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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Creep Testing of Vectran Yarn

NASA and industry are developing inflatable space structures to provide deployable habitable volumes for future exploration missions in space and on the surface of the Moon and Mars. These structures must withstand the constant pressure loading of multi-year missions. These missions therefore require excellent creep resistance in the constituent cordage and webbings that provide the primary structure of the vessel, which is typically constructed using high-strength synthetic materials such as Vectran. Real-time and accelerated creep testing of Vectran webbings has been performed at NASA Langley Research Center (LaRC), however, acceptable correlation between the results of the two approaches has not yet been achieved. Given the additional complexity of the webbing architecture, creep testing at the yarn level is being studied to reduce the number of interacting properties and focus on the core creep behavior to see if better correlation can be achieved between real-time and accelerated tests. To achieve this objective a creep test stand that is able to support simultaneous testing of five Vectran yarns had been previously designed and built. The test stand utilizes two clamp-wrap grips to mount the yarn and has a 10:1 load ratio, via a lever-arm, henceforth, known as the lever-arm test stand. Real-time creep testing (without measuring the strain of the yarn) in this fixture produces yarn ruptures in the gauge section. However, a large scatter in the times to failure was seen in the results across multiple loading conditions. For example, a test at 70% of the ultimate tensile strength (UTS) was found to have specimens that failed within a matter of hours and others that took over 6 weeks to fail. Prior test data on Vectran webbings had indicated high variability in the material strength, leading to higher than average scatter in the creep testing of webbings, which could translate to the scatter in creep behavior at the yarn level as well. However, there was still the possibility that the lever-arm test stand was causing the high scatter in data; specifically, due to potential variability in the loading of each specimen. Therefore, an additional creep test setup was designed and built to attempt to determine if the large scatter in the results was due to inherent material properties, the lever-arm test stand, or both. The newly designed creep test stand, henceforth known as the conventional test stand, utilized the more typical method for creep testing which involved hanging a weight from the yarn with no additional load amplification. The conventional test stand was designed and fabricated in-house at LaRC. High speed cameras were used to validate that the specimens in the conventional test stand failed in the gauge section. Once it was determined that the conventional test stand would provide valid failures in the gauge section, creep tests on the Vectran yarns were run to compare to the lever-arm test stand results. Preliminary results for a 70% UTS creep test have some specimens failing within a number of hours and some failing in excess of 6 weeks. These results are similar to those seen on the lever-arm test stand, pointing towards a large variability inherent in the material. The poster/presentation will focus on the design, fabrication, and validation of the conventional test stand as well as present preliminary results comparing the creep data from the conventional and lever-arm test stands

creep testing↗
NASA NTRS1991

Integrated control of thermally distorted large space antennas

The objective is to develop a control system design method that (1) recognizes the time dependence of the thermal distortion due to orbital motion and (2) controls variables that are directly related to far field performance for earth pointing space antennas. The first objective is accomplished by expanding the distortion into principal components that are orthogonal in space and time. The approach for the second objective is to expand the far zone electric field in a Zernike-Bessel series. The method accommodates tapered feeds and arbitrary polarizations. Simulations are performed for a geosynchronous radiometer to determine the effectiveness of the control system under variations in solar geometry, structure materials and thermal properties.

