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NASA NTRS2024

Considerations for Health and Performance during Surface Extravehicular Activities

BACKGROUND: NASA’s objectives for expanding human presence beyond low Earth orbit will require Extravehicular Activities (EVAs) on lunar and planetary surfaces. Given the physiological and functional demands of conducting surface EVAs in a pressurized spacesuit in reduced gravity environments, there is a possibility that crew injury and compromised physiological and/or functional performance may present. OVERVIEW: Many human health and performance knowledge gaps exist in regards to exploration EVA that require characterization to ensure safety, reliability, and mission success. To address knowledge gaps, EVA simulations in Earth-based analog environments and/or spacesuit simulators can be utilized to provide valuable insights into task-based physiologic and metabolic costs, cognitive loads, and associated operational limitations to inform future mission concepts. Physical workloads approaching 60% of maximum metabolic rates and 85% age-predicted heart rate maxima; core body temperatures approaching 100° F; and subjective responses indicating limited spare cognitive capacity via Bedford scale have been observed during ground-based exploration EVA simulations in the NASA Active Response Gravity Offload Simulator (ARGOS) and Neutral Buoyancy Lab (NBL) during simulated planetary EVAs in pressurized suits. Further, ground-based EVA analogs vary in their ability to simulate planetary EVA and resulting physical workloads. DISCUSSION: Metabolic costs, thermal burdens, functional strength, and cognitive impacts have been and must continue to be assessed in ground-based analogs to fully characterize operational demands and crew readiness levels for exploration EVA. Considerations should be given to enabling a new concept of high-tempo surface EVA operations and associated work-rest intervals, understanding human health and performance impacts of evolving commercial suit designs and capabilities, and predictive modeling and decision support capabilities to enable safe and successful EVA operations.

P Estep↗

DOE OSTI2020

Experimental Test Bed to Enable Realistic Evaluations for Direct Transfer Trip Relaying via Private Wireless LTE Communications: Preprint

Increasing penetration levels of inverter-based distributed energy resources (DERs) in distribution systems are creating challenges in system operation. Currently, wired or proprietary wireless communications are used by advanced distribution management systems (ADMS) to detect the state of the system and control the DERs for optimal operation. Wireless communications are an alternative solution that can enable connectivity between the dispersed assets used in distribution system applications. This paper demonstrates an experimental test bed to enable the realistic evaluation of communications system characteristics for direct transfer trip (DTT) relaying of a photovoltaic inverter system using a private 900-MHz spectrum wireless LTE network. Private LTE network communications can be deployed to many remote DERs and other grid-edge devices to prevent costly infrastructure upgrades across distribution systems. In addition, this paper provides a framework for evaluating the impact of signal strength and network traffic in communications systems. The results shown develop a better understanding of the best practices for using LTE communications systems across multiple utility applications, such as protective relaying, voltage regulation, and supervisory control and data acquisition system messages.

900 MHz LTE network↗

DOE OSTI2021

Experimental Test Bed to Enable Realistic Evaluations for Direct Transfer Trip Relaying via Private Wireless LTE Communications

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

Extending Beryllium Strength Calibration To High Strain-rate Regimes

Current calibration of the PTW strength model for beryllium is accomplished using fits to Hopkinson bar experiments. Unfortunately, Hopkinson bar tests on beryllium only allow for strain-rates of up to $5 * 10^{3} s^{-1}.$ It has been shown previously that, in higher strain-rate experiments such as flyer-plate impact tests, this calibrated strength model causes simulations with beryllium to diverge from the observed response. In this work we use a particle swarm optimization algorithm to arrive at a better calibration of beryllium strength through fits to observed material responses during flyer-plate impact experiments. We show that the PTW strength model for beryllium can be tuned to provide a much better fit to flyer-plate responses. To mitigate the effect of this new calibration on fits to Hopkinson bar data we calibrate to flyer-plate impact data using only parameters within the medium strain-rate regime of the PTW model.

36 MATERIALS SCIENCE↗

NASA NTRS1988

Hypervelocity impact testing of tethers

An experimental test program has been conducted to ascertain the strength losses to which representative space tether materials may be prone upon impact by hypervelocity particles of known size, density, and velocity, when the tether is under tensile loading typical of flight design loads. Twelve hypervelocity impacts were followed by tensile tests to failure to determine residual strength; relationships are established between particle velocity and strength loss due to impact damage, as well as between tether strength loss and the relationship between particle and tether diameters. Tentative design criteria are formulated in terms of a design factor allowing for strength degradation by impact.

