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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Microsample Characterization of Coatings for Grcop-84 for High Heat Flux Applications

A multidisciplinary Johns Hopkins University-NASA Glenn team is undertaking a collaborative research program to elucidate and model the thermal stability and mechanical integrity of candidate coatings for GRCop-84. GRCop-84 is a high conductivity, high strength copper alloy that was recently developed at NASA Glenn for use in high temperature, high heat flux applications. With potential applications in rocket motor combustion chamber liners, nozzle ramps and other actively cooled structures, this new material offers great potential for decreasing weight and increasing reliability of third generation reusable launch vehicles. Current emphasis has turned toward the development of environmentally resistant and thermal barrier coatings for this alloy. Metallic coatings such as NiCrAlY and Cu-8-30%Cr have shown promise in: prohibiting blanching, reducing dog-house failures, increasing operating temperatures and decreasing cooling requirements. The focus of this research program is to develop a fundamental understanding of the substrate-coating interactions that occur during thermal cycling (inter-diffusion, viscoplasticity, morphological evolution, crack formation, etc.) and to derive a science-based protocol for future coating selection, optimization and reliability assurance. The microsample tensile testing approach adopted for this study allows us to characterize small-scale and highly scale-specific coatings and properties in a way not possible by conventional means. In addition to providing much needed design data, the integration of microsample testing with detailed microstructural observations provides a mechanistic foundation for coating optimization and life prediction modeling.

Hemker, Kevin↗
NASA NTRSDate not supplied

Transfer Function Models and Sensitivity Analysis

In many situations, real or induced flaws such as tight cracks with known morphology cannot be manufactured in part configuration specimens or in real parts. Typically, fatigue cracks are manufactured in simple geometry specimens such as flat plates, dog-bone shaped flat or round specimens. If a nondestructive evaluation (NDE) technique is required to provide a reliably detectable target flaw size denoted as α_(90/95) for induced flaws in real part, then the direct method for qualifying the NDE procedure is to use the appropriate induced flaw specimens and perform probability of detection analysis using these flaws. This can be described as direct POD demonstration testing, which may follow guidelines of MIL-HDBK-1823. This paper considers a case, where induced flaws are not available in part configuration specimens. Therefore, a direct POD demonstration study cannot be undertaken. In such situation, general practice for NDE procedure qualification is to use artificial flaws in simple geometry and part configuration specimens, and induced flaws in the chosen simple geometry specimens. Signal response data is taken on all sets of artificial and induced flaws. NDE procedure testing on induced flaw in simple geometry specimen is called NDE demonstration testing here. A transfer function NDE procedure qualification method for forward case calculates predicted induced flaw size for demonstration using a chosen target flaw size. Another transfer function method for inverse case, calculates the target flaw size using a given demonstration flaw size. The transfer function analysis assumes relationship of artificial flaw signal responses in real parts and simple geometry specimens; and induced flaw responses in simple geometry specimens to induced flaws in real parts. The signal response transfer relationships model should be defined before transfer function models can be devised. Assuming that the signal response transfer relationships model is valid, forward and inverse case transfer function methods have been devised. Because of lack of signal response data from induced flaws in real part, 90/95% POD/confidence (P/C) cannot be demonstrated directly. However, the transfer function method may be assessed using simulation to evaluate whether the resulting target flaw size or demonstration flaw size provides adequate confidence to the assumed signal response transfer relationships model. Therefore, the transfer function approach is a risk assessment approach. Both the signal response transfer relationships model and the transfer function model are important in managing risk in results provided by the transfer function NDE technique qualification or assessment. The signal response transfer relationships model needs to be validated with empirical data and then transfer function model needs to be validated for desired P/C on case-by-case basis.

Nondestructive evaluation↗
NASA NTRSDate not supplied

Residual Strength of Hypervelocity Impacted Silica

Windows in the International Space Station are subjected to on-going micrometeoroid and orbital debris damage (MMOD). The reliability of the windows is being ensured by monitoring of damage, life prediction, and measurement of the residual strength of man-made and natural hypervelocity impact damage. The residual strength of man-made craters and MMOD craters harvested from space shuttle windows were used to estimate strength as a function of damage dimensions and thereby derive design allowables for U.S. and Russian fused silicas used in the ISS. US and Russian silica exhibit similar mechanical properties. An effect of impact angle is apparent, with 0o impacts exhibiting the lowest strength for Russian quartz-derived silica. The crater morphology for fused silica consists of a central pit, crush zone, shallow rings and radial cracks dividing petaloids. Morphology of alkaline glass is different from than that of fused silica, with a more distinct pit and pulverized region, and bell and tail-like features below the pit.

