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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

A Nonlinear Viscoelastic Model for Ceramics at High Temperatures

High-temperature creep behavior of ceramics is characterized by nonlinear time-dependent responses, asymmetric behavior in tension and compression, and nucleation and coalescence of voids leading to creep rupture. Moreover, creep rupture experiments show considerable scatter or randomness in fatigue lives of nominally equal specimens. To capture the nonlinear, asymmetric time-dependent behavior, the standard linear viscoelastic solid model is modified. Nonlinearity and asymmetry are introduced in the volumetric components by using a nonlinear function similar to a hyperbolic sine function but modified to model asymmetry. The nonlinear viscoelastic model is implemented in an ABAQUS user material subroutine. To model the random formation and coalescence of voids, each element is assigned a failure strain sampled from a lognormal distribution. An element is deleted when its volumetric strain exceeds its failure strain. Element deletion has been implemented within ABAQUS. Temporal increases in strains produce a sequential loss of elements (a model for void nucleation and growth), which in turn leads to failure. Nonlinear viscoelastic model parameters are determined from uniaxial tensile and compressive creep experiments on silicon nitride. The model is then used to predict the deformation of four-point bending and ball-on-ring specimens. Simulation is used to predict statistical moments of creep rupture lives. Numerical simulation results compare well with results of experiments of four-point bending specimens. The analytical model is intended to be used to predict the creep rupture lives of ceramic parts in arbitrary stress conditions.

Powers, Lynn M.↗
NASA NTRS1971

The role of creep in high temperature low cycle fatigue.

The significance of the role that creep can play in governing high-temperature, low-cycle fatigue resistance is investigated by conducting strain cycling tests on two high-temperature stainless steel alloys and making concurrent measurements of stress, temperature, and strain at various frequencies. The results are then analyzed in terms of damage imposed by creep and fatigue components. It is shown that creep can play an important and sometimes dominant role in low cycle fatigue at high temperatures. The results of the study include the findings that: (1) the simple life-fraction theory described is adequate for calculating creep damage when the cyclic creep rupture curve is used as a basis for analysis; (2) a method of universal slopes originally developed for room temperature use is sufficiently accurate at high temperature to be used to calculate pure fatigue damage; and (3) a linear creep-fatigue damage rule can explain the transitions observed from one failure mode to another.

Manson, S. S.↗
NASA NTRS1989

Analysis of damage in MMC components using an internal state variable model

A metal-matrix composite (MMC) model was developed which includes the concept of damage evolution. The evolution of damage is assumed to be governed by a Kachanov-type equation. This viscoplastic damage model was implemented in the finite element code, MARC. Both uniaxial (creep) and multiaxial (an internally pressurized thick-walled cylinder) problems were analyzed using this implementation. Some preliminary results are presented which consider monotonic (constant) loadings. The creep curves including damage for four fiber orientations are presented. As expected, the minimum creep occurs when load is applied in a direction parallel to the fibers. The tangential strains at the inner radius of a thick-walled MMC-cylinder for four fiber orientations are shown with damage included. The cylinder exhibits the maximum creep resistance when the fibers are oriented in the circumferential direction, perpendicular to the axis of the cylinder. Time-to-failure for the thick-walled cylinder for the same fiber orientation angles is also shown. As expected, the life of the cylinder can be increased by orientating the fibers in the circumferential direction, perpendicular to the axis of the cylinder. The results, although qualitative, indicate that significant benefits in creep-resistance and service life can be achieved by using MMC materials as structural materials for high-temperature design.

Arya, V. K.↗
NASA NTRS2000

A Study of Single Crystal Fatigue Failure Criteria

This paper presents the results of a study whose objective was to study the applicability of different failure equations in modeling low cycle fatigue (LCF) test data for single crystal test specimens. A total of four failure criteria were considered in this study. One of the failure equations was developed by Pratt & Whitney and is based on normal and shear strains on the primary crystallographic slip planes of the single crystal material. Other failure equations considered are based on isotropic criteria. Because these failure equations were originally developed for isotropic materials such as structural steel, they were modified to be applicable to the single crystal slip systems of the LCF specimen material. By observing how closely the various equations were able to reduce the scatter in the LCF test data, the applicability of those equations in modeling the LCF test data was assessed. It is desired to subsequently use the failure equation with the highest correlation in the development of a new single crystal failure criterion for the Alternative Turbopump Development (ATD) for the space shuttle main engine (SSME) High Pressure Fuel Turbopump (HPFTP).

