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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Process Optimization of Bismaleimide (BMI) Resin Infused Carbon Fiber Composite

Engineers today are presented with the opportunity to design and build the next generation of space vehicles out of the lightest, strongest, and most durable materials available. Composites offer excellent structural characteristics and outstanding reliability in many forms that will be utilized in future aerospace applications including the Commercial Crew and Cargo Program and the Orion space capsule. NASA's Composites for Exploration (CoEx) project researches the various methods of manufacturing composite materials of different fiber characteristics while using proven infusion methods of different resin compositions. Development and testing on these different material combinations will provide engineers the opportunity to produce optimal material compounds for multidisciplinary applications. Through the CoEx project, engineers pursue the opportunity to research and develop repair patch procedures for damaged spacecraft. Working in conjunction with Raptor Resins Inc., NASA engineers are utilizing high flow liquid infusion molding practices to manufacture high-temperature composite parts comprised of intermediate modulus 7 (IM7) carbon fiber material. IM7 is a continuous, high-tensile strength composite with outstanding structural qualities such as high shear strength, tensile strength and modulus as well as excellent corrosion, creep, and fatigue resistance. IM7 carbon fiber, combined with existing thermoset and thermoplastic resin systems, can provide improvements in material strength reinforcement and deformation-resistant properties for high-temperature applications. Void analysis of the different layups of the IM7 material discovered the largest total void composition within the [ +45 , 90 , 90 , -45 ] composite panel. Tensile and compressional testing proved the highest mechanical strength was found in the [0 4] layup. This paper further investigates the infusion procedure of a low-cost/high-performance BMI resin into an IM7 carbon fiber material and the optical, chemical, and mechanical analyses performed.

Ehrlich, Joshua W.↗
NASA NTRS1997

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗
NASA NTRS1990

Magnetic properties of high-T(sub c) superconductors: Rigid levitation, flux pinning, thermal depinning, and fluctuation

The levitation of high-T(sub c) superconductors is quite conspicuous: Above magnets of low symmetry a disk of these ceramics floats motionless, without vibration or rotation; it has a continuous range of stable positions and orientations as if it were stuck in sand. Some specimens may even be suspended above or below the same magnet. This fascinating stability, inherent to no other type of levitation, is caused by the pinning of magnetic flux lines by inhomogeneities inside these extreme type-2 superconductors. The talk deals with pinning of magnetic flux in these materials, with flux flow, flux creep, thermally activated depinning, and the thermal fluctuation of the vortex positions in the flux line lattice (often called flux lattice melting). Also discussed are the fluctuations of the (nearly periodic) magnetic field inside these superconductors which are caused by random pinning sites and by the finite temperature. These fluctuations broaden the van-Hove singularities observed in the density of the magnetic field by nuclear magnetic resonance and by muon spin rotation.

Brandt, E. H.↗
NASA NTRS1988

Life prediction modeling based on cyclic damage accumulation

A high temperature, low cycle fatigue life prediction method was developed. This method, Cyclic Damage Accumulation (CDA), was developed for use in predicting the crack initiation lifetime of gas turbine engine materials, where initiation was defined as a 0.030 inch surface length crack. A principal engineering feature of the CDA method is the minimum data base required for implementation. Model constants can be evaluated through a few simple specimen tests such as monotonic loading and rapic cycle fatigue. The method was expanded to account for the effects on creep-fatigue life of complex loadings such as thermomechanical fatigue, hold periods, waveshapes, mean stresses, multiaxiality, cumulative damage, coatings, and environmental attack. A significant data base was generated on the behavior of the cast nickel-base superalloy B1900+Hf, including hundreds of specimen tests under such loading conditions. This information is being used to refine and extend the CDA life prediction model, which is now nearing completion. The model is also being verified using additional specimen tests on wrought INCO 718, and the final version of the model is expected to be adaptable to most any high-temperature alloy. The model is currently available in the form of equations and related constants. A proposed contract addition will make the model available in the near future in the form of a computer code to potential users.