Tolson, Robert H.↗
NASA NTRS2003

Investigation of Dynamic Oxygen Adsorption in Molten Solder Jetting Technology

Surface tension forces play a critical role in fluid dynamic phenomena that are important in materials processing. The surface tension of liquid metals has been shown to be very susceptible to small amounts of adsorbed oxygen. Consequently, the kinetics of oxygen adsorption can influence the capillary breakup of liquid-metal jets targeted for use in electronics assembly applications, where low-melting-point metals (such as tin-containing solders) are utilized as an attachment material for mounting of electronic components to substrates. By interpreting values of surface tension measured at various surface ages, adsorption and diffusion rates of oxygen on the surface of the melt can be estimated. This research program investigates the adsorption kinetics of oxygen on the surface of an atomizing molten-metal jet. A novel oscillating capillary jet method has been developed for the measurement of dynamic surface tension of liquids, and in particular, metal melts which are susceptible to rapid surface degradation caused by oxygen adsorption. The experimental technique captures the evolution of jet swells and necks continuously along the jet propagation axis and is used in conjunction with an existing linear, axisymmetric, constant-property model to determine the variation of the instability growth rate, and, in turn, surface tension of the liquid as a function of surface age measured from the exit orifice. The conditions investigated so far focus on a time window of 2-4ms from the jet orifice. The surface properties of the eutectic 63%Sn-37%Pb solder alloy have been investigated in terms of their variation due to O2 adsorption from a N2 atmosphere containing controlled amounts of oxygen (from 8 ppm to 1000 ppm). The method performed well for situations where the oxygen adsorption was low in that time window. The value of surface tension for the 63Sn-37Pb solder in pure nitrogen was found to be 0.49 N/m, in good agreement with previously published work. A characteristic time of O(1ms) or less was determined for the molten-metal surface to be saturated by oxygen at 1000 ppm concentration in N2.

Megaridis, Constantine M.↗
NASA NTRS2015

Constraining the Texture and Composition of Pore-Filling Cements at Gale Crater, Mars

The Mars Science Laboratory (MSL) rover Curiosity has encountered a wide variety of sedimentary rocks deposited in fluvio-lacuestrine sequences at the base of Gale Crater. The presence of sedimentary rocks requires that initial sediments underwent diagenesis and were lithified. Lithification involves sediment compaction, cementation, and re-crystallization (or authigenic) processes. Analysis of the texture and composition of the cement can reveal the environmental conditions when the cements were deposited, enabling better understanding of early environments present within Gale Crater. The first step in lithification is sediment compaction. The Gale crater sediments do not show evidence for extensive compaction prior to cementation; the Sheepbed mudstone in Yellowknife Bay (YKB) has preserved void spaces ("hollow nodules"), indicating that sediments were cemented around the hollow prior to compaction, and conglomerates show imbrication, indicating minimal grain reorganization prior to lithification. Furthermore, assuming the maximum burial depth of these sediments is equivalent to the depth of Gale Crater, the sediments were never under more than 1 kb of pressure, and assuming a 15 C/km thermal gradient in the late Noachian, the maximum temperature of diagenesis would have been approximately 75 C. This is comparable to shallow burial diagenetic conditions on Earth. The cementation and recrystallization components of lithification are closely intertwined. Cementation describes the precipitation of minerals between grains from pore fluids, and recrystallization (or authigenesis) is when the original sedimentary mineral grains are altered into secondary minerals. The presence of authigenic smectites and magnetite in the YKB formation suggests that some recrystallization has taken place. The relatively high percentage of XRD-amorphous material (25-40%) detected by CheMin suggests that this recrystallization may be limited in scope, and therefore may not contribute significantly to the cementing material. However, relatively persistent amorphous components could exist in the Martian environment (e.g. amorphous MgSO4), so recrystallization, including loss of crystallinity, cannot yet be excluded as a method of cementation. In order to describe the rock cementation, both the rock textures and their composition must be considered. Here, we attempt to summarize the current understanding of the textural and compositional aspects of the cement across the rocks analyzed by Curiosity to this point.

Siebach, K. L.↗
NASA NTRSDate not supplied

History of Structural Stitching Development for Aerospace Applications

Layered composite structures are a commonly used, lightweight option for aerospace vehicles today. However, these structures are prone to delamination between plies as well as separation between co-cured sections such as skins and flanges. In addition, delamination can easily be induced by impact damage from events such as tool drops and hailstones. Since such delaminations are often not visible from the external surface of the structure, additional material or fasteners must be included in the design to ensure the structure will maintain the required load-carrying ability through its lifetime. However, adding extra material increases weight and reduces structural efficiency and adding fasteners and their associated holes reduces manufacturing efficiency and adds the requirement to inspect the holes since they could become crack initiation points. Alternate means to reduce delaminations could be beneficial. An alternative to these options is to build the structure with through-thickness reinforcement, such as using stitching threads, to limit delamination, increase out-of-plane strength, and provide a method to join structural elements together without fasteners. The history of through-thickness stitching as it could be applied to aerospace vehicles is described in this paper.

