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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Evaluation of thermal and mechanical loading effects on the structural behavior of a SIC/titanium composite

Composite specimens of titanium-15-3 matrix reinforced with continuous SCS-6 silicon carbide fibers were tested under a variety of thermal and mechanical loadings. A combined experimental/finite element approach was used to estimate the effective in situ modulus of the matrix material and to evaluate changes in modulus due to the applied loads. Several fiber orientations were tested. Results indicate that the effect of thermal loads on composite stiffness varies with fiber orientation. Applications of this method to test specimens damaged by uniaxial tension, thermal cycling, and isothermal fatigue loadings are used to illustrate that by monitoring overall structural behavior, changes in stiffness caused by thermomechanical loading can be detected.

Grady, J. E.↗
NASA NTRS1990

Evaluation of thermal and mechanical loading effects on the structural behavior of a SiC/titanium composite

Composite specimens of titanium-15-3 matrix reinforced with continuous SCS-6 silicon carbide fibers were tested under a variety of thermal and mechanical loadings. A combined experimental/finite element approach was used to estimate the effective in-situ modulus of the matrix material and to evaluate changes in modulus due to the applied loads. Several fiber orientations were tested. Results indicate that the effect of the thermal loads on composite stiffness varies with fiber orientation. Applications of this method to test specimens damaged by uniaxial tension, thermal cycling, and isothermal fatigue loadings are used to illustrate that by monitoring overall structural behavior, changes in stiffness caused by thermomechanical loading can be detected.

Grady, Joseph E.↗
NASA NTRS2009

Thermal-Structural Analysis of PICA Tiles for Solar Tower Test

Thermal protection materials used in spacecraft heatshields are subjected to severe thermal and mechanical loading environments during re-entry into earth atmosphere. In order to investigate the reliability of PICA tiles in the presence of high thermal gradients as well as mechanical loads, the authors designed and conducted solar-tower tests. This paper presents the design and analysis work for this tests series. Coupled non-linear thermal-mechanical finite element analyses was conducted to estimate in-depth temperature distribution and stress contours for various cases. The first set of analyses performed on isolated PICA tile showed that stresses generated during the tests were below the PICA allowable limit and should not lead to any catastrophic failure during the test. The tests results were consistent with analytical predictions. The temperature distribution and magnitude of the measured strains were also consistent with predicted values. The second test series is designed to test the arrayed PICA tiles with various gap-filler materials. A nonlinear contact method is used to model the complex geometry with various tiles. The analyses for these coupons predict the stress contours in PICA and inside gap fillers. Suitable mechanical loads for this architecture will be predicted, which can be applied during the test to exceed the allowable limits and demonstrate failure modes. Thermocouple and strain-gauge data obtained from the solar tower tests will be used for subsequent analyses and validation of FEM models.

Agrawal, Parul↗
NASA NTRS2015

Nonlinear Analysis and Preliminary Testing Results of a Hybrid Wing Body Center Section Test Article

A large test article was recently designed, analyzed, fabricated, and successfully tested up to the representative design ultimate loads to demonstrate that stiffened composite panels with through-the-thickness reinforcement are a viable option for the next generation large transport category aircraft, including non-conventional configurations such as the hybrid wing body. This paper focuses on finite element analysis and test data correlation of the hybrid wing body center section test article under mechanical, pressure and combined load conditions. Good agreement between predictive nonlinear finite element analysis and test data is found. Results indicate that a geometrically nonlinear analysis is needed to accurately capture the behavior of the non-circular pressurized and highly-stressed structure when the design approach permits local buckling.

