thermal protection system (TPS) materials for spacecraft are composites that are often made out of carbon-based reinforcement and a polymeric matrix. They endure high-temperature oxidation and surface recession when re-entering Earth’s atmosphere. Ablation is the result of many coupled and competing thermal, mechanical, and chemical phenomena, and it is difficult to isolate the role of each on the overall degradation of the TPS. Here we develop an ablation model for material recession coupled explicitly to finite rate carbon oxidation in complex microstructures. In this work, Stochastic PArallel Rarified-gas Time-accurate Analyzer (SPARTA), a direct-simulation Monte Carlo (DSMC) code, is modified to allow oxidation-driven ablation of implicitly defined carbon surfaces. In SPARTA, implicit surfaces are generated from the grid corner point values via a marching cubes algorithm, therefore creating a new set of surface elements every time ablation is performed. The finite-rate oxidation model developed by Gopalan et. al, was adapted to tally surface reactions and other surface data on a per-grid cell basis. The ablation functionality was also adjusted so once the reactions have occurred, the number of reactions leading to CO formation can be converted to corner point reduction values; therefore, carbon removal is directly proportional to surface recession. We also develop robust algorithms which handle the evolution of the flow cells and solid material regions, including split cells (flow cell divided in two by a solid surface). Finally, we demonstrate our implicit chemistry model for 2D and 3D geometries by producing reaction statistics and detailed visualization of oxidation-induced material recession at the microscale.

V Arias↗
NASA NTRS1974

Microdosimetry and the radiation danger of cosmic rays

The radiation danger of space flights is due primarily to intensive proton fluxes accompanying solar flares and heavy multiple charged ions in galactic cosmic radiation. Evaluation of the biological effect of these kinds of rays is based on calculations of tissue dose, taking into account the formation of secondary radiation in shielding and tissue. The essential role in such calculations is played by the dependence of the factor of quality on linear energy transfer (LET) of these charged particles. Recommendations concerning the dependence of the quality factor on LET are based on radiobiological experiments carried out on many biological systems using various kinds of rays, including heavy ions with energies in the 1-10 Mev/nucleon range. Justification of the results of these experiments, as well as their extrapolation to other energies, requires development of a model description of the radiation effect of charged particles on biological microstructures.

Gunter, K.↗
NASA NTRS1991

Mesospheric KHI signatures in reconstructed broadband rocket probe data

In an accepted method of measuring D region electron density with a rocket-borne dc-mode Langmuir probe, the resulting fine-structure signal is modified by a high-pass filter. While this form of data has been successfully used for power spectral analysis, it fails to reveal important spatial domain features without further processing. It is demonstrated that the broadband signal can be recovered by use of a digital filter that corrects for the on-board high-pass filter effects. The D-region broadband structure so recovered for a daytime equatorial flight shows variations in electron density consistent with a model of Kelvin-Helmholtz billows, and not consistent with inertial range turbulence. The isolated regions of irregularity are about 100 m thick near an altitude of 75 km, imbedded in a region with a staircase-structure electron density profile with about 200-m steps. Suggestive similarities to a numerical model of KHI are to undersea observations of KHI-caused microstructure are shown.

Parker, Jay W.↗
NASA NTRS1997

Sulfur Impurities and the Microstructure of Alumina Scales

The relationship between the microstructure of alumina scales, adhesion, and sulfur content was examined through a series of nickel alloys oxidized in 1100 to 1200 deg. C cyclic or isothermal exposures in air. In cyclic tests of undoped NiCrAl, adhesion was produced when the sulfur content was reduced, without any change in scale microstructure. Although interfacial voids were not observed in cyclic tests of NiCrAl, they were promoted by long-term isothermal exposures, by sulfur doping, and in most exposures of NiAl. Two single crystal superalloys, PWA 1480 and Rene' N5, were also tested, either in the as-received condition or after the sulfur content had been reduced to less than 1 ppmw by hydrogen annealing. The unannealed alloys always exhibited spalling to bare metal, but interfacial voids were not observed consistently. Desulfurized PWA 1480 and Rene' N5 exhibited remarkable adhesion and no voidage for either isothermal or cyclic exposures. The most consistent microstructural feature was that, for the cases where voids did form, the scale undersides exhibited corresponding areas with ridged oxide grain boundaries. Voids were not required for spallation nor were other microstructural features essential for adhesion. These observations are consistent with the model whereby scale spallation is controlled primarily by interfacial sulfur segregation and the consequent degradation of oxide-metal bonding.

