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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Application of two creep fatigue life models for the prediction of elevated temperature crack initiation of a nickel base alloy

Cyclic Damage Accumulation (CDA) and Total Strain-Strain Range Partitioning (TS-SRP) models for predicting the creep-fatigue crack initiation life of high temperature alloys are presented. The models differ in their fundamental assumptions regarding the controlling parameters for fatigue crack initiation and in the amount of data required to determine model constants. The CDA model represents a ductility exhaustion approach and uses stress quantities to calculate the cyclic fatigue damage. The TS-SRP model is based on the use of total mechanical strain and earlier concepts of the Strain Range Partitioning Method. Both models were applied to a well controlled fatigue data set at a high temperature nickel base alloy, B1900 + Hf, tested at 1600 F and 1800 F. The tests were divided into a baseline data set required to determine model constants and a verification data set for evaluation of the predictive capability of the models. Both models correlated the baseline data set to within factors of two in life, and predicted the verification data set to within a factor of three or better. In addition, sample calculations to demonstrate the application of each model and discusions of the predictive capabilities and areas requiring further development are presented.

Moreno, V.↗
NASA NTRS2024

Influence of Ductility on the Performance of Lunar Habitat Structures Under Recurrent Disturbances

This research examines how ductility affects the durability of lunar surface structures against recurring disturbances like moonquakes, micrometeorite impacts, and thermal cycles over an extended period. The structural performance at various levels of ductility was determined by adjusting material parameters and the thickness of a reference multilayered dome structure. Moonquake and micrometeorite impact-induced lateral displacements were estimated using a reduced-order model under a control-oriented dynamic computational modeling framework. The study considered the degradation of the metallic dome’s strength properties over time due to thermal cycles. Fragility curves were generated by assessing the likelihood of reaching three predefined damage levels as a result of multiple hazards. Additionally, a discounted cash flow analysis was conducted to incorporate a financial aspect into the performance comparison. The findings revealed that structures with sufficient ductility capacity have a lower probability of sustaining severe damage or collapsing within a shorter time frame. Hence, having ductile structures in lunar environments is advantageous as it allows the postponement of maintenance and repair actions, thereby conserving scarce resources for more urgent tasks. Moreover, the financial analysis demonstrated that lunar habitats with higher ductile capacities result in larger net present values, offering a higher return on the initial investment.

Arsalan Majlesi↗
NASA NTRS1976

Observations on the relationship of structure to the mechanical properties of thin TD-NiCr sheet

A study of the relationship between structure and mechanical properties of thin TD-NiCr sheet indicated that the elevated temperature tensile, stress-rupture, and creep strength properties are dependent on grain aspect ratio and sheet thickness. In general, the strength properties increase with increasing grain aspect ratio and sheet thickness. Tensile testing revealed an absence of ductility at elevated temperatures (not less than 1144 K). Significant creep damage as determined by subsequent tensile testing at room temperature occurs after very small amounts (less than 0.1%) of prior creep deformation over the temperature range 1144-1477 K. A threshold stress for creep appears to exist. Creep exposure below the threshold stress at T not less than 1366 K results in almost full retention of room temperature tensile properties.

Whittenberger, J. D.↗
NASA NTRS1983

Mathematical modeling of damage in unidirectional composites

Extending the work of Goree and Gross (1979), solutions are given for a two-dimensional region of unidirectional fibers embedded in an elastic matrix whose initial flaw may take the form of a transverse notch, a rectangular cutout, or a circular hole. Subsequent flaw-induced damage is generated by remote stresses acting parallel to the fibers. For the case of such ductile matrix composites as boron/aluminum, present results indicate that both longitudinal matrix yielding and transverse notch extension must be included in order for the model to agree with experimental results. Little difference is found for the three types of initial damage considered. In all cases, the presence of additional damage changes the nature of stress distribution through the unbroken fibers.