Woodis, William R.↗

DOE OSTI2018

Effect of Ni content on the microstructure and mechanical properties of weld metal with both-side submerged arc welding technique

Highlights: • This manuscript primarily studied the effects of Ni content on the K65 weld metals; • Increase Ni content could significantly improve the strength and low temperature impact toughness of the weld metal. • The beneficial effect of Ni is attributed to its positive effect on phase transformation. • GBF keeps K-S or N-W relations only with one austenite and the variants belong to the same bain group are two reasons. • The M/A islands are considered to be another reason for the reduced toughness. - Abstract: The effects of nickel (Ni) content on the mechanical properties and microstructure evolution in the weld metals of commercial K65 oil and gas pipeline steel were studied. Increase Ni content could significantly improve the strength and low temperature impact toughness (−40 °C and −60 °C) of the weld metal. The above influences of Ni were attributed to the formation of predominant acicular ferrite (AF), at the expense of grain boundary ferrite (GBF), ferrite side plates (FSP) and martensite/austenite (M/A) constituent in weld metal. EBSD results indicated that GBF keeps K-S or N-W relations only with the prior austensite grain that belongs to one side of the grain boundary and the variants belong to the same bain group which always forms low angle boundary. Moreover, the retained austenite as one part of M/A constituent was mainly found in the weld metal with lower Ni content. It indicated that the transformation process could be promoted more completely by the increase of Ni content. The mechanism of the toughness improvement brought by Ni increasing was ascribed to the relatively uniform transformation to final microstructure, which reduces the appearance of GBF and M/A constituents.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Impact of supercritical carbon dioxide on the frictional strength of and the transport through thin cracks in shale

Understanding the mechanical and transport behavior of thin (i.e. small aperture) cracks slipping under supercritical carbon dioxide (sc-CO 2 ) conditions is essential to evaluate the integrity of sealing formations with buoyant sc-CO 2 below and the success of waterless fracturing. The two major items of interest in this work are frictional strength and permeability change of the crack. We used a triaxial cell that permits in situ visualization to conduct and monitor slippage along the faces of narrow cracks subjected to triaxial stresses. Such cracks are analogs to small geological faults. We tested carbonate-rich, 1-inch diameter Wolfcamp shale samples that are saw cut 30° to vertical to create a thin crack. Friction coefficients ranged from about 0.6 to 0.8 consistent with expectations for brittle rocks. The sc-CO 2 generally did not alter friction coefficient over the time scale of experiments. From a transport perspective, saturating cracks with sc-CO 2 substantially decreased permeability of the crack by 26%–52%, while slip resulted in a variety of permeability responses. Overall, the combined impact of sc-CO 2 saturation and slip reduced fault permeability for all tests. Our observations support the notion that the sealing capacity of some caprocks improves when saturated with sc-CO 2 and that some slip of small fractures is not necessarily detrimental to caprock integrity.

58 GEOSCIENCES↗

NASA NTRS2020

A Brief Overview of the Effects of Impact Damage to Rocket Motor Cases

This Technical Memorandum (TM) presents pertinent results from past experimental work concerning impact damage to composite rocket motor cases. A rocket motor case in this TM refers to filament-wound pressure vessels of a substantial size intended to be used for launch vehicles, such as the new Space Launch System (SLS) rocket. In the early 1980s, as carbon fiber composites were becoming increasingly used on aircraft, concerns about the effects of foreign object impact damage grew, since the compressive strength properties of these composites could be severely affected by impact damage. The tensile properties were not as affected by foreign object impact damage which is fortunate for rocket motor cases as they are driven by tensile loads (burst strength). While great improvements to both carbon fibers and resins have resulted in far superior toughness values compared to the early generation of carbon/epoxy systems, the stigma of composite rocket motor cases being easily damaged and the burst strength compromised persists.

impact damage↗

NASA NTRS1993

Impact damage tolerance of thin wall composite struts

An experimental investigation was made to study the impact damage tolerance of thin wall composite struts made of both brittle epoxy and toughened epoxy based composite materials. Damage parameters such as barely visible surface damage and internal damage represented by the ultrasonic C-scan, and residual compressive strengths were evaluated against impact energy for two impactor sizes. From both a damage resistance (internal damage vs. impact energy) and a damage tolerance (residual compressive strength vs. internal damage) point of view, the toughened IM7/977-2 struts exhibited better performance than the brittle epoxy based T50/934 struts. This is attributed to the toughening mechanism in 977-2 which impedes delamination initiation from impact, and delamination growth and subsequent buckling under a compression loading. At barely visible damage thresholds, regardless of the impactor sizes, a maximum strength reduction of 45-55 percent was observed for the T50/934 struts, and approximately 10 percent for IM7/977-2 struts. This is of great interest for developing a damage tolerance design approach and risk assessment methodology in which the design allowable would be defined by the residual strength at the threshold of barely visible damage.