Smialek, James L.↗
NASA NTRS1997

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

Since 1986, the NASA-Langley Research Center has sponsored the NASA-UVa Light Alloy and Structures Technology (LA2ST) Program at the University of Virginia (UVa). The fundamental objective of the LA2ST program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures. The LA2ST program has aimed to product relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies. The scope of the LA2ST Program is broad. Research areas include: (1) Mechanical and Environmental Degradation Mechanisms in Advanced Light Metals and Composites, (2) Aerospace Materials Science, (3) Mechanics of materials for Aerospace Structures, and (4) Thermal Gradient Structures. A substantial series of semi-annual progress reports issued since 1987 documents the technical objectives, experimental or analytical procedures, and detailed results of graduate student research in these topical areas.

Gangloff, Richard P.↗
NASA NTRS2005

Modeling for Ultrasonic Health Monitoring of Foams with Embedded Sensors

In this report analytical and numerical methods are proposed to estimate the effective elastic properties of regular and random open-cell foams. The methods are based on the principle of minimum energy and on structural beam models. The analytical solutions are obtained using symbolic processing software. The microstructure of the random foam is simulated using Voronoi tessellation together with a rate-dependent random close-packing algorithm. The statistics of the geometrical properties of random foams corresponding to different packing fractions have been studied. The effects of the packing fraction on elastic properties of the foams have been investigated by decomposing the compliance into bending and axial compliance components. It is shown that the bending compliance increases and the axial compliance decreases when the packing fraction increases. Keywords: Foam; Elastic properties; Finite element; Randomness

Wang, L.↗
NASA NTRS2008

Verifying and Validating Proposed Models for FSW Process Optimization

This slide presentation reviews Friction Stir Welding (FSW) and the attempts to model the process in order to optimize and improve the process. The studies are ongoing to validate and refine the model of metal flow in the FSW process. There are slides showing the conventional FSW process, a couple of weld tool designs and how the design interacts with the metal flow path. The two basic components of the weld tool are shown, along with geometries of the shoulder design. Modeling of the FSW process is reviewed. Other topics include (1) Microstructure features, (2) Flow Streamlines, (3) Steady-state Nature, and (4) Grain Refinement Mechanisms

Schneider, Judith↗
NASA NTRS2012

NOR-USA Scientific Traverse of East Antarctica: Science and Logistics on a Three-Month Expedition Across Antarctica's Farthest Frontier

Dr. Albert's current research is centered on transfer processes in porous media, including air-snow exchange in the Polar Regions and in soils in temperate areas. Her research includes field measurements, laboratory experiments, and theoretical modeling. Mary conducts field and laboratory measurements of the physical properties of natural terrain surfaces, including permeability, microstructure, and thermal conductivity. Mary uses the measurements to examine the processes of diffusion and advection of heat, mass, and chemical transport through snow and other porous media. She has developed numerical models for investigation of a variety of problems, from interstitial transport to freezing of flowing liquids. These models include a two-dimensional finite element code for air flow with heat, water vapor, and chemical transport in porous media, several multidimensional codes for diffusive transfer, as well as a computational fluid dynamics code for analysis of turbulent water flow in moving-boundary phase change problems.

