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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 NTRS1983

A nonlinear fracture mechanics approach to the growth of small cracks

An analytical model of crack closure is used to study the crack growth and closure behavior of small cracks in plates and at notches. The calculated crack opening stresses for small and large cracks, together with elastic and elastic plastic fracture mechanics analyses, are used to correlate crack growth rate data. At equivalent elastic stress intensity factor levels, calculations predict that small cracks in plates and at notches should grow faster than large cracks because the applied stress needed to open a small crack is less than that needed to open a large crack. These predictions agree with observed trends in test data. The calculations from the model also imply that many of the stress intensity factor thresholds that are developed in tests with large cracks and with load reduction schemes do not apply to the growth of small cracks. The current calculations are based upon continuum mechanics principles and, thus, some crack size and grain structure exist where the underlying fracture mechanics assumptions become invalid because of material inhomogeneity (grains, inclusions, etc.). Admittedly, much more effort is needed to develop the mechanics of a noncontinuum. Nevertheless, these results indicate the importance of crack closure in predicting the growth of small cracks from large crack data.

Newman, J. C., Jr.↗
NASA NTRS2016

System Level Aerothermal Testing for the Adaptive Deployable Entry and Placement Technology (ADEPT)

The Adaptive Deployable Entry and Placement Technology (ADEPT), a mechanically deployable entry vehicle technology, has been under development at NASA since 2011. As part of the technical maturation of ADEPT, designs capable of delivering small payloads (10 kg) are being considered to rapidly mature sub 1 m deployed diameter designs. The unique capability of ADEPT for small payloads comes from its ability to stow within a slender volume and deploy to achieve a mass efficient drag surface with a high heat rate capability. The low ballistic coefficient results in entry heating and mechanical loads that can be met by a revolutionary three-dimensionally woven carbon fabric supported by a deployable skeleton structure. This carbon fabric has test proven capability as both primary structure and payload thermal protection system. In order to rapidly advance ADEPTs technical maturation, the project is developing test methods that enable thermostructural design requirement verification of ADEPT designs at the system level using ground test facilities. Results from these tests are also relevant to larger class missions and help us define areas of focused component level testing in order to mature material and thermal response design codes. The ability to ground test sub 1 m diameter ADEPT configurations at or near full-scale provides significant value to the rapid maturation of this class of deployable entry vehicles. This paper will summarize arc jet test results, highlight design challenges, provide a summary of lessons learned and discuss future test approaches based upon this methodology.

Hypersonic↗
NASA NTRS1984

The design and development of a release mechanism for space shuttle life-science experiments

The design, development, and testing of a release mechanism for use in two life science experiments on the Spacelab 1, 4, and D1 missions is described. The mechanism is a self latching ball lock device actuated by a linear solenoid. An unusual feature is the tapering of the ball lock plunger to give it a near constant breakout force for release under a wide range of loads. The selection of the design, based on the design requirements, is discussed. A number of problems occurred during development and test, including problems caused by human factors that became apparent after initial delivery for crewtraining sessions. These problems and their solutions are described to assist in the design and testing of similar mechanisms.

Jones, H. M.↗
NASA NTRS1990

Thermomechanical deformation testing and modeling in the presence of metallurgical instabilities

A number of viscoplastic constitutive models were developed to describe deformation behavior under complex combinations of thermal and mechanical loading. Questions remain, however, regarding the validity of procedures used to characterize these models for specific structural alloys. One area of concern is that the majority of experimental data available for this purpose are determined under isothermal conditions. This experimental study is aimed at determining whether viscoplastic constitutive theories characterized using an isothermal data base can adequately model material response under the complex thermomechanical loading conditions typical of power generation service. The approach adopted was to conduct a series of carefully controlled thermomechanical experiments on a nickel-based superalloy, Hastelloy Alloy X. Previous investigations had shown that this material experiences metallurgical instabilities leading to complex hardening behavior, termed dynamic strain aging. Investigating this phenomenon under full thermomechanical conditions leads to a number of challenging experimental difficulties which up to the present work were unresolved. To correct this situation, a number of advances were made in thermomechanical testing techniques. Advanced methods for dynamic temperature gradient control, phasing control and thermal strain compensation were developed and incorporated into real time test control software. These advances allowed the thermomechanical data to be analyzed with minimal experimental uncertainty. The thermomechanical results were evaluated on both a phenomenological and microstructural basis. Phenomenological results revealed that the thermomechanical hardening trends were not bounded by those displayed under isothermal conditions. For the case of Hastelloy Alloy X (and similar dynamic strain aging materials), this strongly suggests that some form of thermomechanical testing is necessary when characterizing a thermoviscoplastic deformation model. Transmission electron microscopy was used to study the microstructural physics, and analyze the unique phenomenological behavior.