Silicia↗
NASA NTRSDate not supplied

Transfer function models for using empirical and physics-based simulation signal response data

In many situations, real or induced flaws such as tight cracks with known morphology cannot be manufactured in part geometry specimens or in real parts. Typically, surface fatigue cracks are manufactured in simple geometry specimens such as flat plates, dog-bone shaped flat or cylindrical specimens. If a nondestructive evaluation (NDE)technique is required to provide a reliably detectable flaw size, denoted asa90/95, for induced flaws in a part, then a direct method for qualifying the NDE procedure is to use appropriate induced flaw specimens and perform NDE procedure demonstration on the specimens. Probability of detection (POD)analysis of the empirical data may provide estimation of a90/95. This approach is described as direct POD demonstration testing, which may follow guidelines of MIL-HDBK-1823. This paper considers a case, where embedded tight cracklike induced flaws are to be detected reliably using a signal response based NDE procedure. Here, it is assumed that it is not practical to make surface or embedded induced flaw specimens in part geometry or configuration. Therefore, a direct POD demonstration testing cannot be undertaken. It is also assumed that simulation of signal response is possible for both surface and embedded induced flaws in part geometry specimens using a physics-based model. The proposed approach for NDE procedure qualification uses artificial flaws in simple geometry and part geometry specimens, and induced flaws in the same type of simple geometry specimens. Signal response data is taken on all sets of artificial and induced flaws in simple geometry and part geometry specimens. Moreover, simulated signal response data is generated for surface and embedded flaws. Thus, a case of five signal response versus flaw size datasets is considered. Three of the datasets are empirical and two datasets are physics model-based simulation datasets. A method of devising and using transfer function calculation dataset blocks to estimate the either the reliably detectable flaw size or the demonstration flaw size is provided.

Nondestructive evaluation↗
NASA NTRS2024

Residual Strength of Hypervelocity Impacted Silica

Windows in the International Space Station (ISS) are subject to ongoing micrometeoroid and orbital debris (MMOD) damage. The reliability of the windows is ensured by monitoring of damage, life prediction, and measurement of the residual strength of man-made and natural hypervelocity impacted window materials. Information on the residual strength of man-made craters and MMOD craters harvested from space shuttle windows was used to estimate strength as a function of damage dimensions and thereby derive design allowables for U.S. and Russian fused silicas used in the ISS. An effect of impact angle is apparent, with 0° impacts exhibiting the lowest strength for Russian quartz-derived silica. The crater morphology for fused silica consists of a central pit, crush zone, shallow rings, and radial cracks dividing shallow, petal-like lateral cracks (petaloids). The morphology of alkaline glass differs from that of fused silica, with a more distinct pit and pulverized region, and bell-shaped and tail-like features below the pit.

International space station,↗
NASA NTRS1981

The fracture morphology of nickel-base superalloys tested in fatigue and creep-fatigue at 650 C

The fracture surfaces of compact tension specimens from seven nickel-base superalloys fatigue tested at 650 C were studied by scanning electron microscopy and optical metallography to determine the nature and morphology of the crack surface in the region of stable growth. Crack propagation testing was performed as part of an earlier study at 650 C in air using a 0.33 Hz fatigue cycle and a creep-fatigue cycle incorporating a 900 second dwell at maximum load. In fatigue, alloys with a grain size greater than 20 micrometers, HIP Astroloy, Waspaloy, and MERL 76, exhibited transgranular fracture. MERL 76 also displayed numerous fracture sites which were associated with boundaries of prior powder particles. The two high strength, fine grain alloys, IN 100 and NASA IIB-7, exhibited intergranular fracture. Rene 95 and HIP plus forged Astroloy displayed a mixed failure mode that was transgranular in the coarse grains and intergranular in the fine grains. Under creep-fatigue conditions, fracture was found to be predominantly intergranular in all seven alloys.

Gayda, J.↗
NASA NTRS1975

A film-rupture model of hydrogen-induced, slow crack growth in alpha-beta titanium

The appearance of the terrace like fracture morphology of gaseous hydrogen induced crack growth in acicular alpha-beta titanium alloys is discussed as a function of specimen configuration, magnitude of applied stress intensity, test temperature, and hydrogen pressure. Although the overall appearance of the terrace structure remained essentially unchanged, a distinguishable variation is found in the size of the individual terrace steps, and step size is found to be inversely dependent upon the rate of hydrogen induced slow crack growth. Additionally, this inverse relationship is independent of all the variables investigated. These observations are quantitatively discussed in terms of the formation and growth of a thin hydride film along the alpha-beta boundaries and a qualitative model for hydrogen induced slow crack growth is presented, based on the film-rupture model of stress corrosion cracking.