carbon-epoxy↗
NASA NTRSDate not supplied

Calculating Mode Mixity in Interlaminar Fracture of Composite Laminates

To accurately predict delamination under mixed-mode loading, cohesive elements must partition the energies dissipated in Mode I and Mode II correctly. The ability of cohesive models to predict mode mixity was evaluated by performing analyses of the single leg bending (SLB) test, which exhibits a variable mode mixity with crack length. Accordingly, two numerical integration methods were developed to compute the energy partitioning: (i) a local calculation of the accumulated work of tractions at each point along the crack path, and (ii) a global J-integral “snapshot” calculation along a contour around the process zone. In the case of a composite laminate with properties characterized by short fracture process zone (FPZ), the results of these two methods correlate well with each other and with a linear elastic fracture mechanics solution. However, FPZscan be long due to fiber bridging or due to the intrinsic toughness of the material. Then, the results of mode-mixity calculations obtained with various methods vary widely from each other. It is argued that the global J-integral calculation is the most accurate interpretation of the energy release rate and mode mixity for either short or long process zones. This solution will provide a more accurate characterization of resistance curves and mode mixity in experimental results, and it will also guide the development of more accurate mixed-mode cohesive laws for tougher materials characterized by strong R-curve responses, such as thermo-plastic composites.

cohesive zone analysis↗
DOE OSTI2025

Diffusion behavior of lanthanide fission products in bcc Fe cladding: A first-principles study

Fuel-cladding chemical interaction poses significant challenges in nuclear reactors, where fission products generated from nuclear fuel interact with Fe-based cladding materials, potentially compromising their structural integrity. This study investigates the diffusion behavior of lanthanide fission products, Lanthanum (La), Cerium (Ce), Praseodymium (Pr), and Neodymium (Nd), within body-centered cubic (bcc) Fe cladding using the density functional theory, nudged elastic band method, and self-consistent mean field theory. Our results reveal significant vacancy binding energies, particularly with the 1st and 2nd nearest neighbors, which diminish beyond the 5th nearest neighbor, with La exhibiting the strongest binding affinity, followed by Nd, Ce, and Pr. The nudged elastic band calculations indicate significant high barriers for the dissociation of 1st nearest neighbor vacancy-solute pairs for all fission products. The tracer diffusion coefficients of these fission products were derived in an Arrhenius form, with a magnetic correction that accounts for the high-temperature paramagnetic state. The significant trapping effect of vacancies caused by a very dilute concentration of fission products reduces vacancy mobility, potentially leading to modifications in point defect supersaturation, void nucleation, and swelling under irradiation. These represent critical challenges for irradiated cladding materials. The tracer diffusion coefficients indicate that Nd diffuses the fastest, followed by La, Ce, and Pr. Furthermore, this study provides essential insights for understanding fission product transport in cladding materials and informs future design strategies to mitigate fuel-cladding chemical interaction, ultimately enhancing nuclear reactor safety and performance.

Diffusion↗
NASA NTRS1984

LEC System Development

The Lajet Energy Company (LEC) 460 is described. A parabolic dish which incorporates a microprocessor to automatically point it toward the Sun from sunrise to sunset is used. The dish is composed of a set of mirrors (made of reflective polymeric film) which focus and concentrate the Sun's energy on a receiver, producing intense but controlled amounts of heat. The LEC 460 employs a design concept that permits the use of common and low cost materials. All major structural components are fabricated from low carbon, low alloy steel using methods adaptable to mass production. The mirrors are supported on a steel tubing frame. This frame is attached near its center of gravity to a cantilevered support structure. The mirrors and frame are counterbalanced by the weight of the receiver, thus reducing the energy needed to move the collector (parasitic load) and allowing movement on two axes. Each LEC 460 solar concentrator contains a reflective array consisting of twenty four 60 inch diameter mirrors.