Albert, Mary R.↗
NASA NTRS2025

Physics-Based Modeling and Simulation of Self-Reacting Friction Stir Welding Using Computational Fluid Dynamics

A physics-based model was developed to simulate the behavior of material in a self-reacting friction stir welding (SR-FSW) process for the joining of metals. This steady-state model builds upon fundamental computational fluid dynamic (CFD) principles within Ansys Fluent to solve the discretized equations. The effective viscosity is calculated using a viscoplastic model using a Sheppard-Wright formulation of flow stress. Numerous advancements have been made in the incorporated physics including (1) temperature-dependent material properties; (2) locally adaptable flow and thermal boundary conditions; and (3) adapting material properties in nugget in response to microstructural changes. Simulation strategies to accelerate computation and improve numerical stability include adapting the mesh refinement and solver relaxation factors during simulation. The result is a highly robust and computationally efficient model capable of providing the material flow and temperature history across the domain. As material history determines the local microstructure and ultimately weld strength, an accurate and detailed physics-based model has the potential to accelerate SR-FSW process development. The model is highly adaptable to changes in process parameters, tool design, or alloy.

Process Modeling↗
NASA NTRS2003

Evolution of Local Microstructures: Spatial Instabilities in Coarsening Clusters

Diffusion-limited capillarity-driven coarsening of precipitates is an important and intensively studied phenomenon. The classic coarsening theory developed by Lifshitz and Syozov and Wagner (LSW theory) is limited to infinitesimally small volume fractions, V(sub nu), therefore neglects all direct interparticle interactions. This work uses modeling and holographic imaging to compare coarsening rates in "high" volume fraction versus low volume fraction microstructures by observing mixed-dimensional droplets (spherical caps on a surface coarsening by two-dimensional diffusion) during ground-based investigations. The method involves filling a cell with selected homogeneous parent phase, and cooling below the consolute temperature to the isopycnic temperature in the two-phase region of a monotectic system. A microgravity holographic experiment is required for three-dimensional observations to minimize sedimentation during long-term coarsening. Determination of sizes and positions of the many droplets in the holographic images requires automation. We have developed software for automated data analysis, and demonstrated good agreement between regenerated maps and scaled photographs of the original holograms for mixed dimensional coarsening. The results of these experiments were presented in a formal microgravity Science Concept Review (SCR) on December 18, 2000.

Source record↗
NASA NTRS2003

Microsample Characterization of Coatings for Grcop-84 for High Heat Flux Applications

A multidisciplinary Johns Hopkins University-NASA Glenn team is undertaking a collaborative research program to elucidate and model the thermal stability and mechanical integrity of candidate coatings for GRCop-84. GRCop-84 is a high conductivity, high strength copper alloy that was recently developed at NASA Glenn for use in high temperature, high heat flux applications. With potential applications in rocket motor combustion chamber liners, nozzle ramps and other actively cooled structures, this new material offers great potential for decreasing weight and increasing reliability of third generation reusable launch vehicles. Current emphasis has turned toward the development of environmentally resistant and thermal barrier coatings for this alloy. Metallic coatings such as NiCrAlY and Cu-8-30%Cr have shown promise in: prohibiting blanching, reducing dog-house failures, increasing operating temperatures and decreasing cooling requirements. The focus of this research program is to develop a fundamental understanding of the substrate-coating interactions that occur during thermal cycling (inter-diffusion, viscoplasticity, morphological evolution, crack formation, etc.) and to derive a science-based protocol for future coating selection, optimization and reliability assurance. The microsample tensile testing approach adopted for this study allows us to characterize small-scale and highly scale-specific coatings and properties in a way not possible by conventional means. In addition to providing much needed design data, the integration of microsample testing with detailed microstructural observations provides a mechanistic foundation for coating optimization and life prediction modeling.

Hemker, Kevin↗
NASA NTRSDate not supplied

A Convolutional Neural Network for Multiscale Modeling of Composite Materials

An artificial convolutional neural network was created to efficiently mimic a micromechanics model, the High Fidelity Generalized Method of Cells, for use in multi-scale structural finite element analysis. The network was found to quickly and accurately replicate the stiffness predicted by the micromechanics model using a 2D image of an idealized representative volume element of a fiber/matrix microstructure. The long-term goal of this work is to efficiently apply multi-scale methods for predicting the damage progression of a composite structure.

