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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Reliability and Qualification of Hardware to Enhance the Mission Assurance of JPL/NASA Projects

Packaging Qualification and Verification (PQV) and life testing of advanced electronic packaging, mechanical assemblies (motors/actuators), and interconnect technologies (flip-chip), platinum temperature thermometer attachment processes, and various other types of hardware for Mars Exploration Rover (MER)/Mars Science Laboratory (MSL), and JUNO flight projects was performed to enhance the mission assurance. The qualification of hardware under extreme cold to hot temperatures was performed with reference to various project requirements. The flight like packages, assemblies, test coupons, and subassemblies were selected for the study to survive three times the total number of expected temperature cycles resulting from all environmental and operational exposures occurring over the life of the flight hardware including all relevant manufacturing, ground operations, and mission phases. Qualification/life testing was performed by subjecting flight-like qualification hardware to the environmental temperature extremes and assessing any structural failures, mechanical failures or degradation in electrical performance due to either overstress or thermal cycle fatigue. Experimental flight qualification test results will be described in this presentation.

PRTs↗
NASA NTRS1977

Analysis and testing of adhesive bonds

An adhesive fracture mechanics approach is described with reference to the identification and design of the best tests for evaluating a given adhesive, the definition of the most meaningful fundamental parameters by which adhesives might be characterized, and the application of these parameters to the design of joints and to the prediction of their performance. Topics include standard adhesive test techniques, the theory of adhesive fracture, and adhesive fracture energy tests. Analytical methods and computer techniques for adhesive bonding, chemical and physical aspects of adhesive fracture, and specific applications and aspects of adhesive fracture mechanics are discussed.

Anderson, G. P.↗
NASA NTRS2015

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations Under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and face-sheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. Fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a strength reduction of 10 percent due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Tolerance↗
NASA NTRS2015

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and facesheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Damage↗
NASA NTRS2015

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations Under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and face-sheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Tolerance↗
DOE OSTI2025

Role of Forest Carbon Change in Shaping Future Land Use and Land Cover Change

Global change, particularly the changes in atmospheric CO 2 concentration, climatic variables, and nitrogen deposition, has been widely recognized and examined to have worldwide impacts on forest carbon. However, its influence on forest area required to meet the demand for timber and carbon storage and subsequent land use and land cover change (LULCC) is rarely studied. This study explores the role of global change-driven forest carbon change in shaping future global LULCC projections and investigates underlying drivers. We incorporated the global change impacts on forest carbon from the Canadian Land Surface Scheme Including Biogeochemical Cycles model simulations (driven by meteorological forcing projections from two Earth system models [ESMs]) into the Global Change Analysis Model, under three combinations of shared socioeconomic pathways and representative concentration pathways (SSP126, SSP370, and SSP585). Including forest carbon change decreases the projected expansion of managed forest and managed pasture, reduces the loss of unmanaged pastures and forests, and provides more cropland. The relative change in managed forest by 2100 is -4.0%, -21.7%, and -31.9%, under SSP126, SSP370, and SSP585, respectively, when forest carbon change is considered. CO 2 fertilization is the dominant driver, increasing forest vegetation and soil carbon by 37% and 4.1%, and leading to 78.6% of the total area with a change in land use types by 2100 under SSP585. In comparison, climate change reduces forest vegetation and soil carbon by -3.5% and -0.8%, influencing 23.9% of the total area with a change in land use types by 2100 under SSP585, while nitrogen deposition has minor impacts. Using meteorological forcing data from two ESMs leads to similar impacts of forest carbon change on LULCC in terms of sign and trend but different magnitudes. This study highlights the large impact of forest carbon change on shaping future LULCC dynamics and the critical role of CO 2 fertilization.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1980

Design, fabrication and test of graphite/polyimide composite joints and attachments for advanced aerospace vehicles

Principal program activities dealt with the literature survey, design of joint concepts, assessment of GR/PI material quality, fabrication of test panels and specimens, and small specimen testing. Bonded and bolted designs are presented for each of the four major attachment types. Quality control data are presented for prepreg Lots 2W4651 and 3W2020. Preliminary design allowables test results for tension tests and compression tests of laminates are also presented.