Przekop, Adam↗
NASA NTRSDate not supplied

Modal Correlation of Complex Aerospace Joints Using Automated Variable Substitution

A critical task involved with being able to predict flight loads accurately in aerospace finite element models (FEMs) is the prior verification of the FEMs by conducting modal survey testing (MST). Experience comparing dynamic response of initial FEMs to MST data tends to demonstrate that FEMs can have unacceptable accuracy even when best modeling practices are followed. One inherent source of inaccuracy in linear dynamic FEMs is the modeling of nonlinear joints with mechanisms such as spherical bearings. These joints are usually designed to freely translate or rotate under the high levels of loading experienced in flight. Engineers who create linear FEMs conventionally model these joints without any stiffness in the mechanism degrees of freedom to meet this design intent. However, inaccuracy is observed during test validation of these FEMs, which usually relies on low-level force excitation orders of magnitude below flight load levels. This low-level modal test rarely overcomes the joint friction that is present, and thus the mechanism joints are able to react loads. This divide between the test results and the FEM creates a significant challenge to the engineer who is performing the correlation, in that the engineer has no basis for what stiffness value should be used to make the FEM match the test results. A compounding challenge is that complicated built-up aerospace structures commonly have multiple joints through a load path where each joint will “stick” and “slip” at different levels of force input. Explicitly matching the dynamics of a system containing these nonlinear mechanisms would require a nonlinear FEM, which is prohibitively costly for dynamic simulations of most aerospace systems. The objective of this paper is to present a workflow that can efficiently cycle through many iterations of a FEM, allowing a Monte Carlo style examination of the design space to identify candidate stiffness values for nonlinear mechanism joints. The outlined approach is specific to MSC Nastran and utilizes MSC Nastran’s symbolic substitution capabilities, coupled with the IMAT™ and Attune™ software packages developed by ATA Engineering, Inc. (ATA). The workflow is demonstrated with a case study from the correlation effort for The Boeing Company’s Crew Space Transportation (CST)-100 Starliner FEM. Keywords: Correlation, MSC Nastran, IMAT™, Attune™, Finite Element Model, Modal Testing

Correlation↗
NASA NTRS2017

Environmental Barrier Coating Fracture, Fatigue and High-Heat-Flux Durability Modeling and Stochastic Progressive Damage Simulation

Advanced environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect emerging light-weight SiC/SiC ceramic matrix composite (CMC) engine components, further raising engine operating temperatures and performance. Because the environmental barrier coating systems are critical to the performance, reliability and durability of these hot-section ceramic engine components, a prime-reliant coating system along with established life design methodology are required for the hot-section ceramic component insertion into engine service. In this paper, we have first summarized some observations of high temperature, high-heat-flux environmental degradation and failure mechanisms of environmental barrier coating systems in laboratory simulated engine environment tests. In particular, the coating surface cracking morphologies and associated subsequent delamination mechanisms under the engine level high-heat-flux, combustion steam, and mechanical creep and fatigue loading conditions will be discussed. The EBC compostion and archtechture improvements based on advanced high heat flux environmental testing, and the modeling advances based on the integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program will also be highlighted. The stochastic progressive damage simulation successfully predicts mud flat damage pattern in EBCs on coated 3-D specimens, and a 2-D model of through-the-thickness cross-section. A 2-parameter Weibull distribution was assumed in characterizing the coating layer stochastic strength response and the formation of damage was therefore modeled. The damage initiation and coalescence into progressively smaller mudflat crack cells was demonstrated. A coating life prediction framework may be realized by examining the surface crack initiation and delamination propagation in conjunction with environmental degradation under high-heat-flux and environment load test conditions.

Mechanical creep and fatigue loading condition↗
NASA NTRS2006

Net Shaped Component Fabrication of Refractory Metal Alloys using Vacuum Plasma Spraying

The vacuum plasma spraying (VPS) technique was employed to produce dense and net shaped components of a new tungsten-rhenium (W-Re) refractory metal alloy. The fine grain size obtained using this technique enhanced the mechanical properties of the alloy at elevated temperatures. The alloy development also included incorporation of thermodynamically stable dispersion phases to pin down grain boundaries at elevated temperatures and thereby circumventing the inherent problem of recrystallization of refractory alloys at elevated temperatures. Requirements for such alloys as related to high temperature space propulsion components will be discussed. Grain size distribution as a function of cooling rate and dispersion phase loading will be presented. Mechanical testing and grain growth results as a function of temperature will also be discussed.