Composites↗
NASA NTRS2009

Application of an Elongated Kelvin Model to Space Shuttle Foams

The space shuttle foams are rigid closed-cell polyurethane foams. The two foams used most-extensively oil space shuttle external tank are BX-265 and NCFL4-124. Because of the foaming and rising process, the foam microstructures are elongated in the rise direction. As a result, these two foams exhibit a nonisotropic mechanical behavior. A detailed microstructural characterization of the two foams is presented. Key features of the foam cells are described and the average cell dimensions in the two foams are summarized. Experimental studies are also conducted to measure the room temperature mechanical response of the two foams in the two principal material directions (parallel to the rise and perpendicular to the rise). The measured elastic modulus, proportional limit stress, ultimate tensile strength, and Poisson's ratios are reported. The generalized elongated Kelvin foam model previously developed by the authors is reviewed and the equations which result from this model are summarized. Using the measured microstructural dimensions and the measured stiffness ratio, the foam tensile strength ratio and Poisson's ratios are predicted for both foams and are compared with the experimental data. The predicted tensile strength ratio is in close agreement with the measured strength ratio for both BX-265 and NCFI24-124. The comparison between the predicted Poisson's ratios and the measured values is not as favorable.

Sullivan, Roy M.↗
NASA NTRS2022

Multiscale Progressive Failure Analysis of 3D Woven Composites

Application of three-dimensional (3D) woven composites is growing as an alternative to the use of ply-based composite materials. However, the design, analysis, modeling, and optimization of these materials is more challenging due to their complex and inherently multiscale geometries. Herein, a multiscale modeling procedure, based on efficient, semi-analytical micromechanical theories rather than the traditional finite element approach, is presented and applied to a 3D woven carbon–epoxy composite. A crack-band progressive damage model was employed for the matrix constituent to capture the globally observed nonlinear response. Realistic microstructural dimensions and tow-fiber volume fractions were determined from detailed X-ray computed tomography (CT) and scanning electron microscopy data. Pre-existing binder-tow disbonds and weft-tow waviness, observed in X-ray CT scans of the composite, were also included in the model. The results were compared with experimental data for the in-plane tensile and shear behavior of the composite. The tensile predictions exhibited good correlations with the test data. While the model was able to capture the less brittle nature of the in-plane shear response, quantitative measures were underpredicted to some degree.

3D woven composites↗
NASA NTRS2002

Minimizing Segregation During the Controlled Directional Solidification of Dendritic Alloys Publication: Metallurgical and Materials Transactions

Gravity-driven thermosolutal convection that arises during controlled directional solidification (DS) of dendritic alloys promotes detrimental macro-segregation (e.g. freckles and steepling) in products such as turbine blades. Considerable time and effort has been spent to experimentally and theoretically investigate this phenomena; although our knowledge has advanced to the point where convection can be modeled and accurately compared to experimental results, little has been done to minimize its onset and deleterious effects. The experimental work demonstrates that segregation can be. minimized and microstructural uniformity promoted when a slow axial rotation is applied to the sample crucible during controlled directional solidification processing. Numerical modeling utilizing continuation and bifurcation methods have been employed to develop accurate physical and mathematical models with the intent of identifying and optimizing processing parameters.

Grugel, R. N.↗
NASA NTRS2010

Microscopic Scale Simulation of the Ablation of Fibrous Materials

This slide presentation reviews the ablation by oxidation of carbon-fiber preforms impregnated in carbonized phenolic-formaldehyde matrix is modeled at microscopic scale. Direct numerical simulations show that the matrix ablates in volume leaving the carbon fibers exposed. This is due to the fact that the reactivity of carbonized phenolics is higher than the reactivity of carbon fibers. After the matrix is depleted, the fibers ablate showing progressive reduction of their diameter. The overall material recession occurs when the fibers are consumed. Two materials with the same carbon-fiber preform, density and chemical composition, but with different matrix distributions are studied. These studies show that at moderate temperatures (< 1000K) the microstructure of the material influences its recession rate; a fact that is not captured by current models that are based on chemical composition only. Surprisingly, the response of these impregnated-fiber materials is weakly dependent on the microstructure at very high temperatures (e.g., Stardust peak heating conditions: 3360K).

Lachaud, Jean↗