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A detailed survey of ice mold and evaporator metal surfaces, physical structures, operational conditions, materials of construction, design of different equipment was reviewed and analyzed. The key objective was to identify different ice related processes’ materials, structures, and operating conditions for designing, optimizing, and applying advance materials to lower ice adhesion strength.
High strength at elevated temperatures, low density, resistance to wear, and abundance of nonstrategic raw materials make structural ceramics attractive for advanced heat engine applications. Unfortunately, ceramics have a low fracture toughness and fail catastrophically because of overload, impact, and contact stresses. Ceramic matrix composites provide the means to achieve improved fracture toughness while retaining desirable characteristics, such as high strength and low density. Materials scientists and engineers are trying to develop the ideal fibers and matrices to achieve the optimum ceramic matrix composite properties. A need exists for the development of failure models for the design of ceramic matrix composite heat engine components. Phenomenological failure models are currently the most frequently used in industry, but they are deterministic and do not adequately describe ceramic matrix composite behavior. Semi-empirical models were proposed, which relate the failure of notched composite laminates to the stress a characteristic distance away from the notch. Shear lag models describe composite failure modes at the micromechanics level. The enhanced matrix cracking stress occurs at the same applied stress level predicted by the two models of steady state cracking. Finally, statistical models take into consideration the distribution in composite failure strength. The intent is to develop these models into computer algorithms for the failure analysis of ceramic matrix composites under monotonically increasing loads. The algorithms will be included in a postprocessor to general purpose finite element programs.
A novel concept of multilayer micro structurally controlled noise mitigation porous material was developed and experimentally validated in the laboratory by normal incidence impedance test. Extensive parametric studies were made to understand various parameters that influence acoustic absorption and transmission loss based on the test specimen size, particle size, porosity, pore size, and its distribution through the thickness. The results were reported in many publications. This work was focused on applying the concept and assessing the validity of the technology to aircraft turbomachine engines. The NASA Glenn Research Center’s Advanced Noise Control Fan (ANCF) low-speed test rig was selected. The liner insert required a 4-ft internal diameter cylinder with a 2-inch thick and 9-inch axial length. The liner was fabricated in eight segments and assembled in an aluminum test rig. The liner was tested for both tonal and broadband noise at the Notre Dame Turbomachinery Lab White Field test facility, where the ANCF is located. The study concludes that: Microstructurally controlled porous material is very effective in dissipating the sound energy; the liner is effective for tonal noise (2 to 13 dB reduction in noise levels) that constitutes the major part of the overall fan noise, especially the blade passing frequency which is generally the dominating component; Also, the liner is effective for broadband noise with reductions in sound pressure level of about 3 dB for the shaft order greater than 20. The proposed two-layer liner model demonstrated the validity of the concept. More studies are required to optimize the design.
The article suggests that the 1980's will see significant improvements in virtually all gas-turbine engine components and their materials and structural design methods. These improvements will be made possible by improved theoretical models, laser Doppler measurement techniques, advances in rotor-spool technology, the evolution of engine controls, etc. It is suggested that the engine components field should expect broad and steady advances in the technologies of flow, materials, and structures in terms of scope, precision, and tools of design.
As one of the most abundant and versatile natural materials on Earth, recently wood has attracted tremendous attention from scientists and engineers due to its outstanding advantages, including hierarchically porous microstructure, high mechanical strength, environmental friendliness, renewability, and biodegradability. Wood’s hierarchically porous structure and chemical components (e.g., cellulose, hemicelluloses, and lignin) enable its mechanical, ionic, optical, and thermal properties to be tuned via physical, chemical, and/or thermal modifications. Among these various approaches, the chemical delignification of bulk wood is the most fascinating, in which the majority of lignin and hemicelluloses is removed while leaving the cellulose intact, maintaining wood’s physical integrity and hierarchical structure. This delignified structure is unique, composed of hollow, aligned channels made up of cellulose microfibrils, and particularly attractive given its origin from a sustainable and renewable resource. As a result, delignified wood has attracted increasing attention for applications that go far beyond traditional wood utilization, such as lightweight yet strong structural materials, energy storage and conversion, environmental remediation, flexible electronics, and bioengineering. Here, we review recent developments in bulk wood delignification strategies toward the achievement of such advanced wood technologies for sustainable applications, with a focus on the research in our group. Similar to chemical pulping and bleaching, wood delignification involves a series of nucleophilic reactions based on alkaline Na 2 SO 3 or Na 2 S systems (i.e., chemical pulping) or electrophilic, radical, and oxidation reactions based on H 2 O 2 , ClO 2 , or NaClO systems (i.e., chemical bleaching) to deconstruct, fragment, and promote the hydrophilicity of lignin macromolecules, which finally make lignin easier to be removed. We discuss the structure and properties of partially and near-completely delignified wood, with a focus on process-structure–property relationships. The resulting delignified wood materials, with tunable structure and properties, demonstrate various advanced functions, in a wide range of advanced applications, such as building and construction, green energy, and electronics. Finally, the potential challenges and appealing perspectives of in situ wood delignification are discussed. In situ wood delignification, as a powerful modification strategy, has speeded up the development of advanced wood technologies and wood-based functional materials and products.