Nelson, Richard S.↗
NASA NTRS1991

Ancient fluvial processes in the equatorial highlands of Mars

Martian highland craters typically lack ejecta deposits, have no noticeable rim, and are flat floored. In addition, crater size frequency distribution curves show that highland craters have depleted populations less than 20 km in diameter. A variety of processes have been suggested to explain these observations including deposition of aeolian or volcanic materials up to the crater rim crests, thermal creep, terrain softening, and mass wasting. However, none of these processes adequately explains both the crater morphology and population distribution. In order to explain both the Martian highland crater morphology and population distribution, a fluvial process is proposed which is capable of removing the loose crater rim material. The resulting effect is to decrease the crater diameter, thereby causing the population curves to bendover. The eroded material is redistributed, burying or partially burying smaller diameter craters before complete erosion. This material may also be deposited into local topographic lows, creating the depositional basins observed. A fluvial process explains both sets of observations: crater morphology and crater population distribution curves.

Craddock, Robert A.↗
NASA NTRS1984

Low cycle fatigue of MAR-M 200 single crystals at 760 and 870 deg C

Fully reversed low cycle fatigue tests were conducted on single crystals of the nickel-base superalloys Mar-M 200 at 760 C and 870 C. At 760 C, planar slip (octahedral) lead to orientation-dependent strain hardening and cyclic lives. Multiple slip crystals strain hardened the most, resulting in relatively high stress ranges and low lives. Single slip crystals strain hardened the least, resulting in relatively low stress ranges and higher lives. A preferential crack initiation site which was related to slip plane geometry was observed in single slip orientated crystals. At 870 C, the trends were quite different, and the slip character was much more homogeneous. As the tensile axis orientation deviated from 001 , the stress ranges increased and the cyclic lives decreased. Two possible mechanisms were proposed to explain the behavior: one is based on Takeuchi and Kuramoto's cube cross-slip model, and the other is based on orientation-dependent creep rates.

Milligan, W. W.↗
NASA NTRS1988

Thermal barrier coating life prediction model development

This report describes work performed to determine the predominat modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consisted of a low pressure plasma sprayed NiCrAlY bond coat, an air plasma sprayed ZrO2-Y2O3 top coat, and a Rene' 80 substrate. The work was divided into 3 technical tasks. The primary failure mode to be addressed was loss of the zirconia layer through spalling. Experiments showed that oxidation of the bond coat is a significant contributor to coating failure. It was evident from the test results that the species of oxide scale initially formed on the bond coat plays a role in coating degradation and failure. It was also shown that elevated temperature creep of the bond coat plays a role in coating failure. An empirical model was developed for predicting the test life of specimens with selected coating, specimen, and test condition variations. In the second task, a coating life prediction model was developed based on the data from Task 1 experiments, results from thermomechanical experiments performed as part of Task 2, and finite element analyses of the TBC system during thermal cycles. The third and final task attempted to verify the validity of the model developed in Task 2. This was done by using the model to predict the test lives of several coating variations and specimen geometries, then comparing these predicted lives to experimentally determined test lives. It was found that the model correctly predicts trends, but that additional refinement is needed to accurately predict coating life.

Hillery, R. V.↗
NASA NTRS1992

The viscoelastic characterization of polymer materials exposed to the low-Earth orbit environment

Recent accomplishments in our research efforts have included the successful measurement of the thermal mechanical properties of polymer materials exposed to the low-earth orbit environment. In particular, viscoelastic properties were recorded using the Rheometrics Solids Analyzer (RSA 2). Dynamic moduli (E', the storage component of the elastic modulus, and E'', the loss component of the elastic modulus) were recorded over three decades of frequency (0.1 to 100 rad/sec) for temperatures ranging from -150 to 150 C. Although this temperature range extends beyond the typical use range of the materials, measurements in this region are necessary in the development of complete viscoelastic constitutive models. The experimental results were used to provide the stress relaxation and creep compliance performance characteristics through viscoelastic correspondence principles. Our results quantify the differences between exposed and control polymer specimens. The characterization is specifically designed to elucidate a constitutive model that accurately predicts the change in behavior of these materials due to exposure. The constitutive model for viscoelastic behavior reflects the level of strain, the rate of strain, and the history of strain as well as the thermal history of the material.

