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At least 397 records · Page 22

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NASA NTRS2013

Multiaxial and Thermomechanical Fatigue of Materials: A Historical Perspective and Some Future Challenges

Structural materials used in engineering applications routinely subjected to repetitive mechanical loads in multiple directions under non-isothermal conditions. Over past few decades, several multiaxial fatigue life estimation models (stress- and strain-based) developed for isothermal conditions. Historically, numerous fatigue life prediction models also developed for thermomechanical fatigue (TMF) life prediction, predominantly for uniaxial mechanical loading conditions. Realistic structural components encounter multiaxial loads and non-isothermal loading conditions, which increase potential for interaction of damage modes. A need exists for mechanical testing and development verification of life prediction models under such conditions.

Kalluri, Sreeramesh↗

NASA NTRS1921

Performance of a Liberty 12 airplane engine

In cooperation with the Engineering Division of the Air Service of the United States Army, a Liberty-12 engine has been tested at the Bureau of Standards. The program of tests was planned to yield that information considered most important in determining the value of the engine for aviation. Full power runs were made at the ground, at 25,000 feet, and at several intermediate altitudes. To determine the mechanical efficiency of the engine, friction horsepower was measured at the ground and at 15,000 feet. As a basis for predicting engine performance with a propeller, a series of tests was made in which the dynamometer load and engine throttle were adjusted at each speed to simulate the engine load which would be imposed at that speed by a propeller operating under normal full load at 1,700 r.p.m. Among the quantities calculated from the test measurements are: brake horsepower; break mean effective pressure; fuel consumption; mixture ratio; mechanical, thermal, and volumetric efficiency; and the percentage of the heat in the fuel appearing in the jacket water and in the exhaust. Jacket water temperature, oil temperature, manifold pressure, etc., are recorded to show the conditions under which the test was made.

Sparrow, S W↗

NASA NTRS2004

Variable Stiffness Spar Wind-Tunnel Model Development and Testing

The concept of exploiting wing flexibility to improve aerodynamic performance was investigated in the wind tunnel by employing multiple control surfaces and by varying wing structural stiffness via a Variable Stiffness Spar (VSS) mechanism. High design loads compromised the VSS effectiveness because the aerodynamic wind-tunnel model was much stiffer than desired in order to meet the strength requirements. Results from tests of the model include stiffness and modal data, model deformation data, aerodynamic loads, static control surface derivatives, and fuselage standoff pressure data. Effects of the VSS on the stiffness and modal characteristics, lift curve slope, and control surface effectiveness are discussed. The VSS had the most effect on the rolling moment generated by the leading-edge outboard flap at subsonic speeds. The effects of the VSS for the other control surfaces and speed regimes were less. The difficulties encountered and the ability of the VSS to alter the aeroelastic characteristics of the wing emphasize the need for the development of improved design and construction methods for static aeroelastic models. The data collected and presented is valuable in terms of understanding static aeroelastic wind-tunnel model development.

Florance, James R.↗

NASA NTRS2024

SMAnalytics Automated Shape Memory Test Analysis Software User's Manual: UCFTC, UPER, and DSC Test Methods, Version 1.0.2

Over the course of 60 years of shape memory alloy research and development, the properties of these alloys have been measured using various testing methods, which are often customized by the organization performing the test. However, commercial adoption of shape memory alloys in aeronautic actuator applications requires reducing property uncertainty through standardizing test methods. Historically, differential scanning calorimetry (DSC) has been used to measure transformation temperatures under stress-free conditions. This testing method is well established, and tests are run under the applicable standard, ASTM F2004-17: Standard Test Method for Transformation Temperature of Nickel-Titanium Alloys by Thermal Analysis. Two other test methods for measuring strains and transformation temperatures under constant load or free recovery after prestraining have only recently been standardized—ASTM E3097: Standard Test Method for Mechanical Uniaxial Constant Force Thermal Cycling of SMAs (UCFTC) and ASTM E3098: Standard Test Method for Mechanical Uniaxial Pre-Strain and Thermal Free Recovery of SMAs (UPFR). These standards represent a critical step forward in producing reliable material property data for the use of these alloys in aeronautics and other commercial areas. However, no standard programs or software packages were previously available for postprocessing UCFTC- and UPFR-type test data to extract property data. Each organization that performed the testing analyzed data using its own custom manual methods, such as using a plot and a straight edge, spreadsheet plotting methods, or custom code routines, to extract the required values for strains, stresses, and transformation temperatures. SMAnalytics represents the first publicly available uniform software package for processing data generated using the DSC, UCFTC, and UPFR test methods, as well as many modifications of these methods, including loading in martensite versus austenite and performing multiple thermal cycles at stress. In doing so, it provides a tool for reducing potential error or variability in the measured values due to the precision of the technique used and person-to-person variability. It is also expected that this automated data-parsing tool can accelerate the data analysis phase of the test campaign, especially for large data files. This User’s Manual describes how the SMAnalytics software works and the method for its use.