Irradiation experiments and post-irradiation examinations, together referred to as irradiation testing (IRT), are prerequisites for nuclear fuel and material qualification for the deployment of new and advanced reactors, as well as radioisotope production, thereby ensuring regulatory compliance. Qualified research and test reactors (RTRs) and testing facilities are essential to enable IRT to verify performance and safety under prototypical reactor conditions. In the past, qualification of new fuels or structural materials required about 20 years. Synergist strategies, advanced tools, and qualified methods are needed to greatly reduce this timeframe of IRT and radioisotope production. This study, termed accelerated-IRT, focuses on identifying gaps and leveraging U.S.-based RTRs and material testing capabilities, leveraging the preliminary evaluation and qualification of selected RTRs to provide a generic as well as specific-case solution paths forward, ensuring adherence to stringent regulatory standards. Furthermore, IRT and radioisotope production utilizing qualified RTRs necessarily includes modeling and simulation to support the design (i.e. neutronics, thermal, and structural aspects) and manufacturing of irradiation test specimens, vehicles, capsules, apparatuses, and flow loops. In addition, IRT can be improved by applying advanced manufacturing techniques and in-pile sensors and instrumentation, as discussed in this study.
Unexpected occurrence of failures, due to stress corrosion cracking (SCC) of structural components, indicate a need for improved characterization of materials and more advanced analytical procedures for reliably predicting structures performance. Accordingly, the purpose of this study was to determine the stress corrosion susceptibility of 15-5PH steel over a wide range of applied strain rates in a highly corrosive environment. The selected environment for this investigation was a highly acidified sodium chloride (NaCl) aqueous solution. The selected alloy for the study was a 15-5PH steel in the H900 condition. The slow strain rate technique was selected to test the metals specimens.
Single-wall carbon nanotubes offer the promise of a new class of revolutionary materials for space applications. The Carbon Nanotube Project at NASA Johnson Space Center has been actively researching this new technology by investigating nanotube production methods (arc, laser, and HiPCO) and gaining a comprehensive understanding of raw and purified material using a wide range of characterization techniques. After production and purification, single wall carbon nanotubes are processed into composites for the enhancement of mechanical, electrical, and thermal properties. This "cradle-to-grave" approach to nanotube composites has given our team unique insights into the impact of post-production processing and dispersion on the resulting material properties. We are applying our experience and lessons-learned to developing new approaches toward nanotube material characterization, structural composite fabrication, and are also making advances in developing thermal management materials and electrically conductive materials in various polymer-nanotube systems. Some initial work has also been conducted with the goal of using carbon nanotubes in the creation of new ceramic materials for high temperature applications in thermal protection systems. Human space flight applications such as advanced life support and fuel cell technologies are also being investigated. This discussion will focus on the variety of applications under investigation.
In its Aircraft Energy Efficiency Program, NASA has expended approximately 200 million dollars toward development and application of advanced airframe technologies to United States's commercial transports. United States manufacturers have already been given a significant boost toward early application of advanced composite materials to control surface and empennage structures and toward selected applications of active controls and advanced aerodynamic concepts. In addition, significant progress in definition and development of innovative, but realistic systems for laminar flow control over the wings of future transports has already been made.