Source record↗
DOE OSTI2023

Microstructural, Corrosion and Mechanical Characterization of Friction-Stir Welded Joints Between Aluminum and Magnesium Alloys

Friction Stir Welding (FSW) of Aluminum-Magnesium (Al-Mg) alloys has garnered increasing attention due to its wide-ranging applications in the automotive and aerospace industries. The microstructural, corrosion, and mechanical properties of FSW Al-Mg welds under selected conditions are critical factors that must be well-investigated to ensure their durability and performance. In this study, electrochemical tests, including Open Circuit Potential (OCP), Linear Polarization Resistance (LPR), Potentiodynamic Polarization Scan (PD), and Electrochemical Impedance Spectroscopy (EIS), have been used to analyze the corrosion resistance of these welds, along with weight loss measurements through cyclic corrosion testing (CCT) and surface evolution via SEM over an 8-week period. Mechanical properties are evaluated through microindentation, nanoindentation, fatigue, and lap-shear tests. The results of the electrochemical tests reveal that the corrosion properties of the center weld zone differ from those of the two base alloys. Indentation tests indicate that the weld zone behaves differently from the base alloys. Surprisingly, the lap shear strength did not decrease significantly even after 8 weeks of cyclic corrosion testing, indicating that the joint prevented any ingress of the electrolyte. Fatigue testing showed that applying an adhesive between the Al and Mg joint improved the fatigue life to some extent, although the corrosion resistance reduced due to the discontinuous bonding of the adhesive layer. Overall, these findings highlight the importance of investigating the corrosion and mechanical properties of FSW Al-Mg welds and provide valuable insights for future modeling works.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1985

Durability predictions of adhesively bonded composite structures using accelerated characterization methods

The utilization of adhesive bonding for composite structures is briefly assessed. The need for a method to determine damage initiation and propagation for such joints is outlined. Methods currently in use to analyze both adhesive joints and fiber reinforced plastics is mentioned and it is indicated that all methods require the input of the mechanical properties of the polymeric adhesive and composite matrix material. The mechanical properties of polymers are indicated to be viscoelastic and sensitive to environmental effects. A method to analytically characterize environmentally dependent linear and nonlinear viscoelastic properties is given. It is indicated that the methodology can be used to extrapolate short term data to long term design lifetimes. That is, the method can be used for long term durability predictions. Experimental results for near adhesive resins, polymers used as composite matrices and unidirectional composite laminates is given. The data is fitted well with the analytical durability methodology. Finally, suggestions are outlined for the development of an analytical methodology for the durability predictions of adhesively bonded composite structures.

Brinson, H. F.↗
DOE OSTI2026

Impact of Site Identity, Location, and Accessibility on Polyethylene Conversion Rates and Product Selectivities over Metal-Free MFI Zeolites

Brønsted (BAS), Lewis (LAS), and surface Brønsted (SBAS) acid sites have been investigated for polyethylene (PE) upcycling by zeolite catalysts, but there is no clear consensus regarding their catalytic roles, partly due to the complexity of the catalysts used and varying reaction conditions across studies. This work systematically determined how these sites impact PE conversion rates and product distributions by utilizing a suite of microporous MFI catalysts with varying Si/Al ratios, acid site densities, and inherent mesoporosities. PE conversion rates did not trend with total BAS or LAS densities due to a combination of internal mass transfer limitation and the apparent inability of LAS alone to cleave C–C bonds, but a strong, statistically significant correlation was present with respect to SBAS density and mesopore surface area, jointly, owing to accelerated polymer activation on external surfaces to smaller diffusion-limited chains. However, ingress of these SBAS-derived fragments ultimately remained rate limiting, as demonstrated by solid conversion rates that increased with mesopore surface area at similar SBAS density and likewise increased with SBAS density at similar mesopore surface area. In batch PE cracking reactions, light gaseous product selectivities were most sensitive to total BAS, with higher densities generally exhibiting higher selectivity to C 3 and linear C 4 –C 7 products and higher alkane/alkene product ratios, consistent with increased β-scission turnovers. Insights from this work help systematically clarify the roles of BAS, LAS, SBAS, and mesopores in PE cracking reactions and inform the development of tailored zeolite catalysts for efficient polyolefin upcycling.

accessibility↗
NASA NTRS1972

Investigation of mounting discrete chip components for hybrid microelectronic applications.

