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At least 307 records · Page 17

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DOE OSTI2023

Thermal insulation versus capacitance: A simulation experiment comparing effects of shade and hyporheic exchange on daily and seasonal stream temperature cycles

In streams where water temperatures stress native biota, management of riparian shade or hyporheic exchange are both considered viable management strategies for reducing the peaks of daily and seasonal stream channel temperature cycles. Although shade and hyporheic exchange may have similar effects on stream temperatures, their mechanisms differ. Improved understanding of the heat-exchange mechanisms influenced by shade and hyporheic exchange will aid in the appropriate application of either stream temperature management strategy. To illustrate a conceptual model highlighting shade as ‘thermal insulation’ and hyporheic exchange imparting ‘thermal capacitance’ to a stream reach, we conducted an in-silico simulation modelling experiment increasing shade or hyporheic exchange parameters on an idealized, hypothetical stream. We assessed the potential effects of increasing shade or hyporheic exchange on a stream reach using an established process-based heat-energy budget model of stream-atmosphere heat exchange and incorporated an advection-driven hyporheic heat exchange routine. The model tracked heat transport through the hyporheic zone and exchange with the stream channel, while including the effects of hyporheic water age distribution on upwelling hyporheic temperatures. Results showed that shade and hyporheic exchange similarly damped diurnal temperature cycles and differentially altered seasonal cycles of our theoretical stream. In winter, hyporheic exchange warmed simulated channel temperatures whereas shade had little effect. In summer, both shade and hyporheic exchange cooled channel temperatures, though the effects of shade were more pronounced. Our simple-to-grasp analogies of ‘thermal insulation’ for shade effects and ‘thermal capacitance’ for hyporheic exchange effects on stream temperature encourage more accurate conceptualization of complex, dynamic heat exchange processes among the atmosphere, stream channel, and alluvial aquifer.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2011

Microcoil Spring Interconnects for Ceramic Grid Array Integrated Circuits

As integrated circuit miniaturization trends continue, they drive the need for smaller higher input/output (I/O) packages. Hermetically sealed ceramic area array parts are the package of choice by the space community for high reliability space flight electronic hardware. Unfortunately, the coefficient of thermal expansion mismatch between the ceramic area array package and the epoxy glass printed wiring board limits the life of the interconnecting solder joint. This work presents the results of an investigation by Marshall Space Flight Center into a method to increase the life of this second level interconnection by the use of compliant microcoil springs. The design of the spring and its attachment process are presented along with thermal cycling results of microcoil springs (MCS) compared with state-of-the-art ball and column interconnections. Vibration testing has been conducted on MCS and high lead column parts. Radio frequency simulation and measurements have been made and the MCS has been modeled and a stress analysis performed. Thermal cycling and vibration testing have shown MCS interconnects to be significantly more reliable than solder columns. Also, MCS interconnects are less prone to handling damage than solder columns. Future work that includes shock testing, incorporation into a digital signal processor board, and process evaluation of expansion from a 400 I/O device to a device with over 1,100 I/O is identified.

Strickland, S. M.↗

NASA NTRS1994

The roles of vertical mixing, solar radiation, and wind stress in a model simulation of the sea surface temperature seasonal cycle in the tropical Pacfic Ocean