To explore the fundamental properties of metamaterials (MMs) / metasurfaces and their potential for control of energy at the sub‐wavelength scale in support of the mission of the Department of Energy and the office of Basic Energy Sciences. Electromagnetic metamaterials provide a platform for the discovery and design of new materials with novel structures, functions, and properties. The PI proposes to advance the knowledge base of these materials through fundamental investigations of the experimental and theoretical properties of metamaterials for the discovery, prediction and design of new materials with novel structures, functions, and properties. The proposed research activities emphasize a complete basic research program including the conceptual / computational design, fabrication / synthesis of the materials, and the characterization and analysis of their electromagnetic properties. The proposed project explores the fundamental properties of metamaterials / metasurfaces and their potential for energy applications. There are three main topics which will be investigated: 1) Dispersion engineering with metamaterials and metasurfaces, 2) Epsilon near zero metamaterial absorbers and emitters, and 3) All dielectric metamaterials. The program implements a complete basic research program consisting of theory / design, modeling, characterization, and analysis, in order to fully characterize metamaterials and metasurfaces, while at the same time minimizing iterations necessary to achieve the proposal goals.
Structural concept trends for future commercial supersonic transport aircraft are considered. Highlights, including the more important design conditions and requirements, of two studies are discussed. Knowledge of these design parameters, as determined through studies involving the application of flexible mathematical models, enabled inclusion of aeroelastic considerations in the structural-material concepts evaluation. The design trends and weight data of the previous contractual study of Mach 2.7 cruise aircraft were used as the basis for incorporating advanced materials and manufacturing approaches to the airframe for reduced weight and cost. Structural studies of design concepts employing advanced aluminum alloys, advanced composites, and advanced titanium alloy and manufacturing techniques are compared for a Mach 2.0 arrow-wing configuration concept. Appraisals of the impact of these new materials and manufacturing concepts to the airframe design are shown and compared. The research and development to validate the potential sources of weight and cost reduction identified as necessary to attain a viable advanced commercial supersonic transport are discussed.
Materials qualification of reactor structural materials is a critical step in rapid implementation of advanced nuclear reactor technologies, particularly to assess the corrosion performance in these designs. Accelerated qualification of reactor structural materials requires incorporating powerful computational toolsets, such as phase field modelling in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, to predict the evolution of structural materials due to corrosion. Accordingly, computational toolsets will require experimental data generated at appropriate length scales to validate accuracy. Focused ion beam (FIB) provides a high degree of control over manipulation of materials for analytical purposes, including capturing data on the evolution in the microstructure and elemental composition of materials at the mesoscale, an appropriate length scale for phase field modelling of intergranular diffusion phenomena using the MOOSE framework. For instance, the FEI Helios G4 UX dual beam plasma FIB microscope at the Irradiated Materials Characterization Laboratory (IMCL) is capable of backscatter diffraction (EBSD) and energy-dispersive x-ray spectroscopy (EDS) documenting the evolution in the microstructure and elemental composition, respectively. The Helios can perform EDS and EBSD three-dimensionally (3D) using tomography, which is then combined using different software packages to visualize 3D volumes correlating elemental composition to microstructural data. The purpose of this investigation was to develop a streamlined characterization and data processing workflow for 3D tomography studies on the FEI Helios G4 plasma FIB. The investigation is segmented into three parts: 1) Optimizing the data collection workflow, 2) identifying appropriate data processing and visualization software (i.e. DREAM.3D, MIPAR, and VGStudioMax), and 3) establishing an infrastructure for public release. The optimization of the data collection workflow is in collaboration with members of the U220 department to setup formal training on the tomography operation of the G4, through ThermoFisher Scientific, and exploring DREAM.3D, MIPAR, and VGStudioMax data processing/visualization software packages. VGStudioMax currently demonstrates the most promise for future use. Optimization of the data collection and processing workflow is still ongoing. A collaboration with INL High Performance Computing (HPC) established an open-source license for expediting the public release of FIB tomography datasets through HPC. FIB tomography data generated by the G4 will provide comprehensive data for validating 3D phase field mesoscale modelling tools within the MOOSE framework for accelerated qualification of reactor structural materials.
The Probabilistic Structures Analysis Method (PSAM) program integrates state of the art probabilistic algorithms with structural analysis methods in order to quantify the behavior of Space Shuttle Main Engine structures subject to uncertain loadings, boundary conditions, material parameters, and geometric conditions. An advanced, efficient probabilistic structural analysis software program, NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) was developed as a deliverable. NESSUS contains a number of integrated software components to perform probabilistic analysis of complex structures. A nonlinear finite element module NESSUS/FEM is used to model the structure and obtain structural sensitivities. Some of the capabilities of NESSUS/FEM are shown. A Fast Probability Integration module NESSUS/FPI estimates the probability given the structural sensitivities. A driver module, PFEM, couples the FEM and FPI. NESSUS, version 5.0, addresses component reliability, resistance, and risk.