Sen, S.↗
NASA NTRS2016

Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiCSiC Ceramic Matrix Composite (CMC) components for next generation turbine engines. The emphasis has been placed on the current design challenges of the 2700F environmental barrier coatings; coating processing and integration with SiCSiC CMCs and component systems; and performance evaluation and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements through advanced compositions and architecture designs, as shown in recent simulated engine high heat flux, combustion environment, in conjunction with mechanical creep and fatigue loading testing conditions.

Simulated Engine Test↗
NASA NTRS2017

Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiC-SiC Ceramic Matrix Composite (CMC) combustors particularly under the NASA Environmentally Responsible Aviation, Fundamental Aeronautics and Transformative Aeronautics Concepts Programs. The emphases have been placed on the current design challenges of the 2700-3000F capable environmental barrier coatings for low NOX emission combustors for next generation turbine engines by using advanced plasma spray based processes, and the coating processing and integration with SiC-SiC CMCs and component systems. The developments also have included candidate coating composition system designs, degradation mechanisms, performance evaluation and down-selects; the processing optimizations using TriplexPro Air Plasma Spray Low Pressure Plasma Spray (LPPS), Plasma Spray Physical Vapor Deposition and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements under the NASA development programs, as demonstrated in the simulated engine high heat flux, combustion environments, in conjunction with high heat flux, mechanical creep and fatigue loading testing conditions.

CMAS↗
NASA NTRS1987

DACS II - A distributed thermal/mechanical loads data acquisition and control system

A distributed data acquisition and control system has been developed for the NASA Flight Loads Research Facility. The DACS II system is composed of seven computer systems and four array processors configured as a main computer system, three satellite computer systems, and 13 analog input/output systems interconnected through three independent data networks. Up to three independent heating and loading tests can be run concurrently on different test articles or the entire system can be used on a single large test such as a full scale hypersonic aircraft. Thermal tests can include up to 512 independent adaptive closed loop control channels. The control system can apply up to 20 MW of heating to a test specimen while simultaneously applying independent mechanical loads. Each thermal control loop is capable of heating a structure at rates of up to 150 F per second over a temperature range of -300 to +2500 F. Up to 64 independent mechanical load profiles can be commanded along with thermal control. Up to 1280 analog inputs monitor temperature, load, displacement and strain on the test specimens with real time data displayed on up to 15 terminals as color plots and tabular data displays. System setup and operation is accomplished with interactive menu-driver displays with extensive facilities to assist the users in all phases of system operation.

Zamanzadeh, Behzad↗
NASA NTRSDate not supplied

Experimental Setup for Mechanically Testing Subscale Triangular, Rollable, and Collapsible Deployable Composite Booms

High-strain composite deployable space structures are used for space infrastructure and science applications such as solar array supports, antennae, camera masts, and lightweight structures supporting solar sailing propulsion elements. Triangular, Rollable, and Collapsible (TRAC) deployable composite booms are one example of a high-strain composite deployable structure and were studied using novel experimental test and characterization methods developed under the Gravity Offloading and Analysis of Long Imperfection-sensitive Elements (GOALIE) project. In the present work, a subscale 7-m-long TRAC boom was suspended vertically to orient gravity along the length of the boom. By orienting vertically, highly nonlinear and unstable behavior often encountered during horizontally oriented gravity offload testing of similar structures was reduced. Pretest analytical predictions of TRAC booms indicated three unique failure modes, loads, and locations for three unique loading cases of in-plane bending, out-of-plane bending, and axial compression. To investigate the predicted behavior, an experimental test was set up to impart mechanical loads to a subscale TRAC boom. The experimental setup, loading cases, and instrumentation used to characterize the mechanical response of a subscale TRAC boom are described in this paper.