Shape Memory Alloy↗

DOE OSTI2026

Coupling Microstructural Evolution Simulations to Material Property Degradation Predictions for Plasma-Facing Materials

Reliable material performance is required for plasma-facing material (PFM) candidates. Previous research has shown that plasma and neutron radiation exposure induces microstructural changes in PFMs; changes in thermal and electrical conductivities and in material hardening and embrittlement were also observed after neutron irradiation. These material property changes will negatively impact the performance of the PFMs in a fusion reactor. Despite the well-known connection between material microstructure, properties, and performance, there is a need for validated modeling capabilities connecting PFM property degradation with microstructural evolution under fusion-relevant conditions. We are developing a simulation capability to couple plasma-induced microstructural evolution to material property degradation. Our approach relies on deliberate mapping between individual simulation models and experimental characterization for validation. The open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) software was used for this simulation capability development. A MOOSE phase-field model was coupled with the cluster dynamics code, Xolotl, to predict microstructural evolution. Microstructure characterization techniques, including scanning electron microscopy (SEM), transmission electron microscopy (TEM), and laser scanning confocal microscopy (LSCM) are used to validate these microstructural evolution simulations. Calculation of thermal and electrical conductivities with first principles simulations was performed for bulk material and for grain boundaries; these results are used within MOOSE models to calculate effective thermal and electrical conductivities as a function of grain characteristics. Thermoreflectance and four-probe techniques were employed to measure the thermal and electrical conductivities, respectively. A MOOSE crystal plasticity model was adapted to predict microstructure-sensitive deformation behavior, and X-ray diffraction (XRD) was used to collect bulk dislocation density data for validation. After individual simulation validation, these models are coupled to predict material property changes resulting from plasma exposure. We focused here on an experimental design to emphasize the separate effects of moderate thermal loads and plasma exposure using tungsten. Annealing of tungsten was performed under a protective environment for temperatures ranging from 500 C to 1500 C. The plasma exposure was completed in the Tritium Plasma Experiment at Idaho National Laboratory under a deuterium flux of 1e22 D/m^2-s. This incremental approach is employed to build confidence in the modeling capability: separate-effects tests ensure that the models capture key mechanisms from single environmental conditions before predicting PFM property degradation under combined loads. We will show our early results from coupling these simulation models to predict PFM property changes from microstructural evolution. Comparisons of the simulation results with preliminary validation data will be discussed.

36 - MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.

Craswhorthiness↗

NASA NTRSDate not supplied

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Craswhorthiness↗

NASA NTRS1952

Effects of wing lift and weight on landing-gear loads

The effects of wing lift and weight on maximum landing gear loads were investigated by drop testing a small landing gear with oleo shock strut in the Langley impact basin. Lift forces were mechanically applied to the dropping mass to produce wing lift factors between 1000 and 2500 pounds. The results show the relationship between lift force, weight, and landing-gear loads for a range of vertical velocities between 0 and 12 feet per second.