Sayyah, Tarek↗
NASA NTRS1991

Thermomechanical and bithermal fatigue behavior of cast B1900 + Hf and wrought Haynes 188

High temperature thermomechanical and bithermal fatigue behavior was investigated for two superalloys: cast nickel-base B1900+Hf and wrought cobalt-base Haynes 188. Experimental results were generated to support development of an advanced thermal fatigue life prediction method. Strain controlled thermomechanical and load-controlled, strain-limited, bithermal fatigue tests were used to determine the fatigue crack initiation and cyclic stress-strain response characteristics of superalloys. Bithermal temperatures of 483 and 871 C were used for B1900+Hf, and 316 and 760 C for Haynes 188. Thermomechanical fatigue tests were conducted by using maximum and minimum temperatures corresponding to those for the bithermal experiments. Lives cover the range from about 10 to 3000 cycles to failure. Isothermal fatigue results obtained previously are also discussed.

Halford, Gary R.↗
NASA NTRS1999

Effects of Internal and External Hydrogen on Inconel 718

Internal hydrogen embrittlement (IHE) and hydrogen environment embrittlement (HEE) tensile and bend crack growth tests were performed on Inconel 718. For the IHE tests, the specimens were precharged to approximately 90 ppm hydrogen by exposure to 34.5 MPa H2 at 650 C. The HEE tests were performed in 34.5 MPa H2. Parameters evaluated were test temperature, strain rate for smooth and notch specimen geometries. The strain rate effect was very significant at ambient temperature for both IHE and HEE and decreased with increasing temperatures. For IHE, the strain rate effect was neglible at 260'C, and for HEE the strain rate effect was neglible at 400 C. At low temperatures, IHE was more severe than HEE, and at high temperatures HEE was more severe than IHE with a cross over temperature about 350 C. At 350 C, the equilibrium hydrogen concentration in Inconel 718 is about 50% lower than the hydrogen content of the precharged IHE specimens. Dislocation hydrogen sweeping of surface absorbed hydrogen was the likely transport mechanism for increasing the hydrogen concentration in the HEE tests sufficiently to produce the same degree of embrittlement as that of the more highly hydrogen charged IHE specimens. The main IHE fracture characteristic was formation of large, brittle flat facets, which decreased with increasing test temperature. The IHE fracture matrix surrounding the large facets ranged between brittle fine faceted to microvoid ductility depending upon strain rate, specimen geometry as well as temperature. The HEE fractures were characteristically fine featured, transgranular and brittle with a significant portion forming a "saw tooth" crystallographic pattern. Both IHE and HEE fractures were predominantly along the {1 1 1) slip and twin boundaries. With respect to embrittlement mechanism, it was postulated that dislocation hydrogen sweeping and hydrogen enhanced localized plasticity were active in HEE and IHE for concentrating hydrogen along (1 1 1) slip and twin planes. Final brittle failure occurred by hydrogen induced planer decohesion.

Walter, R. J.↗
NASA NTRS1985

Elevated temperature biaxial fatigue

A 3 year experimental program for studying elevated temperature biaxial fatigue of a nickel based alloy Hastelloy-X has been completed. A new high temperature fatigue test facility with unique capabilities has been developed. Effort was directed toward understanding multiaxial fatigue and correlating the experimental data to the existing theories of fatigue failure. The difficult task of predicting fatigue lives for nonproportional loading was used as an ultimate test for various life prediction methods being considered. The primary means of reaching improved understanding were through several critical nonproportional loading experiments. The direction of cracking observed on failed specimens was also recorded and used to guide the development of the theory. Cyclic deformation responses were permanently recorded digitally during each test. It was discovered that the cracking mode switched from primarily cracking on the maximum shear planes at room temperature to cracking on the maximum normal strain planes at 649 C. In contrast to some other metals, loading path in nonproportional loading had little effect on fatigue lives. Strain rate had a small effect on fatigue lives at 649 C. Of the various correlating parameters the modified plastic work and octahedral shear stress were the most successful.