Halbert, D. D.↗
NASA NTRS1994

Aerothermodynamics of Pyrolizing Surfaces in Hypersonic Rarefied Flows

Direct simulation Monte Carlo (DSMC) calculations of rarefied flows about entry bodies typically employ a fixed surface temperature or a radiative-equilibrium energy balance to compute that temperature. Such boundary conditions neglect any effects of heat capacitance and heat conduction in the spacecraft heat shield and, therefore, provide an upper bound for the surface temperature. Such calculations also neglect pyrolysis from the heat shield which can be significant for a high-energy incident flow at very low densities. Accurate prediction of both heating and aerodynamic forces requires including pyrolysis and surface heat transfer in the models for gas-surface interaction employed in DSMC methods. Although these physical models have long appeared in various continuum flow calculation codes, they have only recently appeared in DSMC codes which are required to simulate rarefied flows during entry at high altitudes. In the current implementation, routines from the widely distributed Charring Material Thermal Response and Ablation (CMA) program are coupled into a DSMC code to calculate the one-dimensional heat transfer into the carbon phenolic heat shield at each point on a vehicle surface. Temperature-dependent material properties, surface re-radiation, and in-depth pyrolysis were included in the calculation, but surface ablation was neglected. Sample calculations for entry of the Galileo probe into the atmosphere of Jupiter demonstrate that including pyrolysis in the model leads to significant differences in predicted aerodynamics. Granted, the drag coefficient does not depend strongly on the surface temperature which can itself be significantly below the radiative equilibrium value during entry. However, the surface mass flux due to pyrolysis of the material is significant once the probe drops to altitudes characterized by transition flow. This leads to a noticeable increase in drag and a decrease in heating compared to a body without pyrolysis.

Haas, Brian L.↗
NASA NTRS2011

NASA Tech Briefs, June 2011

Topics covered include: Wind and Temperature Spectrometry of the Upper Atmosphere in Low-Earth Orbit; Health Monitor for Multitasking, Safety-Critical, Real-Time Software; Stereo Imaging Miniature Endoscope; Early Oscillation Detection Technique for Hybrid DC/DC Converters; Parallel Wavefront Analysis for a 4D Interferometer; Schottky Heterodyne Receivers With Full Waveguide Bandwidth; Carbon Nanofiber-Based, High-Frequency, High-Q, Miniaturized Mechanical Resonators; Ultracapacitor-Based Uninterrupted Power Supply System; Coaxial Cables for Martian Extreme Temperature Environments; Using Spare Logic Resources To Create Dynamic Test Points; Autonomous Coordination of Science Observations Using Multiple Spacecraft; Autonomous Phase Retrieval Calibration; EOS MLS Level 1B Data Processing Software, Version 3; Cassini Tour Atlas Automated Generation; Software Development Standard Processes (SDSP); Graphite Composite Panel Polishing Fixture; Material Gradients in Oxygen System Components Improve Safety; Ridge Waveguide Structures in Magnesium-Doped Lithium Niobate; Modifying Matrix Materials to Increase Wetting and Adhesion; Lightweight Magnetic Cooler With a Reversible Circulator; The Invasive Species Forecasting System; Method for Cleanly and Precisely Breaking Off a Rock Core Using a Radial Compressive Force; Praying Mantis Bending Core Breakoff and Retention Mechanism; Scoring Dawg Core Breakoff and Retention Mechanism; Rolling-Tooth Core Breakoff and Retention Mechanism; Vibration Isolation and Stabilization System for Spacecraft Exercise Treadmill Devices; Microgravity-Enhanced Stem Cell Selection; Diagnosis and Treatment of Neurological Disorders by Millimeter-Wave Stimulation; Passive Vaporizing Heat Sink; Remote Sensing and Quantization of Analog Sensors; Phase Retrieval for Radio Telescope and Antenna Control; Helium-Cooled Black Shroud for Subscale Cryogenic Testing; Receive Mode Analysis and Design of Microstrip Reflectarrays; and Chance-Constrained Guidance With Non-Convex Constraints.

