Results for “mechanical testing capability” — Page 3

NASA NTRS2017

A Novel UAV Electric Propulsion Testbed for Diagnostics and Prognostics

This paper presents a novel hardware-in-the-loop (HIL) testbed for systems level diagnostics and prognostics of an electric propulsion system used in UAVs (unmanned aerial vehicle). Referencing the all electric, Edge 540T aircraft used in science and research by NASA Langley Flight Research Center, the HIL testbed includes an identical propulsion system, consisting of motors, speed controllers and batteries. Isolated under a controlled laboratory environment, the propulsion system has been instrumented for advanced diagnostics and prognostics. To produce flight like loading on the system a slave motor is coupled to the motor under test (MUT) and provides variable mechanical resistance, and the capability of introducing nondestructive mechanical wear-like frictional loads on the system. This testbed enables the verification of mathematical models of each component of the propulsion system, the repeatable generation of flight-like loads on the system for fault analysis, test-to-failure scenarios, and the development of advanced system level diagnostics and prognostics methods. The capabilities of the testbed are extended through the integration of a LabVIEW-based client for the Live Virtual Constructive Distributed Environment (LVCDC) Gateway which enables both the publishing of generated data for remotely located observers and prognosers and the synchronization the testbed propulsion system with vehicles in the air. The developed HIL testbed gives researchers easy access to a scientifically relevant portion of the aircraft without the overhead and dangers encountered during actual flight.

Gorospe, George E., Jr.↗

NASA NTRS1973

Small, high-pressure ratio compressor mechanical acceptance test, volume 2

The fabrication and mechanical testing of the high-pressure-ratio compressor are reported. Mechanical testing was performed to demonstrate overspeed capability, adequate rotor dynamics, electrical isolation of the gas bearing trunnion mounted diffuser and shroud and the effect of operating parameters (speed and pressure ratio) on clearance of the compressor test rig. The speed range covered was 20 to 120 percent of rated speed (80,000 rpm). Following these tests an acceptance test which consisted of a 5 hour run at 80,000 rpm was made with approximately design impeller to shroud clearances. For Vol. 1, see N73-26483.

Metty, G. R.↗

NASA NTRS1999

Context-Specific Adaptation of Gravity-Dependent Vestibular Reflex Responses (NSBRI Neurovestibular Project 1)

Impairment of gaze and head stabilization reflexes can lead to disorientation and reduced performance in sensorimotor tasks such as piloting of spacecraft. Transitions between different gravitoinertial force (gif) environments - as during different phases of space flight - provide an extreme test of the adaptive capabilities of these mechanisms. We wish to determine to what extent the sensorimotor skills acquired in one gravity environment will transfer to others, and to what extent gravity serves as a context cue for inhibiting such transfer. We use the general approach of adapting a response (saccades, vestibuloocular reflex: VOR, or vestibulocollic reflex: VCR) to a particular change in gain or phase in one gif condition, adapting to a different gain or phase in a second gif condition, and then seeing if gif itself - the context cue - can recall the previously-learned adapted responses. Previous evidence indicates that unless there is specific training to induce context-specificity, reflex adaptation is sequential rather than simultaneous. Various experiments in this project investigate the behavioral properties, neurophysiological basis, and anatomical substrate of context-specific learning, using otolith (gravity) signals as a context cue. In the following, we outline the methods for all experiments in this project, and provide details and results on selected experiments.

Shelhamer, Mark↗

NASA NTRS2011

Payload and Components Real-Time Automated Test System (PACRATS), Data Acquisition of Leak Rate and Pressure Data Test Procedure

The purpose of this activity is to provide the Mechanical Components Test Facility (MCTF) with the capability to obtain electronic leak test and proof pressure data, Payload and Components Real-time Automated Test System (PACRATS) data acquisition software will be utilized to display real-time data. It will record leak rates and pressure/vacuum level(s) simultaneously. This added functionality will provide electronic leak test and pressure data at specified sampling frequencies. Electronically stored data will provide ES61 with increased data security, analysis, and accuracy. The tasks performed in this procedure are to verify PACRATS only, and are not intended to provide verifications for MCTF equipment.