In the assembly of hybrid microcircuits, passive and active discrete chip components are attached by epoxy cements and by solders. This study was initiated to determine the integrity of such attachments. Alumina substrates were subjected to a group of thermal and mechanical test environments defined by test methods in MIL-STD-883. Lot samples of substrates with assembly variations were subjected to separately applied testing and to serial testing. These test methods were applied sequentially to the same lot of substrates. Epoxy cements were generally satisfactory with respect to separate tests, although sequential tests severely degraded epoxy bond strengths of all types. Bond strengths to unglazed substrates were slightly superior to those of the same components on glazed types. Solder joints were vulnerable to catastrophic failure in several environments, especially temperature cycling and thermal shock. Vibration and impact shock also produced solder joint failures.

Caruso, S. V.↗
NASA NTRS1981

A Module Experimental Process System Development Unit (MEPSDU)

Subsequent to the design review, a series of tests was conducted on simulated modules to demonstrate that all environmental specifications (wind loading, hailstone impact, thermal cycling, and humidity cycling) are satisfied by the design. All tests, except hailstone impact, were successfully completed. The assembly sequence was simplified by virtue of eliminating the frame components and assembly steps. Performance was improved by reducing the module edge border required to accommodate the frame of the preliminary design module. An ultrasonic rolling spot bonding technique was selected for use in the machine to perform the aluminum interconnect to cell metallization electrical joints required in the MEPSDU module configuration. This selection was based on extensive experimental tests and economic analyses.

Source record↗
DOE OSTI2024

Dissimilar material joining of densified superwood to aluminum by adhesive bonding

Abstract Superwood is a densified wood product that shows promise as a lightweight and renewable alternative for metallic materials. In order for this high-performance new material to be used in multi-material products, it must be able to be joined with other major materials. For example, joining superwood to aluminum would provide a key enabling technology for its use in automotive components since aluminum is presently a major lightweight material for such applications. In this paper, a methacrylate-based adhesive has been identified to provide high lap shear strength (7.5 MPa) for aluminum-to-superwood joints. The aluminum-to-superwood samples were prepared with different amounts of pre-polishing to create openings to the pores in the superwood so adhesive could penetrate into them and create a mechanical interlock, in addition to the hydrogen/chemical bonding at the surface between the methyl methacrylate (MMA) in methacrylate-based adhesive and the cellulose in superwood. For aluminum samples, a thin layer (typically a few nanometers) of oxide film on the surfaces provides hydrogen/chemical bond to MMA structure in the adhesive layer. The failure strength of the superwood-to-aluminum joint sample is about 50% higher than that of natural wood to natural wood joint sample and comparable to that of aluminum-to-aluminum joint sample.

Automation & Control Systems↗
DOE OSTI2025

Machine learning inversion from small-angle scattering for charged polymers

We develop Monte Carlo simulations for uniformly charged polymers and a machine learning algorithm to interpret the intra-polymer structure factor of the charged polymer system, which can be obtained from small-angle scattering experiments. The polymer is modeled as a chain of fixed-length bonds, where the connected bonds are subject to bending energy, and there is also a screened Coulomb potential for charge interaction between all joints. The bending energy is determined by the intrinsic bending stiffness, and the charge interaction depends on the interaction strength and screening length. All three contribute to the stiffness of the polymer chain and lead to longer and larger polymer conformations. The screening length also introduces a second length scale for the polymer besides the bending persistence length. To obtain the inverse mapping from the structure factor to these polymer conformation and energy-related parameters, we generate a large data set of structure factors by running simulations for a wide range of polymer energy parameters. We use principal component analysis to investigate the intra-polymer structure factors and determine the feasibility of the inversion using the nearest neighbor distance. We employ Gaussian process regression to achieve the inverse mapping and extract the characteristic parameters of polymers from the structure factor with low relative error.