Chen, G.-S.↗

DOE OSTI2016

Development of new generation reduced activation ferritic-martenstic steels for advanced fusion reactors

International development of reduced activation ferritic-martensitic (RAFM) steels has focused on 9 wt percentage Cr, which primarily contain M 23 C 6 (M = Cr-rich) and small amounts of MX (M = Ta/V, X = C/N) precipitates, not adequate to maintain strength and creep resistance above ~500 °C. To enable applications at higher temperatures for better thermal efficiency of fusion reactors, computational alloy thermodynamics coupled with strength modeling have been employed to explore a new generation RAFM steels. The new alloys are designed to significantly increase the amount of MX nanoprecipitates, which are manufacturable through standard and scalable industrial steelmaking methods. Preliminary experimental results of the developed new alloys demonstrated noticeably increased amount of MX, favoring significantly improved strength, creep resistance, and Charpy impact toughness as compared to current RAFM steels. Furthermore, the strength and creep resistance were comparable or approaching to the lower bound of, but impact toughness was noticeably superior to 9–20Cr oxide dispersion-strengthened ferritic alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Investigation and Analysis of Dolomite Dissolution in Variable Strength Systems Relevant to the WIPP

The Waste Isolation Pilot Plant (WIPP) was opened in 1999 as a solution to the long-term disposal of the nation's nuclear defense-generated transuranic (TRU) waste. The salt beds were recommended as the ideal location because they are free from flowing fresh water, easily mined, impermeable, and geologically stable. However, for performance assessment modeling, release scenarios must be considered. The most likely release scenario was determined to be human intrusion leading to direct and/or long-term brine release (US DOE 1995, US DOE 1996, Perkins et al., 1999). The focus of this research is the Rustler formation because it is located above the WIPP and is the most transmissive layer (Perkins et al., 1999). Objective: To determine the effect of chelating ligands ( e.g. EDTA) on dissolution of dolomite in high ionic strength systems. Do brines impact dolomite dissolution and how is it affected by EDTA binding with cations? By varying the ionic strengths, different brine conditions can be simulated similar to those in and around the Culebra member and evaluate trends of dissolved Ca and Mg in the aqueous phase from the quantified data. Conclusions: <2% of dolomite dissolved over one week at pH 8.5. Greater dissolution occurred at higher ionic strength and in the presence of NaCl with approximately 0.4 vs. 0.9% of Mg removed from dolomite in 0.1 and 1.0 M Na. Further, 0.3 vs. 0.9% of Mg was removed from dolomite in 1.0 M IS CaCl{sub 2} versus NaCl. EDTA increased dissolution of dolomite at low ionic strength due to its strong complexation affinity for Ca/Mg with slightly greater removal of Ca than Mg. Significant differences were not observed at high ionic strength due to the presence of large concentrations of competing cations (Na, Ca, Mg). Slightly higher concentrations of Ca were removed from dolomite than Mg after one week, suggesting either incongruent dissolution or release through ion exchange of Ca from trace mineral impurities. Further, when EDTA was present, it may have increased Ca removal due to its greater complexation for Ca than Mg. Environmental Implications: High ionic strength brines and low ionic strength solutions with organic ligands increase dissolution of dolomite. Due to the long half-lives of radionuclides in the TRU waste, it may be important to consider the long term impact of dolomite dissolution for potential release scenarios.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2006

