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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 325 records · Page 18

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NASA NTRS1984

Environmental and structural assessment of four year in-commercial service composite helicopter structures

This paper presents the technical background for including environmental effects in the design of helicopter composite structures. This effort was supported by test results of components and panels having up to four years of field exposure. The preceeding was part of an eight year program to evaluate in-service environmental factors for comparison with laboratory test results. Full scale static and fatigue tests were conducted on composite components removed from S-76 helicopters used in commercial operations in the Gulf Coast region of Louisiana. Small scale tests were conducted using coupons removed from panels exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. Panel configurations were representative of S-76 components. Moisture analysis and strength tests on components and panels are reported after two, three and four years of exposure. Moisture levels were compared with predicted values. Mechanical test results were compared to initial certification tests for component strength, and to baseline laboratory coupon testing.

Ezzo, M. B.↗

NASA NTRS1986

Contact dynamics math model

The Space Station Mechanism Test Bed consists of a hydraulically driven, computer controlled six degree of freedom (DOF) motion system with which docking, berthing, and other mechanisms can be evaluated. Measured contact forces and moments are provided to the simulation host computer to enable representation of orbital contact dynamics. This report describes the development of a generalized math model which represents the relative motion between two rigid orbiting vehicles. The model allows motion in six DOF for each body, with no vehicle size limitation. The rotational and translational equations of motion are derived. The method used to transform the forces and moments from the sensor location to the vehicles' centers of mass is also explained. Two math models of docking mechanisms, a simple translational spring and the Remote Manipulator System end effector, are presented along with simulation results. The translational spring model is used in an attempt to verify the simulation with compensated hardware in the loop results.

Glaese, John R.↗

NASA NTRS2014

Overview of the Development of the Solar Electric Propulsion Technology Demonstration Mission 12.5-kW Hall Thruster

NASA is developing mission concepts for a solar electric propulsion technology demonstration mission. A number of mission concepts are being evaluated including ambitious missions to near Earth objects. The demonstration of a high-power solar electric propulsion capability is one of the objectives of the candidate missions under consideration. In support of NASAs exploration goals, a number of projects are developing extensible technologies to support NASAs near and long term mission needs. Specifically, the Space Technology Mission Directorate Solar Electric Propulsion Technology Demonstration Mission project is funding the development of a 12.5-kW magnetically shielded Hall thruster system to support future NASA missions. This paper presents the design attributes of the thruster that was collaboratively developed by the NASA Glenn Research Center and the Jet Propulsion Laboratory. The paper provides an overview of the magnetic, plasma, thermal, and structural modeling activities that were carried out in support of the thruster design. The paper also summarizes the results of the functional tests that have been carried out to date. The planned thruster performance, plasma diagnostics (internal and in the plume), thermal, wear, and mechanical tests are outlined.

Electric Propulsion↗

NASA NTRS2014

Overview of the Development of the Solar Electric Propulsion Technology Demonstration Mission 12.5-kW Hall Thruster

NASA is developing mission concepts for a solar electric propulsion technology demonstration mission. A number of mission concepts are being evaluated including ambitious missions to near Earth objects. The demonstration of a high-power solar electric propulsion capability is one of the objectives of the candidate missions under consideration. In support of NASA's exploration goals, a number of projects are developing extensible technologies to support NASA's near and long term mission needs. Specifically, the Space Technology Mission Directorate Solar Electric Propulsion Technology Demonstration Mission project is funding the development of a 12.5-kilowatt magnetically shielded Hall thruster system to support future NASA missions. This paper presents the design attributes of the thruster that was collaboratively developed by the NASA Glenn Research Center and the Jet Propulsion Laboratory. The paper provides an overview of the magnetic, plasma, thermal, and structural modeling activities that were carried out in support of the thruster design. The paper also summarizes the results of the functional tests that have been carried out to date. The planned thruster performance, plasma diagnostics (internal and in the plume), thermal, wear, and mechanical tests are outlined.