Castelli, Michael G.↗
NASA NTRSDate not supplied

High-Throughput Strategies that Encompass Experiments and Machine Learning to Predict the Mechanical Properties of Additive Manufactured Aerospace Alloys

Small Punch Test (SPT) uses a thin disk of material to predict mechanical properties. While SPT has existed for decades, it has been used largely as a qualitative evaluator of mechanical properties. Recent advances in computational modeling have enabled the extraction of uniaxial stress-strain response from the measured SPT load-displacement data. Due to small sample volumes and unidirectional testing, SPT is conducive to high-throughput automation and ideally suited to extract properties from high-cost materials. Aerospace alloys have been of recent interest to the Additive Manufacturing (AM) community due to AM’s unique ability to fabricate complex designs not possible, or extremely arduous, with conventional manufacturing. In this research, SPT, coupled with Materials Informatics and computational modeling, is used to develop relevant Process-Structure-Property relationships to decrease the cost and time of process optimization for AM aerospace alloys, namely Inconel 718, Inconel 625, and Niobium C103.

High-throughput Testing↗
NASA NTRS2019

Static Torsion Testing and Modeling of a Variable Thickness Hybrid Composite Bull Gear

Torsional strength of a variable thickness hybrid gear web was measured by performing static testing on the part in a large torsion test frame. The outer rim of the hybrid gear web was fixed to the bottom of the test frame and loading was applied to the web through a shaft. The test setup included the installation of digital image correlation (DIC) systems to obtain deformation and strain measurements from the surfaces of the hybrid gear web and the mechanical test equipment to ensure reliability of the test. The results indicated that the variable thickness hybrid gear web achieved approximately twice the torsional strength compared to that of previous hybrid gear designs. The DIC analysis showed significantly more straining of the loading shaft than the actual test article. Additionally, the results demonstrated the importance and affect that the metallic, lobed interlock features had on the principal strain and out-of-plane displacement fields. The analysis revealed that the fixed outer rim was in fact rotating and a rigid body motion compensation (RBMC) function was computed to determine the actual rotation of the hub and composite web relative to the outer rim. Modeling simulations were performed for the variable thickness hybrid gear web and correlated well with the RBMC rotational deformation seen in the DIC analysis. In addition to benchmarking the load capacity of the hybrid gear web, measuring its strength is useful information to define the parameters needed for dynamic, endurance, and other testing of the part.

Johnston, Joel P.↗
NASA NTRS1980

Research on graphite reinforced glass matrix composites

High levels of mechanical performance in tension, flexure, fatigue, and creep loading situations of graphite fiber reinforced glass matrix composites are discussed. At test temperatures of up to 813 K it was found that the major limiting factor was the oxidative instability of the reinforcing graphite fibers. Particular points to note include the following: (1) a wide variety of graphite fibers were found to be comparable with the glass matrix composite fabrication process; (2) choice of fiber, to a large extent, controlled resultant composite performance; (3) composite fatigue performance was found to be excellent at both 300 K and 703 K; (4) composite creep and stress rupture at temperatures of up to 813 K was limited by the oxidative stability of the fiber; (5) exceptionally low values of composite thermal expansion coefficient were attributable to the dimensional stability of both matrix and fiber; and (6) component fabricability was demonstrated through the hot pressing of hot sections and brazing using glass and metal joining phases.

Prewo, K. M.↗
NASA NTRS1979

Design, analysis, and tests of a shuttle-type heat-pipe-cooled leading edge

A one-half scale heat-pipe-cooled leading edge model was designed and fabricated to verify feasibility and performance of a full-scale Phase B shuttle orbiter design. Model performance was investigated experimentally by radiant heating and aerothermal tests and analytically by using a simple technique which predicts heat pipe start-up from the frozen state and also predicts transient and steady-state thermal behavior. Analytical results agree well with experimental results for start-up and steady-state heat pipe operation. The results indicate that variations in angle of attack and roll orientation had a negligible effect on heat pipe performance. The heat pipes effectively isothermalized the leading edge, and reduced peak temperatures to levels compatible with the use temperatures of superalloys. Results of these tests demonstrated the durability of the heat-pipe-cooled leading edge in withstanding earth-entry thermal and mechanical loads and indicate that the use of heat pipes in leading edge structures is a reliable concept for fully reusable hypersonic cruise and space transportation systems.