Nelson, H. G.↗
NASA NTRS2015

Analyses of Hubble Space Telescope Aluminized-Teflon Multilayer Insulation Blankets Retrieved After 19 Years of Space Exposure

Since its launch in April 1990, the Hubble Space Telescope (HST) has made many important observations from its vantage point in low Earth orbit (LEO). However, as seen during five servicing missions, the outer layer of multilayer insulation (MLI) has become increasingly embrittled and has cracked in many areas. In May 2009, during the 5th servicing mission (called SM4), two MLI blankets were replaced with new insulation and the space-exposed MLI blankets were retrieved for degradation analyses by teams at NASA Glenn Research Center (GRC) and NASA Goddard Space Flight Center (GSFC). The retrieved MLI blankets were from Equipment Bay 8, which received direct sunlight, and Equipment Bay 5, which received grazing sunlight. Each blanket was divided into several regions based on environmental exposure and/or physical appearance. The aluminized-Teflon (DuPont, Wilmington, DE) fluorinated ethylene propylene (Al-FEP) outer layers of the retrieved MLI blankets have been analyzed for changes in optical, physical, and mechanical properties, along with chemical and morphological changes. Pristine and as-retrieved samples (materials) were heat treated to help understand degradation mechanisms. When compared to pristine material, the analyses have shown how the Al-FEP was severely affected by the space environment. Most notably, the Al-FEP was highly embrittled, fracturing like glass at strains of 1 to 8 percent. Across all measured properties, more significant degradation was observed for Bay 8 material as compared to Bay 5 material. This paper reviews the tensile and bend-test properties, density, thickness, solar absorptance, thermal emittance, x-ray photoelectron spectroscopy (XPS) and energy dispersive spectroscopy (EDS) elemental composition measurements, surface and crack morphologies, and atomic oxygen erosion yields of the Al-FEP outer layer of the retrieved HST blankets after 19 years of space exposure.

Radiation↗
NASA NTRS1976

A film-rupture model of hydrogen-induced, slow crack growth in acicular alpha-beta titanium

A study has been conducted of the terrace-like fracture morphology of gaseous hydrogen-induced crack growth in acicular alpha-beta titanium alloys in terms of specimen configuration, magnitude of applied stress intensity, test temperature, and hydrogen pressure. Although the overall appearance of the terrace structure remained essentially unchanged, a distinguishable variation is found in the size of the individual terrace steps, and step size is found to be inversely dependent upon the rate of hydrogen-induced slow crack growth. This inverse relationship is independent of all the variables investigated. These observations are quantitatively discussed in terms of the formation and growth of a thin hydride film along the alpha-beta boundaries and a qualitative model for hydrogen-induced slow crack growth is presented, based on the film-rupture model of stress corrosion cracking.

Nelson, H. G.↗
NASA NTRS1993

Microstructural analysis of the 2195 aluminum-lithium alloy welds

The principal objective of this research was to explain a tendency of 2195 Al-Li alloy to crack at elevated temperature during welding. Therefore, a study was made on the effect of welding and thermal treatment on the microstructure of Al-Li Alloy 2195. The critical roles of precipitates, boundaries, phases, and other features of the microstructure were inferred from the crack propagation paths and the morphology of fracture surface of the alloy with different microstructures. Particular emphasis was placed on the microstructures generated by the welding process and the mechanisms of crack propagation in such structures. Variation of the welding parameters and thermal treatments were used to alter the micro/macro structures, and they were characterized by optical and scanning electron microscopy. A theoretical model is proposed to explain changes in the microstructure of welded material. This model proposes a chemical reaction in which gases from the air (i.e., nitrogen) release hydrogen inside the alloy. Such a reaction could generate large internal stresses capable to induce porosity and crack-like delamination in the material.

Talia, George E.↗
NASA NTRS1993

A formational model for the polygonal terrains of Mars: Taking a crack at the genesis of the Martian polygons

The mechanism for the genesis of the polygonal terrains in Acidalia and Utopia Planitia has long been sought: however, no completely satisfying model was put forth that characterizes the evolution of these complexly patterned terrains. The polygons are roughly hexagonal but some are not entirely enclosed by fractures. These polygonal features range in widths from approximately 5 to 20 km. Several origins were proposed that describe the polygon borders as desiccation cracks, columnar jointing in a cooled lava, or frost-wedge features. These tension-induced cracking hypotheses were addressed by Pechmann, who convincingly disputes these mechanisms of formation based on scale magnitude difficulties and morphology. Pechmann suggests instead that the cracks delineating the 5-20-km-wide polygons on the northern plains of Mars are graben resulting from deep-seated, uniform, horizontal tension. The difficulty with this hypothesis is that no analogous polygonal forms are known to have originated by tectonism on Earth. McGill and Hills propose that the polygonal terrains on Mars resulted from either rapid desiccation of sediments or cooling of volcanics coupled with differential compaction of the material over a buried irregular topographic surface. They suggest that fracturing was enhanced over the areas of positive relief and was suppressed above the topographic lows. McGill and Hills suggest that the spacing of the topographic highs primarily controls the size of the Martian polygons and the physics of the shrinkage process is a secondary concern. Ray et. al. conducted a terrestrial study of patterned ground in periglacial areas of the U.S. to determine the process responsible for polygonal ground formation. They developed a model for polygon formation in which convection of seasonal melt water above a permafrost layer, driven by an unstable density stratification, differentially melts the permafrost interface, causing it to become undulatory.