Strganac, Thomas↗
NASA NTRS2003

Low Cost Heat Treatment Process for Production of Dual Microstructure Superalloy Disks

There are numerous incidents where operating conditions imposed on a component mandate different and distinct mechanical property requirements from location to location within the component. Examples include a crankshaft in an internal combustion engine, gears for an automotive transmission, and disks for a gas turbine engine. Gas turbine disks are often made from nickel-base superalloys, because these disks need to withstand the temperature and stresses involved in the gas turbine cycle. In the bore of the disk where the operating temperature is somewhat lower, the limiting material properties are often tensile and fatigue strength. In the rim of the disk, where the operating temperatures are higher than those of the bore, because of the proximity to the combustion gases, resistance to creep and crack growth are often the limiting properties.

Gayda, John↗
NASA NTRS1959

Factors Affecting the Plasticity of Sodium Chloride, Lithium Fluoride, and Magnesium Oxide Single Crystals

A study was made of the relative magnitude of the effects of various factors on the ductility of single crystals of sodium chloride (NaCl), lithium fluoride (LiF), and magnesium oxide (MgO). Specimen treatments included water-polishing, varying cleavage rate, annealing, quenching, X-irradiation, surface coating, aging, and combinations of some of these treatments. The mechanical behavior of the crystals was studied in flexure and in compression, the latter study being performed at both constant strain rate and constant load. Etch-pit studies were carried out to provide some pertinent information on the results of pretreatment on the dislocation concentration and distribution in the vicinity of the surface. The load deformation curves for these ionic single crystals show an initial region of very low slope which proved to be due to anelastic deformation. The extent of initial anelastic deformation is modified by specimen pretreatment in a way that suggests that this deformation is the result of expansion of cleaved-in dislocation loops, which can contract on the removal of the stress. The effects of the various pretreatments on the load and deflection at fracture are in accord with the prediction one might make with regard to their effect on the nucleation of fatal surface cracks. For NaCl, increases in ductility are always accompanied by increases in strength. The creep constants for NaCl are a function of treatments which affect the bulk structure but are not a function of treatments which only affect the surface.

Stearns, Carl A.↗
NASA NTRS1990

Mechanical testing of advanced coating system, volume 1

The Electron Beam Physical Vapor Deposition (EBPVD) coating material has a highly columnar microstructure, and as a result it was expected to have very low tensile strength. To be able to fabricate the required compression and tensile specimens, a substrate was required to provide structural integrity for the specimens. Substrate and coating dimensions were adjusted to provide sufficient sensitivity to resolve the projected loads carried by the EBPVD coating. The use of two distinctively different strain transducer systems, for tension and compression loadings, mandated two vastly different specimen geometries. Compression specimen and tensile specimen geometries are given. Both compression and tensile test setups are described. Data reduction mathematical models are given and discussed in detail as is the interpretation of the results. Creep test data is also given and discussed.

Cruse, T. A.↗
NASA NTRS1982

Development of cast ferrous alloys for Stirling engine application

Low cost cast ferrous base alloys that can be used for cylinder and regenerator housing components of the Stirling engine were investigated. The alloys must meet the requirements of high strength and thermal fatigue resistance to approximately 1500 F, compatibility and low permeability with hydrogen, good elevated temperature oxidation/corrosion resistance, and contain a minimum of strategic elements. The phase constituents of over twenty alloy iterations were examined by X-ray diffraction. These alloy candidates were further screened for their tensile and stress rupture strength and surface stability in air at 1450 and 1600 F, respectively. Two alloys, NASAUT 1G (Fe-10Mn-20Cr-1.5C-1.0Si) and NASAUT 4G (Fe-15Mn-12Cr-3Mo-1.5C-1.0Si-1.0Nb), were chosen for more extensive elevated temperature testing. These alloys were found to exhibit nearly equivalent elevated temperature creep strength and oxidation resistance. Silicon present in these alloys at the 1 w/o level permitted the achievement of oxide scale adherence to 1600 F without loss of strength (or ductility) as was noted for equivalent additions of aluminum.