Jordan, E. H.↗
NASA NTRS2012

Shape Memory Composite Hybrid Hinge

There are two conventional types of hinges for in-space deployment applications. The first type is mechanically deploying hinges. A typical mechanically deploying hinge is usually composed of several tens of components. It is complicated, heavy, and bulky. More components imply higher deployment failure probability. Due to the existence of relatively moving components among a mechanically deploying hinge, it unavoidably has microdynamic problems. The second type of conventional hinge relies on strain energy for deployment. A tape-spring hinge is a typical strain energy hinge. A fundamental problem of a strain energy hinge is that its deployment dynamic is uncontrollable. Usually, its deployment is associated with a large impact, which is unacceptable for many space applications. Some damping technologies have been experimented with to reduce the impact, but they increased the risks of an unsuccessful deployment. Coalescing strain energy components with shape memory composite (SMC) components to form a hybrid hinge is the solution. SMCs are well suited for deployable structures. A SMC is created from a high-performance fiber and a shape memory polymer resin. When the resin is heated to above its glass transition temperature, the composite becomes flexible and can be folded or packed. Once cooled to below the glass transition temperature, the composite remains in the packed state. When the structure is ready to be deployed, the SMC component is reheated to above the glass transition temperature, and it returns to its as-fabricated shape. A hybrid hinge is composed of two strain energy flanges (also called tape-springs) and one SMC tube. Two folding lines are placed on the SMC tube to avoid excessive strain on the SMC during folding. Two adapters are used to connect the hybrid hinge to its adjacent structural components. While the SMC tube is heated to above its glass transition temperature, a hybrid hinge can be folded and stays at folded status after the temperature is reduced to below its glass transition temperature. After the deployable structure is launched in space, the SMC tube is reheated and the hinge is unfolded to deploy the structure. Based on test results, the hybrid hinge can achieve higher than 99.999% shape recovery. The hybrid hinge inherits all of the good characteristics of a tape-spring hinge such as simplicity, light weight, high deployment reliability, and high deployment precision. Conversely, it eliminates the deployment impact that has significantly limited the applications of a tape-spring hinge. The deployment dynamics of a hybrid hinge are in a slow and controllable fashion. The SMC tube of a hybrid hinge is a multifunctional component. It serves as a deployment mechanism during the deployment process, and also serves as a structural component after the hinge is fully deployed, which makes a hybrid hinge much stronger and stiffer than a tape-spring hinge. Unlike a mechanically deploying hinge that uses relatively moving components, a hybrid hinge depends on material deformation for its packing and deployment. It naturally eliminates the microdynamic phenomenon.

Fang, Houfei↗
NASA NTRS1983

Large rotorcraft transmission technology development program

Testing of a U.S. Army XCH-62 HLH aft rotor transmission under NASA Contract NAS 3-22143 was successfully completed. This test establishes the feasibility of large, high power rotorcraft transmissions as well as demonstrating the resolution of deficiencies identified during the HLH advanced technology programs and reported by USAAMRDLTR-77-38. Over 100 hours of testing was conducted. At the 100% design power rating of 10,620 horsepower, the power transferred through a single spiral bevel gear mesh is more than twice that of current helicopter bevel gearing. In the original design of these gears, industry-wide design methods were employed and failures were experienced which identified problem areas unique to gear size. To remedy this technology shortfall, a program was developed to predict gear stresses using finite element analysis for complete and accurate representation of the gear tooth and supporting structure. To validate the finite element methodology gear strain data from the existing U.S. Army HLH aft transmission was acquired, and existing data from smaller gears were made available.