Lindquist, Dean C↗

DOE OSTI2024

Real-Time Observation of Nanoscale Kink Band Mediated Plasticity in Ion-Irradiated Graphite: An In Situ TEM Study

Graphite IG-110 is a synthetic polycrystalline material used as a neutron moderator in reactors. Graphite is inherently brittle and is known to exhibit a further increase in brittleness due to radiation damage at room temperature. To understand the irradiation effects on pre-existing defects and their overall influence on external load, micropillar compression tests were performed using in situ nanoindentation in the Transmission Electron Microscopy (TEM) for both pristine and ion-irradiated samples. While pristine specimens showed brittle and subsequent catastrophic failure, the 2.8 MeV Au2+ ion (fluence of 4.378 × 1014 cm−2) irradiated specimens sustained extensive plasticity at room temperature without failure. In situ TEM characterization showed nucleation of nanoscale kink band structures at numerous sites, where the localized plasticity appeared to close the defects and cracks while allowing large average strain. We propose that compressive mechanical stress due to dimensional change during ion irradiation transforms buckled basal layers in graphite into kink bands. The externally applied load during the micropillar tests proliferates the nucleation and motion of kink bands to accommodate the large plastic strain. The inherent non-uniformity of graphite microstructure promotes such strain localization, making kink bands the predominant mechanism behind unprecedented toughness in an otherwise brittle material.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Connect microstructure evolution to property degradation with validated simulation

Reliable material performance is required for plasma-facing material (PFM) candidates. Previous research has shown that plasma and neutron radiation exposure induces microstructural changes in PFMs; changes in thermal and electrical conductivities and in material hardening and embrittlement were also observed after neutron irradiation. These material property changes will negatively impact the performance of the PFMs in a fusion reactor. Despite the well-known connection between material microstructure, properties, and performance, there is a need for validated modeling capabilities connecting PFM property degradation with microstructural evolution under fusion-relevant conditions. We are developing a simulation capability to couple plasma-induced microstructural evolution to material property degradation. Our approach relies on deliberate mapping between individual simulation models and experimental characterization for validation. The open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) software was used for this simulation capability development. A MOOSE phase-field model was coupled with the cluster dynamics code, Xolotl, to predict microstructural evolution. Microstructure characterization techniques, including scanning electron microscopy (SEM), transmission electron microscopy (TEM), and laser scanning confocal microscopy (LSCM) are used to validate these microstructural evolution simulations. Calculation of thermal and electrical conductivities with first principles simulations was performed for bulk material and for grain boundaries; these results are used within MOOSE models to calculate effective thermal and electrical conductivities as a function of grain characteristics. Thermoreflectance and four-probe techniques were employed to measure the thermal and electrical conductivities, respectively. A MOOSE crystal plasticity model was adapted to predict microstructure-sensitive deformation behavior, and X-ray diffraction (XRD) was used to collect bulk dislocation density data for validation. After individual simulation validation, these models are coupled to predict material property changes resulting from plasma exposure. We focused here on an experimental design to emphasize the separate effects of moderate thermal loads and plasma exposure using tungsten. Annealing of tungsten was performed under a protective environment for temperatures ranging from 500$^o$C to 1500$^o$C. The plasma exposure was completed in the Tritium Plasma Experiment at Idaho National Laboratory under a deuterium flux of 1e22 $\frac{D}{m^2s}$. This incremental approach is employed to build confidence in the modeling capability: separate-effects tests ensure that the models capture key mechanisms from single environmental conditions before predicting PFM property degradation under combined loads. We will show our early results from coupling these simulation models to predict PFM property changes from microstructural evolution. Comparisons of the simulation results with preliminary validation data will be discussed.

36 - MATERIALS SCIENCE↗

NASA NTRS1975

Stress relaxation and mechanical properties of RL-1973 and PD-200-16 silicone resin sponge materials

Stress relaxation tests were conducted by loading specimens in double-lap shear to a preselected strain level and monitoring the decay of stress with time. The stress relaxation response characteristics were measured over a temperature range of 100 to 300 K and four strain levels. It is concluded that only a slight amount of stress relaxation was observed, and the stiffness increased approximately two orders of magnitude over the range of temperatures.