Source record↗
NASA NTRS2014

Modified Displacement Transfer Functions for Deformed Shape Predictions of Slender Curved Structures with Varying Curvatives

To eliminate the need to use finite-element modeling for structure shape predictions, a new method was invented. This method is to use the Displacement Transfer Functions to transform the measured surface strains into deflections for mapping out overall structural deformed shapes. The Displacement Transfer Functions are expressed in terms of rectilinearly distributed surface strains, and contain no material properties. This report is to apply the patented method to the shape predictions of non-symmetrically loaded slender curved structures with different curvatures up to a full circle. Because the measured surface strains are not available, finite-element analysis had to be used to analytically generate the surface strains. Previously formulated straight-beam Displacement Transfer Functions were modified by introducing the curvature-effect correction terms. Through single-point or dual-point collocations with finite-elementgenerated deflection curves, functional forms of the curvature-effect correction terms were empirically established. The resulting modified Displacement Transfer Functions can then provide quite accurate shape predictions. Also, the uniform straight-beam Displacement Transfer Function was applied to the shape predictions of a section-cut of a generic capsule (GC) outer curved sandwich wall. The resulting GC shape predictions are quite accurate in partial regions where the radius of curvature does not change sharply.

displacement transfer functions↗
NASA NTRS1990

Experimental determination of material damping using vibration analyzer

Structural damping is an important dynamic characteristic of engineering materials that helps to damp vibrations by reducing their amplitudes. In this investigation, an experimental method is illustrated to determine the damping characteristics of engineering materials using a dual channel Fast Fourier Transform (FFT) analyzer. A portable Compaq III computer which houses the analyzer, is used to collect the dynamic responses of three metal rods. Time-domain information is analyzed to obtain the logarithmic decrement of their damping. The damping coefficients are then compared to determine the variation of damping from material to material. The variations of damping from one point to another of the same material, due to a fixed point excitation, and the variable damping at a fixed point due to excitation at different points, are also demonstrated.

Chowdhury, Mostafiz R.↗
NASA NTRS1996

Evaluation of the Edge Crack Torsion (ECT) Test for Mode 3 Interlaminar Fracture Toughness of Laminated Composites

An analytical and experimental investigation was carried out on G40-800/R6376 graphite epoxy laminates to evaluate the Edge Crack Torsion (ECT) test as a candidate for a standard Mode 3 interlaminar fracture toughness test for laminated composites. The ECT test consists of a (90/(+/- 45)(sub 3)/(+/- 45)(sub 3)/90))(sub s) laminate with a delamination introduced by a non-adhesive film at the mid-plane along one edge and loaded in a special fixture to create torsion along the length of the laminate. Dye penetrate enhanced X-radiograph of failed specimens revealed that the delamination initiated at the middle of the specimen length and propagated in a self similar manner along the laminate mid-plane. A three-dimensional finite element analysis was performed that indicated that a pure Mode 3 delamination exists at the middle of specimen length away from both ends. At the ends near the loading point a small Mode 2 component exists. However, the magnitude of this Mode 2 strain energy release rate at the loading point is small compared to the magnitude of Mode 3 component in the mid-section of the specimen. Hence, the ECT test yielded the desired Mode 3 delamination. The Mode 3 fracture toughness was obtained from a compliance calibration method and was in good agreement with the finite element results. Mode 2 End-Notched Flexure (ENF) tests and Mode 1 Double Cantilever Beam (DCB) tests were also performed for the same composite material. The Mode 1 fracture toughness was much smaller than both the Mode 2 and Mode 3 fracture toughness. The Mode 2 fracture toughness was found to be 75% of the Mode 3 fracture toughness.

Li, Jian↗
NASA NTRS1997

Pulse-Echo Ultrasonic Imaging Method for Eliminating Sample Thickness Variation Effects

A pulse-echo, immersion method for ultrasonic evaluation of a material which accounts for and eliminates nonlevelness in the equipment set-up and sample thickness variation effects employs a single transducer and automatic scanning and digital imaging to obtain an image of a property of the material, such as pore fraction. The nonlevelness and thickness variation effects are accounted for by pre-scan adjustments of the time window to insure that the echoes received at each scan point are gated in the center of the window. This information is input into the scan file so that, during the automatic scanning for the material evaluation, each received echo is centered in its time window. A cross-correlation function calculates the velocity at each scan point, which is then proportionalized to a color or grey scale and displayed on a video screen.