Lemkey, F. D.↗
NASA NTRS1972

Time-dependent edge-notch sensitivity of oxide and gamma prime dispersion strengthened sheet materials at 1000 to 1800 F (538 - 982 C)

Research was carried out to determine whether an oxide dispersion hardened alloy, TD-Ni, Cr, and low volume fraction gamma prime strengthened nickel-base alloy, Modified Waspaloy, were susceptible to time-dependent edge-notch sensitivity. The results were evaluated in terms of the mechanical characteristics of the alloys and the dislocation motion mechanisms operative. As far as could be determined, the results of the investigation were consistent with the following important concepts developed for Waspaloy and Inconel 718: (1) Time-dependent edge-notch sensitivity occurs when notched specimens are loaded below the approximate 0.2 percent smooth specimen offset yield strength and when data from smooth specimens indicate that small amounts of creep consume large rupture life fractions. (2) When precipitate particles are sheared by dislocations, the deformation is localized and time-dependent notch sensitivity occurs. When dislocations by-pass precipitate particles the deformation is homogeneous. Under these conditions, no time-dependent notch sensitivity has been observed.

Wilson, D. J.↗
NASA NTRS1993

An analysis of isothermal, bithermal, and thermomechanical fatigue data of Haynes 188 and B1900+Hf by energy considerations

The low-cycle fatigue behavior of Haynes 188 and B1900+Hf under isothermal, bithermal, and thermomechanical loading conditions has been analyzed on the basis of the total hysteresis energy expended per cycle. It has been observed that in the case of isothermal fatigue the total hysteresis energy correlates well with the fatigue life. In the case of bithermal 'high rate' fatigue, for a given total hysteresis energy per cycle, the fatigue life is equal to or greater than the isothermal fatigue life at the maximum bithermal temperature. This observation could be used to establish a lower bound on life for design purposes. In one case of bithermal creep-fatigue and in thermomechanical fatigue, the life is shorter than that corresponding to the isothermal life at the maximum temperature. The energy supplied, per se, may not always give a systematic correlation with the fatigue life in the cases where time-dependent creep and environmental effects are encountered. Thus, in bithermal creep-fatigue and thermomechanical fatigue, the role of creep and environment and their dependence on the energy supplied have to be properly accounted for before the energy term can be used for life prediction.

Radhakrishnan, V. M.↗
NASA NTRS1982

Equivalent damage: A critical assessment

Concepts in equivalent damage were evaluated to determine their applicability to the life prediction of hot path components of aircraft gas turbine engines. Equivalent damage was defined as being those effects which influence the crack initiation life-time beyond the damage that is measured in uniaxial, fully-reversed sinusoidal and isothermal experiments at low homologous temperatures. Three areas of equivalent damage were examined: mean stress, cumulative damage, and multiaxiality. For each area, a literature survey was conducted to aid in selecting the most appropriate theories. Where possible, data correlations were also used in the evaluation process. A set of criteria was developed for ranking the theories in each equivalent damage regime. These criteria considered aspects of engine utilization as well as the theoretical basis and correlative ability of each theory. In addition, consideration was given to the complex nature of the loading cycle at fatigue critical locations of hot path components; this loading includes non-proportional multiaxial stressing, combined temperature and strain fluctuations, and general creep-fatigue interactions. Through applications of selected equivalent damage theories to some suitable data sets it was found that there is insufficient data to allow specific recommendations of preferred theories for general applications. A series of experiments and areas of further investigations were identified.