Experimental testing↗
NASA NTRS2011

BOK-Underfill Optimization for FPGA Package/Assembly

Commercial-off-the-shelf area array package technologies in high-reliability versions are being considered for NASA electronic systems. These packages are prone to early failure due to the severe mechanical shock and vibration of launch, as well as other less severe conditions, such as mechanical loading during descent, rough terrain mobility, handling, and ground tests. As the density of these packages increases and the size of ball interconnections decrease, susceptibility to mechanical loading and cycling fatigue grows. This report presents a summary of the body of knowledge developed for the evaluation of area array packages and is based on surveys of literature from industry and academia. For high-reliability applications, the limited data that exists will be presented. Most data from industry deals with mechanical fatigue caused by four-point bend tests, as well as from drop tests for hand-held electronics; the most recent data will be presented, along with a brief background of prior literature. Understanding the key design guidelines and failure mechanisms from past tests is critical to developing an approach that will minimize future failures. Additional specific testing enables low-risk insertion of these advanced electronic packages.

mechanical fatigue↗
NASA NTRS2014

Evaluating Daily Load Stimulus Formulas in Relating Bone Response to Exercise

Six formulas representing what is commonly referred to as "daily load stimulus" are identified, compared and tested in their ability to relate skeletal mechanical loading to bone maintenance and osteogenic response. Particular emphasis is placed on exercise- induced skeletal loading and whether or not the formulas can adequately capture the known experimental observations of saturation of continuous cyclic loading, rest insertion between repetitions (cycles), recovery of osteogenic potential following saturation, and multiple shorter bouts versus a single long bout of exercise. To evaluate the ability of the formulas to capture these characteristics, a set of exercise scenarios with type of exercise bout, specific duration, number of repetitions, and rest insertion between repetitions is defined. The daily load values obtained from the formulas for the loading conditions of the set of scenarios is illustrated. Not all of the formulas form estimates of daily load in units of stress or in terms of strain at a skeletal site due to the loading force from a specific exercise prescription. The comparative results show that none of the formulas are able to capture all of the experimentally observed characteristics of cyclic loading. However, the enhanced formula presented by Genc et al. does capture several characteristics of cyclic loading that the others do not, namely recovery of osteogenic potential and saturation. This could be a basis for further development of mathematical formulas that more adequately approximates the amount of daily stress at a skeletal site that contributes to bone adaptation.

Pennline, James A.↗
NASA NTRSDate not supplied

Experimental Setup for Mechanically Testing Subscale Triangular, Rollable, and Collapsible Deployable Composite Booms

High-strain composite deployable space structures are used for space infrastructure and science applications such as solar array supports, antennae, camera masts, and lightweight structures supporting solar sailing propulsion ele-ments. Triangular, Rollable, and Collapsible (TRAC) deployable composite booms are one example of a high-strain composite deployable structure and were studied using novel experimental test and characterization methods developed under the Gravity Offloading and Analysis of Long Imperfection-sensitive Ele-ments (GOALIE) project. In the present work, a subscale 7-m-long TRAC boom was suspended vertically to orient gravity along the length of the boom. By ori-enting vertically, highly nonlinear and unstable behavior often encountered dur-ing horizontally oriented gravity offload testing of similar structures was reduced. Pretest analytical predictions of TRAC booms indicated three unique failure modes, loads, and locations for three unique loading cases of in-plane bending, out-of-plane bending, and axial compression. To investigate the predicted behav-ior, an experimental test was set up to impart mechanical loads to a subscale TRAC boom. The experimental setup, loading cases, and instrumentation used to characterize the mechanical response of a subscale TRAC boom are described in this paper.

High-strain composites↗
NASA NTRS1992

Thermal-structural test facilities at NASA Dryden

The National Aero-Space Plane (NASP) has renewed interest in hypersonic flight and hot-structures technology development for both the airframe and engine. The NASA Dryden Thermostructures Research Facility is a unique national facility that was designed to conduct thermal-mechanical tests on aircraft and aircraft components by simulating the flight thermal environment in the laboratory. The layout of the facility is presented, which includes descriptions of the high-bay test area, the instrumentation laboratories, the mechanical loading systems, and the state-of-the-art closed-loop thermal control system. The hot-structures test capability of the facility is emphasized by the Mach-3 thermal simulation conducted on the YF-12 airplane. The Liquid-Hydrogen Structural Test Facility, which is presently in the design phase, will provide the capability of thermally testing structures containing hydrogen.