The climatological seasonal cycle of sea surface temperature (SST) in the tropical Pacific is simulated using a newly developed upper ocean model. The roles of vertical mixing, solar radiation, and wind stress are investigated in a hierarchy of numerical experiments with various combinations of vertical mixing algorithms and surface-forcing products. It is found that the large SST annual cycle in the eastern equatorial Pacific is, to a large extent, controlled by the annually varying mixed layer depth which, in turn, is mainly determined by the competing effects of solar radiation and wind forcing. With the application of our hybrid vertical mixing scheme the model-simulated SST annual cycle is much improved in both amplitude and phase as compared to the case of a constant mixed layer depth. Beside the strong effects on vertical mixing, solar radiation is the primary heating term in the surface layer heat budget, and wind forcing influences SST by driving oceanic advective processes that redistribute heat in the upper ocean. For example, the SST seasonal cycle in the western Pacific basically follows the semiannual variation of solar heating, and the cycle in the central equatorial region is significantly affected by the zonal advective heat flux associated with the seasonally reversing South Equatorial Current. It has been shown in our experiments that the amount of heat flux modification needed to eliminate the annual mean SST errors in the model is, on average, no larger than the annual mean uncertainties among the various surface flux products used in this study. Whereas a bias correction is needed to account for remaining uncertainties in the annual mean heat flux, this study demonstrates that with proper treatment of mixed layer physics and realistic forcing functions the seasonal variability of SST is capable of being simulated successfully in response to external forcing without relying on a relaxation or damping formulation for the dominant surface heat flux contributions.

Chen, Dake↗

DOE OSTI2022

Extended Accelerated Stress Testing (EAST) of Glass/Glass, Glass/Backsheet and Glass/Transparent Backsheet PV Modules: Influence of EVA and POE Encapsulants: Preprint

This paper presents the indoor extended accelerated stress testing (EAST) results of glass/glass (GG), glass/backsheet (GB) and glass/transparent backsheet (GT) modules having identical cells and two different encapsulant types, ethyl-vinyl-acetate (EVA) and polyolefin-elastomer (POE). Six 4-cell modules having the above-mentioned construction combinations were subjected to extended ultraviolet (UV; 600 kWh/m2), damp-heat (DH; 2000 hours) and thermal-cycling (TC; 600 cycles) tests. The post-stress UV fluorescent imaging, electroluminescent imaging, reflectance spectrophotometry and colorimetry results indicated that the grid finger degradation and encapsulant browning are slightly higher in the GG modules compared to the GB modules. The post-stress IV test results indicated, in general, that the GG/EVA modules tend to perform inferior to the GG/POE modules with the EAST evaluation.

EVA↗

NASA NTRS1979

Clock performance, reliability and cost interrelationships

Problems encountered by clock manufacturers in attempting to supply reasonably priced, reliable clocks for critical aerospace applications arise from the inherent technical difficulties of designing and fabricating equipment to provide performance at the limits of the state of the art in demanding environments. The difficulties are compounded by inconsistent and unstandardized specification practices, and by an emphasis on initial acquisition costs, rather than on life cycle costs. Conventional parts stress analyses, which do not provide a useful indication of the reliability of a clock, lead to increased parts costs for high performance aerospace clocks without comensurate benefits in improved reliability or performance. The characterization of clocks in terms of the mean time between resynchronizations, facilitates the estimation of life cycle costs and provides a means to evaluate clocks in a realistic fashion for specific systems applications.

Levine, M. W.↗

NASA NTRS1969

Probabilistic-graphical and phenomenological analysis of combined bending-torsion fatigue reliability data

Fatigue data generated by three combined bending-torsion fatigue reliability research machines at The University of Arizona are probabilistic-graphically and phenomenologically analyzed. Distributions that are applicable to fatique life and static strength data are discussed. Phenomenological justifications for the use of these distributions are presented. It is found that the normal distribution represents the cycles-to-failure data at the highest stress levels best. The lognormal distribution appears to fit the cycles-to-failure data at the lower stress levels best and quite well at all stress levels including the highest. A regression analysis and least-squares goodness-of-fit test was performed for normal and lognormal plots. In most cases, the correlation coefficient gave a better fit to the data using the normal distribution, but the difference between the two was so slight that positive discrimination could not be made.