Saylak, D.↗

DOE OSTI2024

High-throughput quantification of quasistatic, dynamic and spall strength of materials across 10 orders of strain rates

Abstract The response of metals and their microstructures under extreme dynamic conditions can be markedly different from that under quasistatic conditions. Traditionally, high strain rates and shock stresses are achieved using cumbersome and expensive methods such as the Kolsky bar or large spall experiments. These methods are low throughput and do not facilitate high-fidelity microstructure–property linkages. In this work, we combine two powerful small-scale testing methods, custom nanoindentation, and laser-driven microflyer (LDMF) shock, to measure the dynamic and spall strength of metals. The nanoindentation system is configured to test samples from quasistatic to dynamic strain-rate regimes. The LDMF shock system can test samples through impact loading, triggering spall failure. The model material used for testing is magnesium alloys, which are lightweight, possess high-specific strengths, and have historically been challenging to design and strengthen due to their mechanical anisotropy. We adopt two distinct microstructures, solutionized (no precipitates) and peak-aged (with precipitates) to demonstrate interesting upticks in strain-rate sensitivity and evolution of dynamic strength. At high shock-loading rates, we unravel an interesting paradigm where the spall strength vs. strain rate of these materials converges, but the failure mechanisms are markedly different. Peak aging, considered to be a standard method to strengthen metallic alloys, causes catastrophic failure, faring much worse than solutionized alloys. Our high-throughput testing framework not only quantifies strength but also teases out unexplored failure mechanisms at extreme strain rates, providing valuable insights for the rapid design and improvement of materials for extreme environments.

Eswarappa Prameela, Suhas (ORCID:0000000334530184)↗

DOE OSTI2022

Compressive strength of the plastic-bonded explosive surrogate idoxuridine under quasistatic and dynamic compression

Inert simulant materials, or “mocks”, are often used as surrogates for plastic-bonded explosives (PBX) in non-detonative tests in order to mitigate hazards. Mocks should reproduce as many non-detonative properties of the explosive as possible, including structural behavior in a variety of thermal and mechanical environments. Recently, the molecular crystal idoxuridine (IDOX) has been identified as an ideal mock for the main component in the explosive polymer-matrix composite PBX 9501, and has performed favorably under quasistatic loading conditions. Here, in order to assess robustness over a range of mechanical environments, plastic-bonded IDOX was compression tested from 0.001/s to 2000/s strain rates and compared to PBX 9501 historical data. Plastic-bonded IDOX showed good agreement to PBX 9501 across these strain rates, justifying continued development and production as a mock.

Burch, Alexandra C.↗

NASA NTRSDate not supplied

Understanding Variability in Mechanical Behavior of Adhesively Bonded Sandwich Joints due to Stochastic Material Damage

A mesoscale progressive damage analysis was applied to the analysis of recently tested adhesively bonded sandwich panels, in which ten nominally identical tension loaded panels failed in three different failure modes, with peakloads ranging from 13.0 –16.1 kips. A parametric finite element model for progressive damage analysis of an adhesively bonded joint (ABJ) considering matrix and fiber damage, and delamination cracks in unidirectional and fabric composite sections of the joint, as well as core crushing, and adhesive fracture was developed. The model was developed using Abaqus/Explicit and utilized continuum damage mechanics material models for intralaminar damage in the facesheet and doubler plies, cohesive elements for delamination and adhesive debonding, and discretized cells considering plasticity to model crushing of the aluminum honeycomb core. Analysis predictions obtained with a pristine model agreed well with the average experimental peak load, strain in the joint, and post-test damage states. Then, various methods to incorporate stochastic material variability into ABJ model were evaluated. These methods included simulation of pre-existing matrix damage, pre-existing adhesive porosity, and uniform modification of adhesive properties. These material and manufacturing defects changed the damage mode predictions in some cases. The analysis of stochastic strength due to the considered defects revealed unintuitive damage mode interaction in the ABJ, explaining some structure-property relationships observed experimentally.

Richard Larson↗

NASA NTRS2009

Development, Testing, and Failure Mechanisms of a Replicative Ice Phase Change Material Heat Exchanger

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM s have over evaporators in this scenario is that they do not use a consumable. Wax PCM units have been baselined for the Orion thermal control system and also provide risk mitigation for the Altair Lander. However, the use of water as a PCM has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. An ice PCM heat exchanger that replicates the thermal energy storage capacity of an existing wax PCM unit was fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion are investigated. This paper presents the results to date of this investigation.