Deangelis, V. Michael↗
NASA NTRS1991

Contact dynamics testing of automated three-point docking mechanism

An evaluation of an OMV docking mechanism, based on an adaptation of the Shuttle Flight Support System Pallet Berthing Mechanism was completed. The mechanism uses automatically actuated motorized latches to engage towel bars on the target satellite. LED sensors establish the towel bar position within the capture envelope and the latch capture commands are issued. Then, locking pawls engage the bar, locking and pre-loading the mechanism. Two series of tests were conducted to test nominal and failure mode captures and to evaluate design parameters such as LED sensor locations, automatic closure algorithms, latch closure velocity, position/velocity entry envelopes, and closure method. The first test series involved single latch testing on the Flat Floor Facility, the 6 DOF Facility, and an analytic simulation model. The intent was to compare results in order to validate the various facilities. Reasonably good agreement was achieved. The second test series repeated the single latch testing on the refurbished 6 DOF Facility to validate the facility modifications. The individual latches were tested under free-drift conditions for functionality and performance. Next, the three-latch configuration underwent parametric testing. Test results validated the improved fidelity of the 6 DOF Facility and verified successful docking at the required entry velocity. The tests determined the 'best' design parameter definitions and concluded that the locking pawls should not lock until all three latches completely close.

Rourke, Kenneth H.↗
NASA NTRS2001

Durability Characterization of Advanced Polymeric Composites at Cryogenic Temperatures

The next generation of reusable launch vehicles will require technology development in several key areas. Of these key areas, the development of polymeric composite cryogenic fuel tanks promises to present one of the most difficult technical challenges. It is envisioned that a polymer matrix composite (PMC) tank would be a large shell structure capable of containing cryogenic fuels and carrying a range of structural loads. The criteria that will be imposed on such a design include reduced weight, conformal geometry, and impermeability. It is this last criterion, impermeability, that will provide the focus of this paper. The essence of the impermeability criterion is that the tank remains leak free throughout its design lifetime. To address this criterion, one of the first steps is to conduct a complete durability assessment of the PMC materials. At Langley Research Center, a durability assessment of promising new polyimide-based PMCs is underway. This durability program has focused on designing a set of critical laboratory experiments that will determine fundamental material properties under combined thermal-mechanical loading at cryogenic temperatures. The test program provides measurements of lamina and laminate properties, including strength, stiffness, and fracture toughness. The performance of the PMC materials is monitored as a function of exposure conditions and aging time. Residual properties after exposure are measured at cryogenic temperatures and provide quantitative values of residual strength and stiffness. Primary degradation mechanisms and the associated damage modes are measured with both destructive and nondestructive techniques. In addition to mechanical properties, a range of physical properties, such as weight, glass transition, and crack density, are measured and correlated with the test conditions. This paper will report on the progress of this research program and present critical results and illustrative examples of current findings.

Gates, T. S.↗
NASA NTRS2017

Overview of the Acoustic Testing of the European Service Module Structural Test Article (E-STA)

The European Space Agency (ESA) and their prime contractor Airbus Defense Space (ADS) are developing the European Service Module (ESM) for integration and utilization with other modules of NASAs Orion Multi-Purpose Crew Vehicle. As part of this development, ESA, ADS, NASA and the Lockheed Martin Company performed a series of reverberant acoustic tests in April-May 2016 on the ESM Structural Test Article (E-STA), the mechanical mock-up of the ESM designated for mechanical tests. Testing the E-STA under acoustic qualification loads verifies whether it can successfully withstand the medium and high frequency mechanical environment occurring during the vehicles lift-off and atmospheric phases of flight. The testing occurred at the Reverberant Acoustic Test Facility (RATF) at the NASA Glenn Research Centers Plum Brook Station site in Sandusky, OH, USA. This highly successful acoustic test campaign excited the E-STA to acoustic test levels as high as 149.4 dB Overall Sound Pressure Level. This acoustic testing met all the ESA and ADSs test objectives, including establishing/verifying the random vibration qualification test levels for numerous hardware components of the ESM, and qualifying the ESMs Solar Array Wing electrical power system. This paper will address the test objectives, the test articles configuration, the test instrumentation and excitation levels, the RATF site and capabilities, the series of acoustic tests performed, and the technical issues faced and overcome to result in a successful acoustic test campaign for the ESM. A discussion of several test results is also included.

Qualification↗