Kececioglu, D.↗

DOE OSTI2025

Propagation and Periodicity of Mars's Northern Annular Mode Modulates the Dust Cycle

Abstract We document the propagation of annular modes—zonally symmetric patterns of variability—in Mars's atmosphere using a reanalysis dataset. Mars's Northern Annular Mode (MNAM) sees anomalies of zonal‐mean zonal wind emerge near the subtropics and migrate poleward with a period of 150 days, similarly to Earth's Southern Annular Mode. The mechanism of propagation involves the interaction of the two leading empirical orthogonal functions that define the MNAM. Moreover, the propagation encourages alternating bands of surface wind stress to migrate polewards with a 150‐day period. In addition, a 150‐day periodicity in anomalous column dust optical depth most likely emerges in response to extrema of the MNAM. The combination of the impact of the MNAM's internally forced periodicity on the surface wind stress and the seasonal cycle may contribute to the inter‐annual variability of global dust events, as suggested by a Monte Carlo estimate that correctly approximates the observed incidence of global dust events.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Solid-state batteries: The critical role of mechanics

Solid-state batteries with lithium metal anodes have the potential for higher energy density, longer lifetime, wider operating temperature, and increased safety. Although the bulk of the research has focused on improving transport kinetics and electrochemical stability of the materials and interfaces, there are also critical challenges that require investigation of the mechanics of materials. In batteries with solid-solid interfaces, mechanical contacts, and the development of stresses during operation of the solid-state batteries, become as critical as the electrochemical stability to keep steady charge transfer at these interfaces. In conclusion, this review will focus on stress and strain that result from normal and extended battery cycling and the associated mechanisms for stress relief, some of which lead to failure of these batteries.

25 ENERGY STORAGE↗

NASA NTRS1995

Time-dependent deformation of titanium metal matrix composites

A three-dimensional finite element program called VISCOPAC was developed and used to conduct a micromechanics analysis of titanium metal matrix composites. The VISCOPAC program uses a modified Eisenberg-Yen thermo-viscoplastic constitutive model to predict matrix behavior under thermomechanical fatigue loading. The analysis incorporated temperature-dependent elastic properties in the fiber and temperature-dependent viscoplastic properties in the matrix. The material model was described and the necessary material constants were determined experimentally. Fiber-matrix interfacial behavior was analyzed using a discrete fiber-matrix model. The thermal residual stresses due to the fabrication cycle were predicted with a failed interface, The failed interface resulted in lower thermal residual stresses in the matrix and fiber. Stresses due to a uniform transverse load were calculated at two temperatures, room temperature and an elevated temperature of 650 C. At both temperatures, a large stress concentration was calculated when the interface had failed. The results indicate the importance of accuracy accounting for fiber-matrix interface failure and the need for a micromechanics-based analytical technique to understand and predict the behavior of titanium metal matrix composites.

Bigelow, C. A.↗

DOE OSTI2024

Evaluation of proposed Section III Division 5 Class B rules: Piping example problem

Evaluation of proposed Section III Division 5 Class B rules: Piping example problem to be presented include Z pipe geometry and model problem statement, Z pipe loads and design inputs problem statement, Primary Stress Limit overview, Primary stress limit pseudo yield stress calculation, Primary stress limited factored load procedure, Strain limit evaluation composite load cycle, Strain limit evaluation pseudo yield stress, Strain limit evaluation strain limit criteria and ratcheting check, Creep fatigue damage evaluation overview, Creep fatigue damage evaluation alternating stress calculations, Creep fatigue damage evaluation lower bound stress, Creep fatigue damage evaluation stress relaxation history, Creep fatigue damage evaluation damage fractions, and Recommendations to consider for Z-pipe problem.