Camarda, C. J.↗
NASA NTRS1981

Experience with high performance V/STOL fighter projects at MBB

Flight control systems and aerodynamic aspects of experimental V/STOL aircraft are discussed. The VJ 101 C featured tilting engines for increased thrust, reheat for takeoff, simple translation, triangular decentralization of the engines for thrust modulation, and moderate ground effects. Two experimental aircraft were built, with and without reheat, capable of Mach 2 and Mach 1.04, respectively. The mechanical flight control system and tests are outlined, both for hover rig and flight configurations. Ground suction, acoustic and thermal loading, sodium silicate coatings to avoid ground corrosion, and recirculation are considered. Results of the follow-on project to the VJ 101 C, the AVS, which was developed by NASA, are reviewed, and it is noted that trends toward thrust-to-weight ratios exceeding one, in concert with low wing loading, favor the development of V/STOL aircraft.

Aulehla, F.↗
NASA NTRS1990

Billion shot flashlamp for spaceborne lasers

A billion-shot flashlamp developed under a NASA contract for spaceborne laser missions is presented. Lifetime-limiting mechanisms are identified and addressed. Two energy loadings of 15 and 44 Joules were selected for the initial accelerated life testing. A fluorescence-efficiency test station was used for measuring the useful-light output degradation of the lamps. The design characteristics meeting NASA specifications are outlined. Attention is focused on the physical properties of tungsten-matrix cathodes, the chemistry of dispenser cathodes, and anode degradation. It is reported that out of the total 83 lamps tested in the program, 4 lamps reached a billion shots and one lamp is beyond 1.7 billion shots, while at 44 Joules, 4 lamps went beyond 100 million shots and one lamp reached 500 million shots.

Richter, Linda↗
NASA NTRS1994

Root-sum-square structural strength verification approach

Utilizing a proposed fixture design or some variation thereof, this report presents a verification approach to strength test space flight payload components, electronics boxes, mechanisms, lines, fittings, etc., which traditionally do not lend themselves to classical static loading. The fixture, through use of ordered Euler rotation angles derived herein, can be mounted on existing vibration shakers and can provide an innovative method of applying single axis flight load vectors. The versatile fixture effectively loads protoflight or prototype components in all three axes simultaneously by use of a sinusoidal burst of desired magnitude at less than one-third the first resonant frequency. Cost savings along with improved hardware confidence are shown. The end product is an efficient way to verify experiment hardware for both random vibration and strength.

Lee, Henry M.↗
NASA NTRS2016

Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities

Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.

ceramic matrix composites↗
NASA NTRS1985

A study of spectrum fatigue crack propagation in two aluminum alloys. 1: Spectrum simplification

The fatigue crack propagation behavior of two commercial Al alloys was studied using spectrum loading conditions characteristics of those encountered at critical locations in high performance fighter aircraft. A tension dominated (TD) and tension compression (TC) spectrum were employed for each alloy. Using a mechanics-based analysis, it was suggested that negative loads could be eliminated for the TC spectrum for low to intermediate maximum stress intensities. The suggestion was verified by subsequent testing. Using fractographic evidence, it was suggested that a further similification in the spectra could be accomplished by eliminating low and intermediate peak load points resulting in near or below threshold maximum peak stress intensity values. It is concluded that load interactions become more important at higher stress intensities and more plasticity at the crack tip. These results suggest that a combined mechanics/fractographic mechanisms approach can be used to simplify other complex spectra.

Telesman, J.↗
NASA NTRS1994

New Testing Tool For Composite Interfaces

Mechanical strength of fiber/matrix interface key factor in overall strength and toughness of composite material. Desktop fiber pushout apparatus generates load and acoustic-emission (soundwave) data as function of translation-table displacement. Video camera gives view of specimen. Compact, easy to operate, and inexpensive. Appropriate for wide range of composites, including metal, intermetallic, and ceramic matrix composites. Not restricted to aerospace/aeronautics applications.