This report presents an overview of a Mobile Lunar Habitat (MLH) structural design consisting of advanced composite materials. The habitat design is derived from the cylindrical-shaped U.S. Lab module aboard the International Space Station (ISS) and includes two lateral ports and a hatch at each end that geometrically match those of the ISS Nodes. Thus, several MLH units can be connected together to form a larger lunar outpost of various architectures. For enhanced mobility over the lunar terrain, the MLH uses six articulated insect-like robotic, retractable legs enabling the habitat to .t aboard a launch vehicle. The carbon-composite shell is sandwiched between two layers of hydrogen-rich polyethylene for enhanced radiation shielding. The pressure vessel is covered by modular double-wall panels for meteoroid impact shielding supported by externally mounted stiffeners. The habitat s structure is an assembly of multiple parts manufactured separately and bonded together. Based on the geometric complexity of a part and its material system, an appropriate fabrication process is proposed.
This paper presents the results of a NASA funded contract and Sikorsky research and development programs to evaluate structural composite components in flight service on Sikorsky Model S-76 helicopters. Selected components were removed and tested at prescribed intervals over a nine year time frame. Four horizontal stabilizers and thirteen tail rotor spars were returned from commercial service in West Palm Beach, Florida and in the Gulf Coast region of Louisiana to determine the long term effects of operations in hot and humid climates on component performance. Concurrent with the flight component evaluation, panels of materials used in their fabrication were exposed to the environment in ground racks. Selected panels were tested annually to determine the effects of exposure on physical and mechanical properties. The results of 55,741 component flight hours and 911 months of field exposure are reported and compared with initial Federal Aviation Administration (FAA) certification data. The findings of this program have provided increased confidence in the long term durability of advanced composite materials used in helicopter structural applications.
Hexagonal boron nitride (h-BN) is a layered inorganic synthetic crystal exhibiting high temperature stability and high thermal conductivity. As a ceramic material it has been widely used for thermal management, heat shielding, lubrication, and as a filler material for structural composites. Recent scientific advances in isolating atomically thin monolayers from layered van der Waals crystals to study their unique properties has propelled research interest in mono/few layered h-BN as a wide bandgap insulating support for nanoscale electronics, tunnel barriers, communications, neutron detectors, optics, sensing, novel separations, quantum emission from defects, among others. Realizing these futuristic applications hinges on scalable cost-effective high-quality h-BN synthesis. Here, in this work, the authors review scalable approaches of high-quality mono/multilayer h-BN synthesis, discuss the challenges and opportunities for each method, and contextualize their relevance to emerging applications. Maintaining a stoichiometric balance B:N = 1 as the atoms incorporate into the growing layered crystal and maintaining stacking order between layers during multi-layer synthesis emerge as some of the main challenges for h-BN synthesis and the development of processes to address these aspects can inform and guide the synthesis of other layered materials with more than one constituent element. Finally, the authors contextualize h-BN synthesis efforts along with quality requirements for emerging applications via a technological roadmap.
An optical bench and associated mirror support structural components were designed and fabricated for the HEAO-B satellite. Stringent dimensional stability criteria dictated the use of a graphite/epoxy composite as the basic structural material. Design, analysis, and fabrication aspects are discussed for the resulting structures, which pioneer the use of advanced composite materials for significant applications to orbital flight hardware.
Advanced high-temperature nuclear reactors rely on structural components that will operate for decades under combined mechanical, thermal, and environmental loading. Materials surveillance programs are a promising strategy for managing the resulting uncertainty in long-term structural integrity by monitoring degradation in service using passively actuated mechanical test articles. Previous reports have developed a simplified, spreadsheetimplementable framework for sizing these test articles and for inferring accumulated creep damage and remaining life from ex-situ test data. This report advances that work toward practical deployment by providing a sample-problem book: a collection of worked, end-toend examples in which the ASME Section III, Division 5 design analysis of a representative high-temperature reactor component is carried through to a sized surveillance article, verified with detailed finite-element analysis, and concluded with a remaining-life assessment based on an assumed ex-situ creep-rate measurement on the retrieved specimen. The report also summarizes ongoing ANL engagement with ASTM Committee E10 on Nuclear Technology and Applications toward drafting a standard covering surveillance procedures for advanced reactors.