Impact Damage and Strain Rate Effects for Toughened Epoxy Composite Structures

Structural integrity of composite systems under dynamic impact loading is investigated herein. The GENOA virtual testing software environment is used to implement the effects of dynamic loading on fracture progression and damage tolerance. Combinations of graphite and glass fibers with a toughened epoxy matrix are investigated. The effect of a ceramic coating for the absorption of impact energy is also included. Impact and post impact simulations include verification and prediction of (1) Load and Impact Energy, (2) Impact Damage Size, (3) Maximum Impact Peak Load, (4) Residual Strength, (5) Maximum Displacement, (6) Contribution of Failure Modes to Failure Mechanisms, (7) Prediction of Impact Load Versus Time, and (8) Damage, and Fracture Pattern. A computer model is utilized for the assessment of structural response, progressive fracture, and defect/damage tolerance characteristics. Results show the damage progression sequence and the changes in the structural response characteristics due to dynamic impact. The fundamental premise of computational simulation is that the complete evaluation of composite fracture requires an assessment of ply and subply level damage/fracture processes as the structure is subjected to loads. Simulation results for the graphite/epoxy composite were compared with the impact and tension failure test data, correlation and verification was obtained that included: (1) impact energy, (2) damage size, (3) maximum impact peak load, (4) residual strength, (5) maximum displacement, and (6) failure mechanisms of the composite structure.

Chamis, Christos C.↗

NASA NTRS2015

Fracture Strength of Fused Silica From Photonic Signatures Around Collision Sites

Impact sites in glass affect its fracture strength. An analytical model that predicts fracture strength from grey-field polariscope (GFP) readings (photoelastic retardations) has been developed and reported in the literature. The model is suggestive that stress fields, resulting from impact damage, destablizes sites within the glass, which lead to pathways that cause strength degradation. Using data collected from fused silica specimens fabricated from outer window panes that were designed for the space shuttle, the model was tested against four categories of inflicted damage. The damage sites were cored from the window carcasses, examined with the GFP and broken using the ASTM Standard C1499-09 to measure the fracture strength. A correlation is made between the fracture strength and the photoelastic retardation measured at the damage site in each specimen. A least-squares fit is calculated. The results are compared with the predictions from the model. A plausible single-sided NDE damage site inspection method (a version of which is planned for glass inspection in the Orion Project) that relates photoelastic retardation in glass components to its fracture strength is presented.

Yost, William T.↗

DOE OSTI2020

The Transition From Rebound to Bonding in High-Velocity Metallic Microparticle Impacts: Jetting-Associated Power-Law Divergence

A metallic microparticle impacting a metallic substrate with sufficiently high velocity will adhere, assisted by the emergence of jetting—the splash-like extrusion of solid matter at the periphery of the impact. In this work, we compare real-time observations of high-velocity single-microparticle impacts to an elastic–plastic model to develop a more thorough understanding of the transition between the regimes of rebound and bonding. We first extract an effective dynamic yield strength for copper from prior experiments impacting alumina spheres onto copper substrates. We then use this dynamic yield strength to analyze impacts of copper particles on copper substrates. We find that up to moderate impact velocities, impacts and rebound velocities follow a power-law behavior well-predicted on the basis of elastic-perfectly plastic analysis and can be captured well with a single value for the dynamic strength that subsumes many details not explicitly modeled (rate and hardening effects and adiabatic heating). However, the rebound behavior diverges from the power-law at higher impact velocities approaching bonding, where jetting sets on. This divergence is associated with additional lost kinetic energy, which goes into the ejection of the material associated with jetting and into breaking incipient bonds between the particle and substrate. These results further support and develop the idea that jetting facilitates bonding where a critical amount of bond formation is required to effect permanent particle deposition and prevent the particle from rebounding.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Effect of impact damage and open holes on the compression strength of tough resin/high strain fiber laminates

Structural damage and design-based inclusions such as cutouts can reduce significantly the strength of graphite-epoxy laminates. One composite mechanics research activity at the Langley Research Center is to assess and improve the performance of composite structures in strength are common to both tension and compression loaded laminates; however, the problem associated with compression performance is the most illusive to solve. Compression failure involves both shear crippling and delamination modes. Several graphite-epoxy material systems proposed for improved damage-tolerance were studied. Material parameters included both tough resin formulations and high strain fibers.

Williams, J. G.↗

DOE OSTI2017

Shock-Driven Hydrodynamic Instability Growth Near Phase Boundaries and Material Property Transitions: Final Report