42 ENGINEERING↗

NASA NTRS1983

Validation of structural analysis methods using burner liner cyclic rig test data

The objectives of the hot section technology (HOST) burner liner cyclic rig test program are basically threefold: (1) to assist in developing predictive tools needed to improve design analyses and procedures for the efficient and accurate prediction of burner liner structural response; (2) to calibrate, evaluate and validate these predictive tools by comparing the predicted results with the experimental data generated in the tests; and (3) to evaluate existing as well as advanced temperature and strain measurement instrumentation, both contact and noncontact, in a simulated engine cycle environment. The data generated will include measurements of the thermal environment (metal surface temperatures) as well as structural (strain) and life (fatigue) responses of simulated burner liners and specimens under controlled boundary and operating conditions. These data will be used to calibrate, compare and validate analytical theories, methodologies and design procedures, as well as improvements in them, for predicting liner temperatures, stress-strain responses and cycles to failure. Comparison of predicted results with experimental data will be used to show where the predictive theories, etc. need improvements. In addition, as the predictive tools, as well as the tests, test methods, and data acquisition and reduction techniques, are developed and validated, a proven, integrated analysis/experiment method will be developed to determine the cyclic life of a simulated burner liner.

Thompson, R.↗

NASA NTRS1992

Effect of KOH concentration on LEO cycle life of IPV nickel-hydrogen flight cell - Update II

An update of validation test results confirming the breakthrough in LEO cycle life of nickel-hydrogen cells containing 26 percent KOH electrolyte is presented. A breakthrough in the LEO cycle life of individual pressure vessel (IPV) nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent potassium hydroxide (KOH) electrolyte was about 40,000 LEO cycles, compared to 3500 cycles for cells containing 31 percent KOH. The cycle regime was a stressful accelerated LEO, which consisted of a 27.5 min charge followed by a 17.5 min discharge (2X normal rate). The depth-of-discharge was 80 percent. Six 48-Ah Hughes recirculation design IPV nickel-hydrogen flight battery cells are being evaluated. Three of the cells contain 26 percent KOH (test cells), and three contain 31 percent KOH (control cells). They are undergoing real time LEO cycle life testing. The cycle regime is a 90-min LEO orbit consisting of a 54-min charge followed by a 36-min discharge. The depth-of-discharge is 80 percent. The cell temperature is maintained at 10 C. The three 31 percent KOH cells failed (cycles 3729, 4165, and 11355). One of the 26 percent KOH cells failed at cycle 15314. The other two 26 percent KOH cells were cycled for over 16,000 cycles during the continuing test.

Smithrick, John J.↗

DOE OSTI2019

Structural Changes in Si–CuSi Films upon Intercalation of Lithium Ions

We studied the possibility of using composite films representing amorphous silicon reinforced with crystalline inclusions of copper silicide as an anode material for lithium-ion batteries with liquid electrolyte. The films were made by layer-by-layer magnetron sputtering of amorphous silicon and copper, followed by low-temperature (100–200°C) annealing of the structure. The tests of the anodes revealed the effect of prolonged intense growth of their reversible capacity. To describe the effect, a phenomenological model based on the multidirectional migration of silicon and copper atoms in an inhomogeneous field of elastic mechanical stresses arising during electrode cycling is proposed.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Performance and Durability of Heavy-Duty Fuel Cell Systems with an Advanced Ordered Intermetallic ORR Alloy Catalyst and Novel Support

Ordered PtCo intermetallic (OIM) catalyst (L1 0 -PtCo/C) is a promising candidate as the oxygen reduction reaction (ORR) catalyst in hybrid fuel cell systems (FCS) for class-8 heavy duty (HD) trucks. Compared to a baseline annealed Pt on high surface area carbon (a-Pt/HSC) catalyst, its mass activity (MA) is 71% higher initially and 144% higher after 90,000 potential cycles in an accelerated stress test (AST). Analysis of the AST data indicates that the ORR kinetic constants do not change with aging and the degradation in the OIM catalyst activity is linearly proportional to the loss in the electrochemically active surface area (ECSA). Several operational strategies are investigated to mitigate catalyst degradation and achieve 25,000-h electrode lifetime and 2.5 kW g −1 Pt utilization on a HD truck duty cycle including load sharing with the hybrid battery, regulating the radiator fan power to maintain the coolant temperature close to 60 °C, clipping the maximum cell voltage below 850 mV, limiting the ECSA loss to 55%, and oversizing the active area of the membrane electrode assemblies by 20%. Drive cycle simulations indicate that the lifetime average voltage degradation rate is about 1.8 μV h −1 and the integrated stack and FCS drive cycle efficiencies decrease by 3.5 to 3.9%.