Mack, J. C.↗
NASA NTRS1992

Damage and failure mechanisms of continuous glass fiber reinforced polyphenylene sulfide

The damage that accompanies flexural deformation of a unidirectional glass fiber composite of polyphenylene sulfide was examined by AE and SEM. These complementary techniques were used to identify damage mechanisms at the microscale and correlate them with the macroscopic stress state in four-point bending. The flexural stress-strain curve was nominally linear to about 1.0 percent strain, but the onset of damage detectable by AE occurred at 0.3 percent strain. Two peaks in the AE amplitude distribution were observed at 35 dB and 60 dB. Low-amplitude events were detected along the entire length of the specimen, and correlation with direct observations of damage made by deforming the composite on the SEM stage suggested that these events arose from matrix cracking and fiber debonding concentrated at flaws on the composite. High amplitude events occurred primarily in the region of highest flexural stress between the inner loading points. They were attributed to fracture of glass fibers on the tension side and surface damage on the compressive side.

Chen, F.↗
NASA NTRS2020

Bioinspired multilayered cellular composites with enhanced energy absorption and shape recovery

Inspired by the multiscale configuration of the microstructure of cork, the paper describes the design, 3D printing, and evaluation of a new type of multilayered cellular composite (MCC) structure composed of hard brittle and soft flexible phases. The mechanical behavior of 3D printed MCC structures have been investigated both experimentally and numerically. The experiments show that the MCC structure absorbs four times the amount of energy of a conventional cellular configuration under compressive strains up to 70%. Finite element simulations and 2D digital image correlation (DIC) also show that the multilayered architecture provides a more uniform strain distribution and higher stress transfer efficiency, with a resulting progressive failure mode rather than a catastrophic one. Cyclic loading tests demonstrate that the MCC structure also possesses exceptional shape recoverability under compressive deformations up to 40%. These remarkable performance characteristics result from synergies between the properties of the two constituent materials and the chosen multilayered cellular microstructure. The soft phase, in particular, plays a pivotal role in absorbing elastic energy during loading and then releasing the stored energy while unloading. The volume fraction of the soft phase is also essential to control energy absorption and the transition of failure modes. The deformation mechanisms demonstrated here are robust and applicable to other architected cellular materials across multiple length scales and suggest new ways to design lightweight and high-resilience structural materials.

bioinspired composites↗
NASA NTRS2014

Slow Strain Rate Tensile Testing to Assess the Ability of Superalloys to Resist Environment-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720, ATI 718Plus alloy, Haynes 282, and Inconel 740. Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

Heat resistant alloys↗
NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗
NASA NTRS2014

Use of Slow Strain Rate Tensile Testing to Assess the Ability of Several Superalloys to Resist Environmentally-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720(TradeMark) ATI 718Plus(Registered TradeMark) alloy, Haynes 282(Trademark), and Inconel 740(TradeMark) Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

fatigue(materials)↗
NASA NTRS2007

Deep Space Network Antenna Logic Controller

The Antenna Logic Controller (ALC) software controls and monitors the motion control equipment of the 4,000-metric-ton structure of the Deep Space Network 70-meter antenna. This program coordinates the control of 42 hydraulic pumps, while monitoring several interlocks for personnel and equipment safety. Remote operation of the ALC runs via the Antenna Monitor & Control (AMC) computer, which orchestrates the tracking functions of the entire antenna. This software provides a graphical user interface for local control, monitoring, and identification of faults as well as, at a high level, providing for the digital control of the axis brakes so that the servo of the AMC may control the motion of the antenna. Specific functions of the ALC also include routines for startup in cold weather, controlled shutdown for both normal and fault situations, and pump switching on failure. The increased monitoring, the ability to trend key performance characteristics, the improved fault detection and recovery, the centralization of all control at a single panel, and the simplification of the user interface have all reduced the required workforce to run 70-meter antennas. The ALC also increases the antenna availability by reducing the time required to start up the antenna, to diagnose faults, and by providing additional insight into the performance of key parameters that aid in preventive maintenance to avoid key element failure. The ALC User Display (AUD) is a graphical user interface with hierarchical display structure, which provides high-level status information to the operation of the ALC, as well as detailed information for virtually all aspects of the ALC via drill-down displays. The operational status of an item, be it a function or assembly, is shown in the higher-level display. By pressing the item on the display screen, a new screen opens to show more detail of the function/assembly. Navigation tools and the map button allow immediate access to all screens.