High power long life hall thrusters↗

NASA NTRS2018

An Internship in Cryogenic Propulsion

Presentation on intern rotations. Summer 2013 I worked in cryolab and learned about calorimitry testing. Spring 2014 I helped create themalcouple arm for GODU-LH2. Summer 2014 I assisted with hardware failures on GPIM fracture mechanics testing. Summer 2017 I created a qualification test plan and test fixture to test vacuum seal-off valves.

Tucker, Corey J.↗

NASA NTRS1985

Development of acceptance criteria for batches of silane primer for external tank thermal protection system bonding applications

Fourier transform infrared spectroscopy is currently the best technique for observing hydrolytic changes in DC 1200 silane the primers caused by moisture in the atmosphere. To further prove that FTIR can be used as a criterion test for acceptance of silane primer lots, intensities of the FTIR OH- band are being compared with primer adhesive bond strength using a mechanical test suggested by NASA. Results of tests for shear strength and Oh-absorption are tabulated and compared with FTIR absorption intensities in the OH-region.

Mikes, F.↗

NASA NTRS1964

Mechanical plan, rf test console, appendix j part of the final report

Mechanical plan of radio frequency test console

TEST EQUIPMENT↗

NASA NTRSDate not supplied

Innovations in Continuous Ultrasonic Welding of Thermoplastic Composites and Evaluation for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite materials were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding of candidate materials to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

thermoplastic composite↗

DOE OSTI2024

Mechanical properties of freestanding few-layer graphene/boron nitride/polymer heterostacks investigated with local and non-local techniques

van der Waals two-dimensional materials and heterostructures combined with polymer films continue to attract research attention to elucidate their functionality and potential applications. This study presents the fabrication and mechanical testing of 2D material heterostacks, consisting of few-layer boron nitride and graphene heterostructures synthesized via chemical vapor deposition, capped with a polymethyl methacrylate layer and suspended across ∼200 μm wide trenches using a combined wet–dry transfer method. The mechanical characterization of the heterostacks was performed using two independent approaches: (a) non-local testing with a custom-built tensile testing platform and (b) local load–displacement testing employing atomic force microscopy probes, complemented by finite element simulations. Both approaches provided new results, which are in good agreement with each other. Overall, our findings offer new insights into a combined load capacity in complex multi-material two-dimensional systems, and can contribute to advancing micro and nano-scale device designs and implementations.

Lespasio, Marcus↗

NASA NTRS1974

Testing of a flat conductor cable baseboard system for residential and commercial wiring

The results of extensive testing (mechanical, electrical, chemical, environmental, thermal, and analytical) are reported for a flat conductor cable baseboard system for residential and commercial wiring. In all of the tests, Underwriters Laboratories (UL) Standards, UL Tentative Test Programs, or Accepted Engineering Practices were followed during test selection, test setup, and test accomplishment.

Hankins, J. D.↗

NASA NTRS1977

Bent glass optics

The paper describes how a glass strip may be bent to match any curve of large radius of curvature, to a high degree of accuracy, so that it may be used as a glancing incidence X-ray or extreme ultraviolet optical element. The desired match is obtained by applying a suitable combination of end couples and adjusting the cross-sectional moment of inertia along the length of the strip by varying its breadth. Two applications are described; a parabolic reflector for use as a laboratory X-ray collimator for testing mechanical collimators to be used in space instruments, and an elliptical reflector for point-to-point focussing. The latter device has been used for testing gratings in the X-ray and extreme ultraviolet (EUV) regions and for concentrating radiation on the entrance slit of a spectrometer, with a resultant gain in speed and resolution. It is suggested that the technique may have other laboratory and space applications, which are briefly described.