Roth, Don J.↗
DOE OSTI2025

Surface smoothing for laser powder-bed Ti-6Al-4V by a transient liquid phase

Surface roughness is the primary driver of fatigue for additively manufactured metals. To address surface roughness, this work introduces a new method to smooth features beyond line-of-sight without material removal. The method applies a coating that triggers local surface remelting by activating a eutectic reaction during heat treatment. The associated liquid phase then wets and isothermally solidifies into a smoother surface. For Ti-6Al-4V fabricated with laser powder bed fusion, samples with and without TLP smoothing (using a Cu coating) were characterized with a suite of techniques, including mechanical testing, electron backscatter diffraction, synchrotron X-ray tomography, and fractography. TLP smoothing reduced surface roughness by 80% and amplified compressive residual stress at the surface by about 50%. With statistically equivalent virtual microstructures, crystal plasticity scrutinized the roles of phases, porosity, and surface roughness. Although the tensile strain-to-failure was reduced to 1% strain, the TLP smoothing process increased high-cycle fatigue strength by about 20% compared to control samples, pointing to future opportunities to optimize the new process through various coating compositions and heat treatment schedules. Overall, this work establishes a new paradigm for treating surfaces of materials for smoothness and compressive residual stress.

Additive manufacturing↗
DOE OSTI2026

Development of Ternary Transition Metal Oxide Catalysts for Oxygen Evolution Reaction

Electrochemical water splitting, a promising method for green hydrogen production, is currently hindered by the high cost of precious-group metal (PGM)-based catalysts for the oxygen evolution reaction (OER). This study addresses this challenge by advancing the development of catalysts for OER, focusing on the development of high-performance PGM-free catalysts using nickel-iron-cobalt (NiFeCo)-based aerogels. The catalysts were synthesized via a sol-gel method and critical point drying to achieve a highly porous structure with an exceptionally high surface area. The designed catalyst structure provides an ideal platform for maximizing catalytic active sites and enhancing mass transport kinetics. Co has been systematically incorporated into the current PGM-free state-of-the-art, NiFeOx catalyst, and the metal ratios have been optimized. In addition to the experimental studies, density functional theory calculations were performed to study the material’s properties of this ternary catalyst and the effect of Co addition on enhancing OER catalysis.

Mizrahi, Michal [Bar-Ilan University, Ramat Gan, I↗
DOE OSTI2025

Defect Detection Model Development for Large Scale Thermoplastic Printing

Large-format additive manufacturing (LFAM) offers several advantages, including high throughput, cost-effective pellet-fed extrusion, and the capability to produce large-scale structures. The main pain points of LFAM include start and stops during the printing process, warpage, long layer times that lead to bead freezing, and bead separation due to shrinkage. These issues can lead to overfill, underfill and buildup of material in different sections of a print. This can lead to hidden defects embedded within the printed layers, or even ultimate failure of the printed structure. This ensures these defects can only be identified through nondestructive testing (NDT) inspection methods after printing, which can be timely and costly. Aligned Vision work specializes in 2D projectors with visual inspection systems and machine learning. Traditionally system is used for composite layup and layup inspections. In this work we used the LFAM system at Oak Ridge National Laboratory to create defect rich samples. The Aligned Vision inspection system then performed in-situ monitoring of the print process after each part was printed. This in-situ vision inspection system was used to develop a layer-by-layer inspection model that looks for overfill, underfill, and the buildup of defects using only a camera-based vision system. This leads to the assurance of high-quality production components.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Pulse-echo ultrasonic imaging method for eliminating sample thickness variation effects

A pulse-echo, immersion method for ultrasonic evaluation of a material is discussed. It accounts for and eliminates nonlevelness in the equipment set-up and sample thickness variation effects employs a single transducer, automatic scanning and digital imaging to obtain an image of a property of the material, such as pore fraction. The nonlevelness and thickness variation effects are accounted for by pre-scan adjusments of the time window to insure that the echoes received at each scan point are gated in the center of the window. This information is input into the scan file so that, during the automatic scanning for the material evaluation, each received echo is centered in its time window. A cross-correlation function calculates the velocity at each scan point, which is then proportionalized to a color or grey scale and displayed on a video screen.

Roth, Don J.↗