Eldridge, Jeffrey I.↗
NASA NTRS1993

RSRM nozzle actuator bracket/lug fracture mechanics qualification test

This is the final report for the actuator bracket/lug fracture mechanics qualification test. The test plan (CTP-0071) outlined a two-phase test program designed to answer questions about the fracture criticality of the redesigned solid rocket motor (RSRM) nozzle actuator bracket. An analysis conducted using the NASA/FLAGRO fracture mechanics computer program indicated that the actuator bracket might be a fracture critical component. In the NASA/FLAGRO analysis, a simple lug model was used to represent the actuator bracket. It was calculated that the bracket would fracture if subjected to an actuator stall load in the presence of a 0.10 in. corner crack at the actuator attachment hole. The 0.10 in. crack size corresponds to the nondestructive inspection detectability limit for the actuator bracket. The inspection method used is the dye penetrant method. The actuator stall load (103,424 lb) is the maximum load which the actuator bracket is required to withstand during motor operation. This testing was designed to establish the accuracy of the analytical model and to directly determine whether the actuator bracket is capable of meeting fracture mechanics safe-life requirements.

Kelley, Peggy↗
NASA NTRS1996

Development of a Pressure Box to Evaluate Reusable-Launch-Vehicle Cryogenic-Tank Panels

A cryogenic pressure-box test machine has been designed and is being developed to test full-scale reusable launch vehicle cryogenic-tank panels. This machine is equipped with an internal pressurization system, a cryogenic cooling system, and a heating system to simulate the mechanical and thermal loading conditions that are representative of a reusable launch vehicle mission profile. The cryogenic cooling system uses liquid helium and liquid nitrogen to simulate liquid hydrogen and liquid oxygen tank internal temperatures. A quartz lamp heating system is used for heating the external surface of the test panels to simulate cryogenic-tank external surface temperatures during re-entry of the launch vehicle. The pressurization system uses gaseous helium and is designed to be controlled independently of the cooling system. The tensile loads in the axial direction of the test panel are simulated by means of hydraulic actuators and a load control system. The hoop loads in the test panel are reacted by load-calibrated turnbuckles attached to the skin and frame elements of the test panel. The load distribution in the skin and frames can be adjusted to correspond to the tank structure by using these turnbuckles. The seal between the test panel and the cryogenic pressure box is made from a reinforced Teflon material which can withstand pressures greater than 52 psig at cryogenic temperatures. Analytical results and tests on prototype test components indicate that most of the cryogenic-tank loading conditions that occur in flight can be simulated in the cryogenic pressure-box test machine.

Ambur, Damodar R.↗
NASA NTRS1988

Constitutive response of Rene 80 under thermal mechanical loads

The applicability of a classical constitutive model for stress-strain analysis of a nickel base superalloy, Rene' 80, in the gas turbine thermomechanical fatigue (TMF) environment is examined. A variety of tests were conducted to generate basic material data and to investigate the material response under cyclic thermomechanical loading. Isothermal stress-strain data were acquired at a variety of strain rates over the TMF temperature range. Creep curves were examined at 2 temperature ranges, 871 to 982 C and 760 to 871 C. The results provide optimism on the ability of the classical constitutive model for high temperature applications.

Kim, K. S.↗
NASA NTRS1982

Accelerated fatigue durability of a high performance composite

The fatigue behavior of multidirectional graphite-epoxy laminates was analyzed theoretically and experimentally in an effort to establish an accelerated testing methodology. Analysis of the failure mechanism in fatigue of the laminates led to the determination of the failure mode governing fracture. The nonlinear, cyclic-dependent shear modulus was used to calculate the changing stress field in the laminate during the fatigue loading. Fatigue tests were performed at three different temperatures: 25 C, 74 C, and 114 C. The prediction of the S-N curves was made based on the artificial static strength artificial static strength at a reference temperature and the fatigue functions associated with them. The prediction of an S-N curve at other temperatures was performed using shifting factors determined for the specific failure mode. For multidirectional laminates, different S-N curves at different temperatures could be predicted using these shifting factors. Different S-N curves at different temperatures occur only when the fatigue failure mode is matrix dominated. It was found that whenever the fatigue failure mode is fiber dominated, temperature, over the range investigated, had no influence on the fatigue life. These results permit the prediction of long-time, low temperature fatigue behavior from data obtained in short time, high temperature testing, for laminates governed by a matrix failure mode.

Rotem, A.↗