36 MATERIALS SCIENCE↗
NASA NTRS1968

Method for reinforcing tubing joints

Joint repair technique uses a longitudinally split aluminum shield over the joint ferrule and immediately adjacent tubing to reseal or reinforce leaking or weak joints in small tubing. Epoxy resin coating on inside surfaces of the two shield halves provides a tightly sealed bond between shield and tubing.

Kinzler, J.↗
NASA NTRS1975

Retort braze bonding of borsic/aluminum composite sheet to titanium

Braze bonding studies between Borsic/aluminum composite and titanium sheet were conducted to establish acceptable brazing techniques and to assess potential joint efficiencies. Excellent braze joints were produced which exhibited joint strengths exceeding 117 MPa (17,000 psi) and which retained up to 2/3 of this strength at 589 K (600 F). Noticeable composite strength degradation resulting from the required high temperature braze cycle was found to be a problem.

Webb, B. A.↗
NASA NTRS1987

Experimental evaluation of small-scale erectable truss hardware

To aid in the prediction of the dynamic behavior of the space station, a one-tenth scale dynamic test model is to be constructed of commercially available, small scale truss hardware. Tests have been performed to determine the axial stiffness characteristics and failure loads of the truss joint. A parametric study has shown that the stiffness of the joint increases as the attachment bolt torque value is increased. Furthermore, at torque values equal to or higher than 250 in-lbs, hysteresis in the load-deflection curve is essentially eliminated. Also, the joint stiffness remained relatively constant between specimens. The effective stiffness of a joint subassembly tested is 76 percent that of the strut. Tensile and compressive failure occurred in the region of the bonded plug, with lower failure loads corresponding to compressive loadings.

Mcgowan, David M.↗
NASA NTRS2001

Microstructure, Mechanical Properties, Hot-Die Forming, and Joining of 47XD Gamma TiAl Rolled Sheets

The microstructure and mechanical properties, along with the hot-die forming and joining of Ti-47Al-2Nb-2Mn-0.8 vol% TiB, sheets (known as 47XD), produced by a low-cost rolling process, were evaluated. A near-gamma microstructure was obtained in the as-rolled condition. The microstructures of heat-treated sheets ranged from a recrystallized equiaxed near-gamma microstructure at 1,200 to 1,310 C, to a duplex microstructure at 1,350 C, to a fully lamellar microstructure at 1,376 C. Tensile behavior was determined for unidirectionally rolled and cross-rolled sheets for room temperature (RT) to 816 C. Yield stress decreased gradually with increasing deformation temperature up to 704 C; above 704 C, it declined rapidly. Ultimate tensile strength exhibited a gradual decrease up to 537 C before peaking at 704 C, followed by a rapid decline at 816 C. The modulus showed a gradual decrease with temperature, reaching approximately 72% of the RT value at 816 C. Strain to failure increased slowly from RT to 537 C; between 537 C and 704 C it exhibited a phenomenal increase, suggesting that the ductile-brittle transition temperature was below 704 C. Fracture mode changed from transgranular fracture at low temperature, to a mixture of transgranular and intergranular fracture at intermediate temperature, to ductile fracture at 816 C, coupled with dynamic recrystallization at large strains. Creep rupture response was evaluated between 649 and 816 C over the stress range of 69 to 276 MPa. Deformation parameters for steady-state creep rate and time-to-rupture were similar: activation energies of approximately 350 kJ/mol and stress exponents of approximately 4.5. Hot-die forming of sheets into corrugations was done at elevated temperatures in vacuum. The process parameters to join sheets by diffusion bonding and brazing with TiCuNi 70 filler alloy were optimized for test coupons and successfully used to fabricate large truss-core and honeycomb structures. Nondestructive evaluation methods, e.g., ultrasonic C-scans and thermography along with metallography, were used to characterize bond quality. Microstructural evaluation during heat treatment, identification of phases at the braze/matrix interface, determination of shear strengths of brazed joints, and deformation mechanisms during tensile and creep processes will be discussed.

Das, G.↗