Activities for this grant included: 1) Development of dynamic impact experiments to probe strength and phase transition influence on dynamic deformation, 2) development of modern strength and phase aware simulation capabilities, 3) and post-processing of experimental data with simulation and closed form analytical techniques. Two different dynamic experiments were developed to probe material strengths in solid metals (largely copper and iron in this effort). In the first experiment a flyer plate impacts a flat target with an opposite rippled surface that is partially supported by a weaker window material. Post mortem analysis of the target sample showed a strong and repeatable residual plastic deformation dependence on grain orientation. Yield strengths for strain rates near 10 5 s -1 and plastic strains near ~50% were estimated to be around 180 to 240 MPa, varying in this range with grain orientation. Unfortunately dynamic real-time measurements were difficult with this setup due to diagnostic laser scattering; hence, an additional experimental setup was developed to complement these results. In the second set of experiments a rippled surface was ablated by a controlled laser pulsed, which launched a rippled shock front to an opposite initially flat diagnostic surface that was monitored in real-time with spatially resolved velocimetry techniques, e.g., line VISAR in addition to Transient Imaging Displacement Interferometry (TIDI) displacement measurements. This setup limited the displacements at the diagnostic surface to a reasonable level for TIDI measurements (~ less than one micrometer). These experiments coupled with analytical and numerical solutions provided evidence that viscous and elastic deviatoric strength affect shock front perturbation evolution in clearly different ways. Particularly, normalized shock front perturbation amplitudes evolve with viscosity (η) and perturbation wavelength (λ) as η/λ, such that increasing viscosity (or decreasing the initial wavelength) delays the perturbation decay. Conversely our experimental data, analysis and simulations show that for materials with elastic yield strength Y the normalized shock perturbation amplitude evolves with Yλ/A 0 , which shows wavelength increases have the opposite effect as in viscous materials and perturbation decay is also dependent on initial amplitude A 0 (viscous materials are independent of this parameter). Materials where strength had clear strain rate dependence, e.g., such as a PTW material law, behaved similarly to materials with only an effective yield stress (elastic-perfectly plastic) in the shock front perturbation studies obeying a Y eff λA 0 relationship where Y eff was a constant (near ~400 MPa for Cu for strain rates around 10 6 s -1 ). Magnitude changes in strain rate would increase Y eff as would be expected from the PTW behavior, but small perturbations (typical of regions behind the shock front) near a mean had little effect. Additional work based on simulations showed that phase transformation kinetics can affect the behavior of the perturbed shock front as well as the evolution of the RM-like instability that develops due to the imprint of the perturbed shock front on the initially flat surface as the shock breaks out.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Characterization of Laser-Welded Ti Alloy and Stainless Steel Joint Using Cu Interlayer

In this study, Cu was used as an interlayer to restrain the formation of brittle Ti-Fe intermetallics when joining Ti alloy to SS. Microstructures of the joint were analyzed using optical microscopy, scanning electron microscopy and x-ray diffraction. Besides, the tensile strength of the joint was also measured. The melting amount of base materials was controlled by changing thickness of Cu interlayer to control the melting proportion in weld. The melting amount of base materials in weld decreased with the thickness of Cu interlayer. The content of Cu solid solution in weld increased with the thickness of Cu interlayer. Ti-Cu compound layer was formed on the Ti alloy side. The width of the Ti-Cu compound layer increased with the increase in heat input. The tensile strength of joint was largely impacted by Ti-Cu compound layer. The tensile strength of joint first increased and then decreased with the increase in width of the Ti-Cu compound layer.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Strength and ductility of additively manufactured 316L stainless steel: Impact of neutron irradiation and data variability

Here, this article presents the mechanical properties of additively manufactured (AM) 316L stainless steel processed via the laser powder bed fusion (LPBF) method, focusing on the effects of neutron irradiation on mechanical properties and the variability in strength and ductility data. The rapid melting-solidification process and multiple heating-cooling cycles inherent in LPBF typically result in a fine, metastable microstructure with significant local variability. AM 316L builds of varying thicknesses were fabricated, and SS-J3 miniature tensile specimens were machined from six different locations. These specimens were irradiated with fast neutrons to doses of 2 and 10 dpa at target temperatures of 300 °C and 600 °C. Post-irradiation tensile tests were conducted at room temperature, 300 °C, and 600 °C. Compared to conventional 316L stainless steel, AM 316L exhibited higher initial strength but lower ductility. Irradiation at 300 °C caused significant hardening and prompt necking at yield, with limited uniform ductility, although embrittlement was not observed up to 10 dpa. While neutron irradiation, particularly at 600 °C, increased the variability in strength and ductility data, no clear dependence of mechanical properties on build thickness or sampling location was found—contrary to the conventional perception that AM materials may exhibit high property variability. Furthermore, we observed that the variability in property data for LPBF-processed 316L was relatively low compared to that of wrought 316L stainless steel. This reduced variability in AM 316L steel may be attributed to its highly metastable, stress-containing microstructure, which is discussed in the context of general tensile property variations.

Additively manufactured 316L stainless steel↗