Ahlstrom, Harlow↗
NASA NTRS1996

Design and evaluation of a bolted joint for a discrete carbon-epoxy rod-reinforced hat section

The use of prefabricated pultruded carbon-epoxy rods has reduced the manufacturing complexity and costs of stiffened composite panels while increasing the damage tolerance of the panels. However, repairability of these highly efficient discrete stiffeners has been a concern. Design, analysis, and test results are presented in this paper for a bolted-joint repair for the pultruded rod concept that is capable of efficiently transferring axial loads in a hat-section stiffener on the upper skin segment of a heavily loaded aircraft wing component. A tension and a compression joint design were evaluated. The tension joint design achieved approximately 1.0% strain in the carbon-epoxy rod-reinforced hat-section and failed in a metal fitting at 166% of the design ultimate load. The compression joint design failed in the carbon-epoxy rod-reinforced hat-section test specimen area at approximately 0.7% strain and at 110% of the design ultimate load. This strain level of 0.7% in compression is similar to the failure strain observed in previously reported carbon-epoxy rod-reinforced hat-section column tests.

Rousseau, Carl Q.↗
NASA NTRS2010

Evaluation of Small Form Factor Fiber Optic Interconnects for the NASA Electronics Parts and Packaging Program (NEPP)

The Diamond AVIM optical fiber connector has been used for over a decade in flight environments. AVIM which stands for Aviation Intermediate Maintenance is always referenced as a fiber optic connector type from the DIN (Deutsches Institut fur Normung) family of optical fiber connectors. The newly available Mini AVIM and DMI (Definition Multimedia Interface) connectors also by Diamond provide similar features as the high performance AVIM with the added benefits of being small form factor for board mount and internal box use where long connectors and strain relief can not be accommodated. Transceiver, fiber laser technology and receiver optic technology based on small sized constraints will benefit the most by the reduction in connector form factor. It is for this reason that the Mini AVIM is being evaluated for multimode and single mode optical fiber use in both fiber based and cable based packaging configurations. In a fiber based termination, there are no cable materials to bond to the connector. The only bonding that is conducted is the mounting of the fiber with epoxy to the connector ferrules (which are called DMI ferrules). In a cable configuration, the compatibility of the connector subcomponents along with the upjacketing materials of the cable around the fiber needs to be considered carefully for termination fabrication. Cabled terminations will show greater insertion loss and high probability of failures during thermal cycling testing. This is due to the stressing of the combination of materials that each have different Coefficients of Thermal Expansion (CTE's) and that are bonded together to the connector subcomponents. As the materials flex during thermal excursions, forces are applied to the termination and can make the system fail if the grouping of materials (per their CTE's) are not compatible and this includes cable materials, epoxies, ferrule and connector body components. For this evaluation, multimode 100 micron core step index fiber was used for the fiber terminated condition, and single mode SMF-28 upjacketed with W.L. Gore Flexlite was used for the cabled configuration. For background purposes, a comparison is presented here for information purposes between the high performance AVIM connector features and the Mini AVIM small form factor connectors. Basic connector features are described here.

Ott, Melanie↗
NASA NTRS2004

Reliability-Based Life Assessment of Stirling Convertor Heater Head

Onboard radioisotope power systems being developed and planned for NASA's deep-space missions require reliable design lifetimes of up to 14 yr. The structurally critical heater head of the high-efficiency Stirling power convertor has undergone extensive computational analysis of operating temperatures, stresses, and creep resistance of the thin-walled Inconel 718 bill of material. A preliminary assessment of the effect of uncertainties in the material behavior was also performed. Creep failure resistance of the thin-walled heater head could show variation due to small deviations in the manufactured thickness and in uncertainties in operating temperature and pressure. Durability prediction and reliability of the heater head are affected by these deviations from nominal design conditions. Therefore, it is important to include the effects of these uncertainties in predicting the probability of survival of the heater head under mission loads. Furthermore, it may be possible for the heater head to experience rare incidences of small temperature excursions of short duration. These rare incidences would affect the creep strain rate and, therefore, the life. This paper addresses the effects of such rare incidences on the reliability. In addition, the sensitivities of variables affecting the reliability are quantified, and guidelines developed to improve the reliability are outlined. Heater head reliability is being quantified with data from NASA Glenn Research Center's accelerated benchmark testing program.

Shah, Ashwin R.↗