Wenrich, M. L.↗
NASA NTRS2018

Composite Overwrapped Pressure Vessel (COPV) Life Test

Recent attention has been focused on how NASA and its commercial partners have been placing less emphasis on testing and have become more dependent on analytical methods when evaluating design margins for fracture-critical components. Of high concern is the possible misuse of such analytic models for thin-walled metallic liners for composite overwrapped pressure vessels (COPVs). The NASA Engineering and Safety Center (NESC) has initiated an assessment to understand the limitations of linear-elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate behavior of small cracks in thin metal liners for COPVs. It has been observed that fabrication of some thin metallic liners results in a wide variation in microstructure morphology, which results in varying microscale crack growth mechanisms. The ultimate goal is to develop and demonstrate a test-based methodology validating the safe-life requirements for COPVs with thin, elastically responding metal liners where LEFM methods are not appropriate.

Russell, Richard↗
NASA NTRS2004

Analysis of Europan Cycloid Morphology and Implications for Formation Mechanisms

Europa's highly fractured crust has been shown to contain features with a range of differing morphologies. Most lineaments on Europa are believed to have initiated as cracks, although the type of cracking (e.g. tensile vs. shear) remains unclear and may vary for different morphologies. Arcuate lineaments, called cycloids or flexi, have been observed in nearly all imaged regions of Europa and have been modeled as tensile fractures that were initiated in response to diurnal variations in tides. Despite this hypothesis about the formation mechanism, there have been no detailed analyses of the variable morphologies of cycloids. We have examined Galileo images of numerous locations on Europa to develop a catalog of the different morphologies of cycloids. This study focuses on variations in morphology along individual cycloid segments and differences in cusp styles between segments, while illustrating how morphologic evidence can help unravel formation mechanisms. In so doing, we present evidence for cycloid cusps forming due to secondary fracturing during strike-slip sliding on pre-existing cycloid segments.

Marshall, S. T.↗
NASA NTRS1997

The Characteristics of Fatigue Damage in the Fuselage Riveted Lap Splice Joint

An extensive data base has been developed to form the physical basis for new analytical methodology to predict the onset of widespread fatigue damage in the fuselage lap splice joint. The results of detailed destructive examinations have been cataloged to describe the physical nature of MSD in the lap splice joint. ne catalog includes a detailed description, e.g., crack initiation, growth rates, size, location, and fracture morphology, of fatigue damage in the fuselage lap splice joint structure. Detailed examinations were conducted on a lap splice joint panel removed from a full scale fuselage test article after completing a 60,000 cycle pressure test. The panel contained a four bay region that exhibited visible outer skin cracks and regions of crack link-up along the upper rivet row. Destructive examinations revealed undetected fatigue damage in the outer skin, inner skin, and tear strap regions. Outer skin fatigue cracks were found to initiate by fretting damage along the faying surface. The cracks grew along the faying surface to a length equivalent to two to three skin thicknesses before penetrating the outboard surface of the outer skin. Analysis of fracture surface marker bands produced during full scale testing revealed that all upper rivet row fatigue cracks contained in a dim bay region grow at similar rates; this important result suggests that fracture mechanics based methods can be used to predict the growth of outer skin fatigue cracks in lap splice structure. Results are presented showing the affects of MSD and out-of-plane pressure loads on outer skin crack link-up.

Piascik, Robert S.↗
NASA NTRS2003

Secondary Fracturing of Europa's Crust in Response to Combined Slip and Dilation Along Strike-Slip Faults

A commonly observed feature in faulted terrestrial rocks is the occurrence of secondary fractures alongside faults. Depending on exact morphology, such fractures have been termed tail cracks, wing cracks, kinks, or horsetail fractures, and typically form at the tip of a slipping fault or around small jogs or steps along a fault surface. The location and orientation of secondary fracturing with respect to the fault plane or the fault tip can be used to determine if fault motion is left-lateral or right-lateral.

Kattenhorn, S. A.↗
NASA NTRSDate not supplied

Correlations Between Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.

Qualification↗