Goree, J. G.↗
NASA NTRS1994

Neutral Ion Figuring of Chemical Vapor Deposited SiC

Ion figuring of optical components is a relatively new technology that can alleviate some of the problems associated with traditional contact polishing. Because the technique is noncontacting, edge distortions and rib structure print through do not occur. This investigation was aimed at determining the effect of ion figuring on surface roughness of previously polished or ductile ground ceramic optical samples. This is the first step in research directed toward the combination of a prefinishing process (ductile grinding or polishing) with ion figuring to produce finished ceramic mirrors. Multiple, chemical vapor deposited silicon carbide (CVD SiC) samples were polished or ductile ground to specular or near-specular roughness. These samples were then characterized to determine topographic surface information. The surface evaluation consisted of stylus profilometry, interferometry, and optical and scanning electron microscopy. The surfaces were then ion machined to depths from 0 to 5 micron. The finished surfaces were characterized to evaluate the effects of the ion-machining process with respect to the previous processing methods and the preexisting subsurface damage. This study provides some of the information required to effectively utilize a combined ductile grinding or polishing with ion machining as a procedure for figuring optical components.

Fawcett, Steven C.↗
NASA NTRS1974

Low-cost methods for fabrication of aluminum-boron shapes

Deformation processing has not been seriously considered as applicable to composite fabrication, particularly if the filament (e.g., boron) lacks plasticity. When, however, the brittle filament is clad with a ductile matrix such as 6061 Al, the underlying filament is protected from damage even when cold worked severely as in drawing and rolling. These two metal-working processes have been applied successfully to produce seven ply aluminum 50 vol % boron tubes up to 2 in. O.D. by 3 feet in length and flats 1 in. in width by 2 feet in length respectively. Although adequate densification is achieved via drawing and rolling, the former has been given major emphasis. Mechanical properties of rolled and drawn flats and tubes compare favorably with those prepared by static methods. However, the objective of the presentation is to focus on lower processing costs. In specific terms, 2 in. tubes in lengths up to 12 feet can be produced for as little as $150/lb. This is possible only because standard drawbench and carbide dies can be utilized. Furthermore, the major steps including cladding, preform preparation and drawing are conducive to automation.

Divecha, A. P.↗
NASA NTRS2018

Plasticity and Damage Modeling of Stress Asymmetry and Dynamic Behavior of AFS Additive Manufactured Aluminum Alloy 2219