Laflen, J. R.↗
NASA NTRS1986

Technology for Bayton-cycle powerplants using solar and nuclear energy

Brayton cycle gas turbines have the potential to use either solar heat or nuclear reactors for generating from tens of kilowatts to tens of megawatts of power in space, all this from a single technology for the power generating system. Their development for solar energy dynamic power generation for the space station could be the first step in an evolution of such powerplants for a very wide range of applications. At the low power level of only 10 kWe, a power generating system has already demonstrated overall efficiency of 0.29 and operated 38 000 hr. Tests of improved components show that these components would raise that efficiency to 0.32, a value twice that demonstrated by any alternate concept. Because of this high efficiency, solar Brayton cycle power generators offer the potential to increase power per unit of solar collector area to levels exceeding four times that from photovoltaic powerplants using present technology for silicon solar cells. The technologies for solar mirrors and heat receivers are reviewed and assessed. This Brayton technology for solar powerplants is equally suitable for use with the nuclear reactors. The available long time creep data on the tantalum alloy ASTAR-811C show that such Brayton cycles can evolve to cycle peak temperatures of 1500 K (2240 F). And this same technology can be extended to generate 10 to 100 MW in space by exploiting existing technology for terrestrial gas turbines in the fields of both aircraft propulsion and stationary power generation.

English, R. E.↗
NASA NTRS2002

Ti-48Al-2Cr-2Nb Evaluated Under Fretting Conditions

Material parameters govern many of the design decisions in any engineering task. When two materials are in contact and microscopically small, relative motions (either vibratory or creeping) occur, and fretting fatigue can result. Fretting fatigue is a material response influenced by the materials in contact as well as by such variables as loading and vibratory conditions. Fretting produces fresh, clean interacting surfaces and induces adhesion, galling, and wear in the contact zone. Time, money, and materials are unnecessarily wasted when galling and wear result in excessive fretting fatigue that leads to poorly performing, unreliable mechanical systems. Fretting fatigue is a complex problem of significant interest to aircraft engine manufacturers. It can occur in a variety of engine components. Numerous approaches, depending on the component and the operating conditions, have been taken to address the fretting problems. The components of interest in this investigation were the low-pressure turbine blades and disks. The blades in this case were titanium aluminide, Ti-48Al-2Cr- 2Nb, and the disk was a nickel-base superalloy, Inconel 718 (IN 718). A concern for these airfoils is the fretting in fitted interfaces at the dovetail where the blade and disk are connected. Careful design can reduce fretting in most cases, but not completely eliminate it, because the airfoils frequently have a skewed (angled) blade-disk dovetail attachment, which leads to a complex stress state. Furthermore, the local stress state becomes more complex when the influence of the metal-metal contact and the edge of contact are considered.

Miyoshi, Kazuhisa↗
NASA NTRS2007

Capabilities and History of NASA Marshall Space Flight Center's Hydrogen Test Facility

The Hydrogen Test Facility (HTF) has conducted mechanical testing for aerospace materials at NASA's Marshall Space Flight Center for many years. One of the first facilities of its kind to run high-pressure cryogenic permeability tests in liquid hydrogen, HTF is now characterized as a unique national resource capable of overcoming hazardous conditions to perform tests directly in various hydrogen environments. At HTF, custom test systems are operated in eight structurally reinforced test cells from 0 to 68,948 kPa (0 to 10,000 psi) at -253 to 982 C (--423 to 1800 F) in hydrogen, air, helium, and nitrogen, with other environments available upon request. Standard mechanical procedures include compression, fatigue crack growth rate, four-point bend, high/low cycle fatigue, fracture toughness, shear, strain-to-crack, and tensile testing. Cryogenic permeability and thermal conductivity and gaseous creep testing are offered, as well as simulated service under different combinations of operating environment(s), stress, pressure, and ambient-to-extreme temperatures. Advanced tests are routinely developed upon demand, and special component testing is also available. Current efforts include the renovation of two high-pressure gaseous test cells to generate data for a J-2X engine designed for Constellation's Ares I and V vehicles. In the past, HTF has supported other critical NASA programs, such as Apollo, Space Shuttle, and Next Generation Launch Technologies. During the 1990's, hundreds of tests were conducted in liquid hydrogen and liquid nitrogen during development of the Space Shuttle's super lightweight tank, which provided the thrust required to achieve low Earth orbit for the International Space Station. This facility was designed and built in 1963. Originally called the Low Temperature Test Facility, it became known as the Cryogenic Test Facility in the late 1980's and HTF in the early 1990's.

Malone, T. W.↗