Underwood, J. H.↗

NASA NTRS2003

Influence Of Holes On The In-Plane Tensile Strength And Fatigue Durability Of A NICALON(Trademark)/Si-N-C Ceramic Matrix Composite

Effects of different sizes of holes as well as different percentages of open areas on the in-plane tensile strength and fatigue durability of the SiC/Si-N-C composite were investigated in this study. Test specimens with no holes, four different diameters of holes (1.0 to 3.2 mm), and four different open areas (20 to 35%) were machined. All mechanical testing was performed in air at a temperature of 910 C. Fatigue tests were conducted with a load ratio, R = 0.05, and a frequency of 0.33 Hz. In general, both the in-plane tensile strength of the composite and its fatigue durability decreased with an increase in the size of the hole and percentage of the open area. Reductions in the in-plane tensile strength and cyclic fatigue life of the composite were described by empirical equations with the diameter of the hole and the percent open area as the independent variables. The validity of these two empirical equations was verified with additional tensile and fatigue test data generated on the composite specimens.

Kalluri, Sreeramesh↗

NASA NTRS2005

Thermal and Mechanical Property Characterization of the Advanced Disk Alloy LSHR

A low solvus, high refractory (LSHR) powder metallurgy disk alloy was recently designed using experimental screening and statistical modeling of composition and processing variables on sub-scale disks to have versatile processing-property capabilities for advanced disk applications. The objective of the present study was to produce a scaled-up disk and apply varied heat treat processes to enable full-scale demonstration of LSHR properties. Scaled-up disks were produced, heat treated, sectioned, and then machined into specimens for mechanical testing. Results indicate the LSHR alloy can be processed to produce fine and coarse grain microstructures with differing combinations of strength and time-dependent mechanical properties, for application at temperatures exceeding 1300 F.

Gabb, Timothy P.↗

NASA NTRS2015

Impact and Penetration of Thin Aluminum 2024 Flat Panels at Oblique Angles of Incidence

The U.S. Federal Aviation Administration (FAA) and the National Aeronautics and Space Administration (NASA) are actively involved in improving the predictive capabilities of transient finite element computational methods for application to safety issues involving unintended impacts on aircraft and aircraft engine structures. One aspect of this work involves the development of an improved deformation and failure model for metallic materials, known as the Tabulated Johnson-Cook model, or MAT224, which has been implemented in the LS-DYNA commercial transient finite element analysis code (LSTC Corp., Livermore, CA) (Ref. 1). In this model the yield stress is a function of strain, strain rate and temperature and the plastic failure strain is a function of the state of stress, temperature and strain rate. The failure criterion is based on the accumulation of plastic strain in an element. The model also incorporates a regularization scheme to account for the dependency of plastic failure strain on mesh size. For a given material the model requires a significant amount of testing to determine the yield stress and failure strain as a function of the three-dimensional state of stress, strain rate and temperature. In addition, experiments are required to validate the model. Currently the model has been developed for Aluminum 2024 and validated against a series of ballistic impact tests on flat plates of various thicknesses (Refs. 1 to 3). Full development of the model for Titanium 6Al-4V is being completed, and mechanical testing for Inconel 718 has begun. The validation testing for the models involves ballistic impact tests using cylindrical projectiles impacting flat plates at a normal incidence (Ref. 2). By varying the thickness of the plates, different stress states and resulting failure modes are induced, providing a range of conditions over which the model can be validated. The objective of the study reported here was to provide experimental data to evaluate the model under more extreme conditions, using a projectile with a more complex shape and sharp contacts, impacting flat panels at oblique angles of incidence.