The Solid State Additive Manufacturing (AM) process referred as MELD that fabricated the samples in this study, provides a new path for repairing, coating, joining and additive manufacturing metals and metal matrix composites. This research will be the first application of a physics-based microstructure dependent internal state variable (ISV) plasticity and damage material model to capture the mechanical response of an AM Aluminum Alloy (AA) 2219 via the MELD process. In this research, a microstructure-based internal state variable (ISV) plasticity-damage model was used to capture the mechanical behavior of AFS 2219 aluminum alloy. Aeroprobe Corporation, creator and patent holder for the MELD process, fabricated the material by pushing a solid filler rod of AA2219-T861 material through a hollow rotating tool onto an AA2219 T851 plate substrate. As feedstock, solid or powder precursor metals are pushed through a nonconsumable rotating cylindrical tool. Herein, added layers are deposited and metallurgically bonded to substrate material or previously deposited layers by the heat generated from the rotating tool through plastic deformation of the filler material. Once a layer has been added, the tool height increases, and starts the deposition of the next layer. This process results in beneficial properties such as grain refinement, homogenization and reduced porosity (fully dense). This process will experience temperatures similar to those in the weld nugget zone (WNZ) in friction stir welding (FSW), ranging from 0.6-0.9 Tm, with Tm being the melting point of the material. MELD is highly scalable with AA deposition rates reaching over 1000 cm3/hr, which allows for MELD being used for repairs, coatings, and building components. A motivating factor driving the research for physics-based history dependent material modeling of MELD components is the ability to accurately capture the stress-state and strain rate dependence in the material caused by variations in material microstructure from the MELD processing of new or repaired components. The ISV model incorporates microstructural content and is consistent with continuum level kinematics, kinetics, and thermodynamics. These features allow the ISV model to capture large deformations at the structural scale using the kinematic and isotropic hardening, while microscale damage is obtained from the microstructural features. The benefits of the ISV model arise from the inclusion of structure-property relationships identified from microstructural characterization and experimentation. The Bauschinger effect (BE) is an important concept, vital in the accurate prediction of cyclic stress-strain response of ductile materials such as metals. The ISV model has been successfully used to capture the behavior and damage, and the BE of different aluminum alloys and steels. The ISV model uses kinematic and isotropic hardening to help capture deformations of the material at the macro scale. To understand this hardening relationship, calculating the kinematic and isotropic hardening relationship in the material is warranted for a high-fidelity model. Electron Backscattered Diffraction (EBSD) was used to characterize the as-fabricated microstructure, where a fully-dense equiaxed grain morphology with average grain size of 2.5 μm was observed. Microhardness mapping of the as-built structures, monotonic tension and compression experiments at both quasi-static (0.001/s) strain rates, tension-followed-by-compression and compression-followed-by-tension experiments were performed to obtain the set of plasticity and damage constants necessary to capture strain rate and stress state behavior of this additive material. To calibrate the plasticity-damage model, a single set of constants were determined to capture the different stress states the MELD AA2219. One set of the constants was determined from experimental true stress-strain curves for the tension and compression data. Additionally, microstructural information and data from the open literature were used as the other model constants. This research is a first of its kind for AFS AA2219, includes correlating the ISV model to the monotonic experimental results that capture the isotropic and kinematic plasticity mechanical response.

Rivera, O. G.↗
NASA NTRS2011

Surrogate Modeling of High-Fidelity Fracture Simulations for Real-Time Residual Strength Predictions

A surrogate model methodology is described for predicting, during flight, the residual strength of aircraft structures that sustain discrete-source damage. Starting with design of experiment, an artificial neural network is developed that takes as input discrete-source damage parameters and outputs a prediction of the structural residual strength. Target residual strength values used to train the artificial neural network are derived from 3D finite element-based fracture simulations. Two ductile fracture simulations are presented to show that crack growth and residual strength are determined more accurately in discrete-source damage cases by using an elastic-plastic fracture framework rather than a linear-elastic fracture mechanics-based method. Improving accuracy of the residual strength training data does, in turn, improve accuracy of the surrogate model. When combined, the surrogate model methodology and high fidelity fracture simulation framework provide useful tools for adaptive flight technology.

Spear, Ashley D.↗
NASA NTRS1989

Ductile-regime turning of germanium and silicon

Single-point diamond turning of silicon and germanium was investigated in order to clarify the role of cutting depth in coaxing a ductile chip formation in normally brittle substances. Experiments based on the rapid withdrawal of the tool from the workpiece have shown that microfracture damage is a function of the effective depth of cut (as opposed to the nominal cutting depth). In essence, damage created by the leading edge of the tool is removed several revolutions later by lower sections of the tool edge, where the effective cutting depth is less. It appears that a truly ductile cutting response can be achieved only when the effective cutting depth, or critical chip thickness, is less than about 20 nm. Factors such as tool rake angle are significant in that they will affect the actual value of the critical chip thickness for transition from brittle to ductile response. It is concluded that the critical chip thickness is an excellent parameter for measuring the effects of machining conditions on the ductility of the cut and for designing tool-workpiece geometry in both turning and grinding.

Blake, Peter N.↗
NASA NTRS1972

Irradiation effects studies of NERVA materials

Several materials used in the NERVA project were irradiated at cryogenic temperatures to neutron fluences between 10 to the 17th and 10 to the 19th power newtons per square centimeter. Tensile properties were determined over a temperature range to evaluate the effects of irradiation on the material properties. The expected radiation damage typical of other materials was observed. A general increase in strength and decrease in ductility occurred. The effects at liquid nitrogen temperatures are more pronounced since radiation induced defects are not annealed out.