Leimkuehler, Thomas O.↗

NASA NTRS2010

Development, Testing, and Failure Mechanisms of a Replicative Ice Phase Change Material Heat Exchanger

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM's have over evaporators in this scenario is that they do not use a consumable. Wax PCM units have been baselined for the Orion thermal control system and also provide risk mitigation for the Altair Lander. However, the use of water as a PCM has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. An ice PCM heat exchanger that replicates the thermal energy storage capacity of an existing wax PCM unit was fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion are investigated. This paper presents the results to date of this investigation. Nomenclature

Leimkuehler, Thomas O.↗

NASA NTRS2016

Tethered Space Satellite-1 (TSS-1): Technical Roundabouts

In the early 1990's US and Italian scientists collaborated to study the electrodynamics of dragging a satellite on a tether through the electrically charged portion of Earth's atmosphere called the ionosphere. An electrical current induced in the long wire could be used for power and thrust generation for a satellite. Other tether uses include momentum exchange, artificial gravity, deployment of sensors or antennas, and gravity-gradient stabilization for satellites. Before the Tethered Space Satellite (TSS-1), no long tether had ever been flown, so many questions existed on how it would actually behave. The TSS consisted of a satellite with science experiments attached to a 12.5 mile long, very thin (0.10 inch diameter) copper wire assembly wound around a spool in the deployer reel mechanism. With the Space Shuttle at an altitude of 160 nautical miles above earth, the satellite was to be deployed by raising it from the Shuttle bay on a boom facing away from Earth. Once cleared of the bay, the deployer mechanism was to slowly feed out the 12-plus miles of tether. Scientific data would be collected throughout the operation, after which the satellite would be reeled back in. Pre-flight testing system level tests involved setting up a tether receiver to catch the 12.5 mile tether onto another reel as it was being unwound by the deployer reel mechanism. Testing only the reel mechanism is straightforward. This test becomes more complicated when the TSS is mounted on the flight pallet at Kennedy Space Center (KSC). The system level tests must be passed before the pallet can be installed into the Space Shuttle cargo bay. A few months before flight, the TSS payload had been integrated onto the Spacelab pallet and system level tests, including unreeling and reeling the tether, had been successfully completed. Some of this testing equipment was then shipped back to the contractor Martin Marietta. Systems-level load analyses, which cannot be run until all information about each payload is finalized, was run in parallel with the physical integration of the hardware into the Shuttle payload bay. The coupled loads analysis, as it is called, incorporates any updates to the model due to system level tests, and any changes that were found during integration. The coupled loads analysis revealed that a single bolt attaching the deployer reel mechanism to the support structure had a "negative margin" - which is an indication that it might fail during operation. Hardware certification rules do not allow for hardware to fly with negative margins, so this issue had to be resolved before the flight. Since there is conservatism in engineering analysis, there is an option to "waive" the margin requirement, and fly the experiment as is. On the other hand, a structural failure of one payload could have serious or catastrophic consequences to other payloads and possibly the mission. Minor design changes or fixes might be feasible within the payload bay prior to launch. Any major design changes that required the spooling test to validate the hardware, or for the pallet to be removed, would cause TSS not to be ready for the Shuttle launch.

O'Connor, Brian↗

NASA NTRS2016

Design and Operation of a Calorimeter for Advanced Multilayer Insulation Testing

A calorimeter has been constructed to accurately measure insulation performance with a nominal 90K cold outer boundary and a 20K inner boundary. Unique features of this design include use of mechanical cryocoolers instead cryogens and measurement of the heat load with a calibrated rod to serve as a conduction path. The calorimeter is operational and has completed its first test series. The initial test series was designed to look for differences in performance between a single layer of aluminum foil and a sheet of double aluminized mylar (DAM). Although it has been speculated that the aluminum foil would perform better, since the mylar coating might not thick enough to stop the transmission of long wave length infrared radiation, our testing showed a higher heat load for the aluminum foil than the DAM. The aluminum foil showed a heat load of 132 mW at an 87 K outer temperature and 152 mW at a 107K outer temperature. Whereas the DAM showed a heat load of 66 mW at an 88 K outer temperature and 81 mW at 108 K.

Cryogenics↗