Ruggeri, Charles R.↗

DOE OSTI2025

Multilayer Architecture Barriers for High Temperature Nuclear Applications

Innovative thin film multilayer metal/ceramic barrier coatings have been developed by Argonne National Laboratory to protect fuel cladding against different phenomena that can be encountered under the harsh operating conditions of advanced nuclear reactors. One phenomenon is Fuel-Cladding Chemical Interaction (FCCI), which can represent a challenge to the performance of steel-clad metallic fuels in sodium-cooled fast reactors (SFRs), especially when operating to high burnups at elevated cladding temperatures, and long fuel residence time. Another phenomenon is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated cladding during off normal conditions, including loss of coolant accidents (LOCA). This work provides details of the development and testing of a thin film (few microns) multilayer metal/ceramic (CrY/Y 2 O 3 ) coatings on steel cladding and its performance against FCCI. The coating architecture evolved through systematic mechanical testing, radiation tolerance assessments, and high-temperature diffusion studies from a preliminary multilayer concept to an optimized high-performance design. The optimized structure leverages stoichiometric Y 2 O 3 for its exceptional radiation stability, chemical inertness, and ultra-low fission product diffusivity (e.g., Ce diffusivity ~10 -20 m 2 /s in irradiated Y 2 O 3 at 650 °C). This is paired with ductile chromium-rich interlayers (Cr 95 Y 5 ), which significantly enhance fracture toughness and mechanical resilience. Design refinements, including increased ceramic layer thickness and optimized Cr–Y interlayer composition, eliminated fracture propagation and preserved coating integrity under extreme mechanical stress (>10× typical reactor conditions) and prolonged radiation exposure (~300 dpa). Those conditions are well beyond expected conditions during normal operations in SFR, and cover some of the transient conditions as well. In addition, the coating deposition was demonstrated to be applied uniformly to the inner surface of steel tubes representing prototypic SFR cladding. Another phenomenon under consideration in this work is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated off normal conditions including loss of coolant accident (LOCA). Another multilayer thin film coating is considered for mitigation of this phenomenon, where a coating of yttrium aluminum and yttrium aluminum ceramic/metal thin film coating. Preliminary results on the coating performance during high temperature thermal cycling (up to 1000 C) have shown promising performance of the coating. On-going optimization of the coating will continue in FY26.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Optimal Geometry for Focused Ion Beam-Milled Samples for Direct-Pull Micro-Tensile Testing Performed In Situ in a Scanning Electron Microscope

A thorough procedure was developed to efficiently manufacture dogbone samples using focused ion beam (FIB) milling for micro-tensile testing. A Bruker PI 89 PicoIndenter, Billerica, MA, USA, was used as a case study, although the analysis and results are applicable to other micro-mechanical testing systems capable of mounting a standard, Ø12.7 mm × Ø3.2 mm pin, scanning electron microscopy (SEM) pin stub (Ted Pella, Redding, CA, USA). Nine dogbones were made from an Fe-45Cu alloy additively manufactured using powder-fed laser-directed energy deposition (DED-LB). Testing showed that fracture was confined to the gauge section for all dogbones and that the fracture mode, ductile vs. brittle, was entirely dependent on the grain orientation relative to the loading direction. The analysis showed that the measured plastic strain to failure can vary from >11% (optimal geometry) to <1% (non-optimal geometry) in micro-tensile testing of high-tensile-strength (>1 GPa) metallic materials. Subsequently, a finite element analysis (FEA) was conducted to identify the improved dogbone geometries. A total of ten thousand dogbone geometries were tested, and their dimensions were defined by a set of four adjustable parameters (corner radius, load surface angle, load surface length, and dogbone head length). The gauge width and gauge length were fixed to 4 µm and 10 µm, respectively. Three-dimensional surface plots of the stress concentration as a function of two parameters were used to identify the optimal ranges of parameter values. The addition of maximum width and length constraints, measuring 25 µm and 30 µm, respectively, allowed us to identify an optimal geometry at load surface angles of 30° and 45°. Their respective dimensions (corner radius, load surface length, and dogbone head length) are, in µm, 12, 6, and 7 and 10, 7, and 7. Testing these two optimal geometries with a range of gauge lengths from 4 to 20 µm showed that smaller gauge lengths only slightly reduced the detrimental stress concentration outside the gauge section. However, smaller gauge lengths will notably improve the FIB surface polishing step as tapering is reduced with smaller dogbone lengths.

Chemistry↗