Demastry, J. A.↗
NASA NTRS1995

Effect of Processing Route on Strain Controlled Low Cycle Fatigue Behavior of Polycrystalline NiAl

The present investigation examines the effects of manufacturing process on the total axial strain controlled low cycle fatigue behavior of polycrystalline NiAl at 1000 K, a temperature above the monotonic Brittle-to-Ductile Transition Temperature (BDTT). The nickel aluminide samples were produced by three different processing routes: hot isostatic pressing of pre- alloyed powders, extrusion of prealloyed powders, and extrusion of vacuum induction melted ingots. The LCF behavior of the cast plus extruded material was also determined at room temperature (below the BD77) for comparison to the high temperature data. The cyclic stress response, cyclic stress-strain behavior, and strain-life relationships were influenced by the alloy preparation technique and the testing temperature. Detailed characterization of the LCF tested samples was conducted by optical and electron microscopy to determine the variations in fracture and deformation modes and to determine any microstructural changes that occurred during LCF testing. The dependence of LCF properties on processing route was rationalized on the basis of starting microstructure, brittle-to-ductile transition temperature, deformation induced changes in the basic microstructure, deformation substructure, and synergistic interaction between the damage modes.

Rao, K. Bhanu Sankara↗
NASA NTRS2009

Electron Backscatter Diffraction (EBSD) Analysis and U-Pb Geochronology of the Oldest Lunar Zircon: Constraining Early Lunar Differentiation and Dating Impact-Related Deformation

The evolution of the early moon was dominated by two processes (i) crystallization of the Lunar Magma Ocean (LMO) and differentiation of potassium-rare earth element-phosphorous-rich residual magma reservoir referred to as KREEP, and (ii) an intense meteorite bombardment referred to as lunar cataclysm . The exact timing of these processes is disputed, and resolution relies on collection and interpretation of precise age data. This study examines the microstructure and geochronology of zircon from lunar impact breccias collected during the Apollo 17 mission. A large zircon clast within lunar breccia 72215,195 shows sector zoning in optical microscopy, cathodoluminescence (CL) imaging and Raman mapping, and indicates that it was a relict fragment of a much larger magmatic grain. Sensitive high resolution ion microprobe (SHRIMP) U-Pb analysis of the zircon shows that U and Th concentration correlate with sector zoning, with darkest CL domains corresponding with high-U and Th (approx.150 and approx.100 ppm respectively), and the brightest-CL sectors containing approx.30-50 ppm U and approx.10-20 ppm Th. This indicates that variations in optical CL and Raman properties correspond to differential accumulation of alpha-radiation damage in each sector. Electron backscatter diffraction (EBSD) mapping shows that the quality of electron backscatter patterns (band contrast) varies with sector zoning, with the poorest quality patterns obtained from high-U and Th, dark-CL zones. EBSD mapping also reveals a deformation microstructure that is cryptic in optical, CL and Raman imaging. Two orthogonal sets of straight discrete and gradational low-angle boundaries accommodate approx.12 misorientation across the grain. The deformation bands are parallel to the crystallographic {a}-planes of the zircon, have misorientation axes parallel to the c-axis, and are geometrically consistent with formation by dislocation creep associated with <100>{010} slip. The deformation bands are unlike curved morphology of crystal-plastic microstructures in tectonically deformed terrestrial zircon, and geometrically similar to dislocation microstructures reported in experimentally shocked zircon. We interpret these crystal-plastic deformation microstructures to have resulted from a significant impact, either directly from impact shock, or during ductile flow directly following the impact. The deformation bands appear to continue undeflected through the non-indexed, radiation-damaged areas of the grain, which suggests that the orientation variation predates any significant mechanical weakening from radiation damage in the grain, and therefore occurred early in its history.