25 ENERGY STORAGE↗

NASA NTRS1991

System reliability and risk assessment task goals and status

The major focus for continued development of the Numerical Evaluation of Stochastic Structures Under Stress (NESSUS) codes is in support of system testing and certification of advanced propulsion systems. Propulsion system testing has evolved over the years from tests designed to show success, to tests designed to reveal reliability issues before service use. Such test conditions as performance envelope corners, high rotor imbalance, power dwells, and overspeed tests are designed to shake out problems that can be associated with low and high cycle fatigue, creep, and stress rupture, bearing durability, and the like. Subsystem testing supports system certification by standing as an early evaluation of the same durability and reliability concerns as for the entire system. The NESSUS software system is being further developed to support the definition of rigorous subsystem and system test definition and reliability certification. The principal technical issues are outlined which are related to system reliability, including key technology issues such as failure mode synergism, sequential failure mechanisms, and fault tree definition.

Cruse, T. A.↗

NASA NTRS1982

Accelerated stress testing of terrestrial solar cells

The development of an accelerated test schedule for terrestrial solar cells is described. This schedule, based on anticipated failure modes deduced from a consideration of IC failure mechanisms, involves bias-temperature testing, humidity testing (including both 85-85 and pressure cooker stress), and thermal-cycle thermal-shock testing. Results are described for 12 different unencapsulated cell types. Both gradual electrical degradation and sudden catastrophic mechanical change were observed. These effects can be used to discriminate between cell types and technologies relative to their reliability attributes. Consideration is given to identifying laboratory failure modes which might lead to severe degradation in the field through second quadrant operation. Test results indicate that the ability of most cell types to withstand accelerated stress testing depends more on the manufacturer's design, processing, and worksmanship than on the particular metallization system. Preliminary tests comparing accelerated test results on encapsulated and unencapsulated cells are described.

Lathrop, J. W.↗

NASA NTRS1982

Measuring Cyclic-Stress Properties of Pressure Vessels

Simulated-service cycle differs from conventional proof-test cycle in that specimen is subjected to sine-wave variation of stress instead of prolonged steady stress. Simulated-service testing is performed at low and high temperatures as well as at room temperatures. (Flaws initiated by severe stresses of proof testing can later develop into leaks during service, thus effectively reducing useful service life.) Method may be useful for commercial thin-wall vessels.

Fiftal, C. F.↗

NASA NTRS1995

Probabilistic simulation of long term behavior in polymer matrix composites

A methodology to compute cumulative probability distribution functions (CDF) of fatigue life for different ratios, r of applied stress to the laminate strength based on first ply failure criteria has been developed and demonstrated. Degradation effects due to long term environmental exposure and mechanical cyclic loads are considered in the simulation process. A unified time-stress dependent multi-factor interaction equation model developed at NASA Lewis Research Center has been used to account for the degradation/aging of material properties due to cyclic loads. Fast probability integration method is used to perform probabilistic simulation of uncertainties. Sensitivity of fatigue life reliability to uncertainties in the primitive random variables are computed and their significance in the reliability based design for maximum life is discussed. The results show that the graphite/epoxy (0/+45/90) deg laminate with ply thickness 0.125 in. has 500,000 cycles life for applied stress to laminate strength ratio of 0.6 and a reliability of 0.999. Also, the fatigue life reliability has been found to be most sensitive to the ply thickness and matrix tensile strength. Tighter quality controls must therefore be enforced on ply thickness and matrix strength in order to achieve high reliability of the structure.

Shah, A. R.↗