Timms, Nick↗
NASA NTRS2016

Annular Air Leaks in a Liquid Hydrogen Storage Tank

Large liquid hydrogen (LH2) storage tanks are vital infrastructure for NASA, the DOD, and industrial users. Over time, air may leak into the evacuated, perlite filled annular region of these tanks. Once inside, the extremely low temperatures will cause most of the air to freeze. If a significant mass of air is allowed to accumulate, severe damage can result from nominal draining operations. Collection of liquid air on the outer shell may chill it below its ductility range, resulting in fracture. Testing and analysis to quantify the thermal conductivity of perlite that has nitrogen frozen into its interstitial spaces and to determine the void fraction of frozen nitrogen within a perlite-frozen nitrogen mixture is presented. General equations to evaluate methods for removing frozen air, while avoiding fracture, are developed. A hypothetical leak is imposed on an existing tank and a full analysis of that leak is detailed. This analysis includes a thermal model of the tank and a time-to-failure calculation. Approaches to safely remove the frozen air are analyzed, leading to the conclusion that the optimal approach is to allow the frozen air to melt and use a water stream to prevent the outer shell from chilling.

Krenn, A. G.↗
NASA NTRS2012

Small-Scale Mechanical Characterization of Space-Exposed Fluorinated Ethylene Propylene Recovered from the Hubble Space Telescope

Multi-layer insulation panels from the Hubble Space Telescope have been recovered after 19.1 years of on-orbit service and micro-tensile experiments have been performed to characterize the effect of space exposure on the mechanical response of the outermost layer. This outer layer, 127 m thick fluorinated ethylene propylene with a 100 nm thick vapor deposited aluminum reflective coating, maintained significant tensile ductility but exhibited a degradation of strength that scales with severity of space exposure. This change in properties is attributed to damage from incident solar flux, atomic oxygen damage, and thermal cycling.

Jones, J. S.↗
NASA NTRS1995

The effect of interface properties on nickel base alloy composites

This program was performed to assess the extent to which mechanical behavior models can predict the properties of sapphire fiber/nickel aluminide matrix composites and help guide their development by defining improved combinations of matrix and interface coating. The program consisted of four tasks: 1) selection of the matrices and interface coating constituents using a modeling-based approach; 2) fabrication of the selected materials; 3) testing and evaluation of the materials; and 4) evaluation of the behavior models to develop recommendations. Ni-50Al and Ni-20AI-30Fe (a/o) matrices were selected which gave brittle and ductile behavior, respectively, and an interface coating of PVD YSZ was selected which provided strong bonding to the sapphire fiber. Significant fiber damage and strength loss was observed in the composites which made straightforward comparison of properties with models difficult. Nevertheless, the models selected generally provided property predictions which agreed well with results when fiber degradation was incorporated. The presence of a strong interface bond was felt to be detrimental in the NiAI MMC system where low toughness and low strength were observed.

Groves, M.↗
NASA NTRS1992

Composites of low-density trialuminides: Particulate and long fiber reinforcements

An examination of the ternary L1(sub 2) trialuminides, Al66Ti25Mn9, Al67Ti25Cr8, and Al22Ti8Fe3 in compression, bending, and tension revealed that none of these compounds exhibited a desirable balance of strength, ductility, and oxidation resistance. Subsequently, specific quaternary and quinary compositions were cast, homogenized, and isothermally forged. Both, the monolithic material and its particulate reinforced counterparts were examined in compression, three point bend, and tension as a function of temperature, and at high temperatures as a function of strain rate. An alternate approach that was examined in this program to enhance the low temperature damage tolerance of these materials was to incorporate long refractory metal wires in the matrix. In summary, it appears that of the various matrix compositions examined, ternary Al66Ti25Mn9 exhibits the best balance in strength, ductility, and oxidation resistance. Although the idea of refractory metal wire reinforcement is an attractive one, a successful combination remains to be identified.

Kumar, K. S.↗