Rinehart, Maegan L.↗

NASA NTRS1966

The first experimental flight package of an advanced telemetry system with adaptive capability Technical summary report, 1 Jul. 1963 - 15 Feb. 1965

Mechanical design, and environmental and functional testing of advanced telemetry system flight package with adaptive capability

ENVIRONMENTAL TESTING↗

NASA NTRS2008

Overview of the Orion Vibroacoustic Test Capability at NASA Glenn Research Center

In order to support the environmental test needs for our new Orion and Constellation program, NASA is developing unique world-class test facilities. To optimize this testing of spaceflight hardware while minimizing transportation issues, a one-stop, under one roof test capability is being developed at the Space Power Facility at the NASA Glenn Research Center's Plum Brook Station. This facility will provide the capability to perform the following environmental testing: (1) reverberation acoustic testing, (2) mechanical base-shake sine testing, (3) modal testing, (4) thermal-vacuum testing, and (5) EMI/EMC (electromagnetic interference and compatibility) testing. An overview of this test capability will be provided in this presentation, with special focus on the two new vibroacoustic test facilities currently being designed and built, the Reverberant Acoustic Test Facility (RATF) and the Mechanical Vibration Facility (MVF). Testing of the engineering developmental hardware and qualification hardware of the Orion (Crew Exploration Vehicle) will commence shortly after the facilities are commissioned.

Hughes, William O.↗

DOE OSTI2024

Predicted Fracture Tendency of Naturally Occurring Aluminum Surface Coatings under Tensile Loading

Naturally occurring coatings on aluminum metal, such as its oxide or hydroxide, serve to protect the material from corrosion. Understanding the conditions under which these coatings mechanically fail is therefore expected to be an important aspect of predictive models for aluminum component lifetimes. To this end, we develop and apply a molecular dynamics (MD) modeling framework for conducting tension tests that is capable of isolating factors governing the mechanical strength as a function of coating chemistry, defect morphology, and variables associated with the loading path. We consider two representative materials, including γ-Al 2 O 3 and γ-Al(OH) 3 (i.e., oxide and hydroxide), both of which form readily as aluminum surface coatings. Our results indicate that defects have a significant bearing on the strength of aluminum oxide, with grain boundaries serving to reduce the strain at failure from ε zz = 0.300 to 0.219, relative to perfect single crystal. Our simulations also predict that porosity lowers the elastic stiffness and yield strength of the oxide. Relative to perfect crystal, we find porosity factors of 5%, 10% and 20% decrease the yield stress by 26%, 36% and 53%, respectively. MD predicts that perfect hydroxide and oxide single crystal have respective strains at failure of 0.08 and 0.31 under tensile uniaxial strain loading, and that the corresponding yield stresses are respectively 1.6 and 11.1 GPa. These data indicate that the hydroxide is substantially more susceptible to mechanical failure than the oxide. Our results, coupled with literature findings that indicate hot and humid conditions favor formation of hydroxide and defective oxide coatings, indicate the potential for a complicated dependence of aluminum corrosion susceptibility and stress corrosion cracking on aging history.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Enhancing Post-Irradiation Examination (PIE) Efficiency with High-Throughput Experiments

Nuclear materials testing is essential for understanding changes in reactor environments, but traditional methods are costly and time-consuming. High-Throughput Experimentation (HTE) enables rapid screening and optimization of material properties by significantly increasing the number of specimens in the experiment. In this work, HTE methods were employed to irradiate novel materials at the Advanced Test Reactor (ATR) at Idaho National Laboratory. A total of 367 sub-sized tensile specimens were irradiated using the standard capsule design. To facilitate HTE, automated systems such as the Automated Mechanical Testing System were implemented for mechanical testing within hot cell environments, thereby reducing the need for manual interaction with hot cell manipulators and significantly lowering both the cost and duration of experiments. Digital image correlation (DIC) was used to measure displacement during mechanical testing, providing precise, non-contact measurement capabilities. The methodologies developed in this research will support the advancement of HTE techniques for future nuclear materials testing experiments at ATR. This approach allows for more efficient and cost-effective evaluation of new materials, ultimately leading to improved reactor performance, enhanced safety, and extended longevity within the nuclear industry.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRSDate not supplied

Additive Manufacture of Refractory Metals for Aerospace Applications

High temperature refractory metals are required for a number of high temperature propulsion applications. Refractory metals are expensive, difficult to manufacture with high buy-to-fly ratios, and few vendors. Additive manufacture (AM) is used to produce C103, Molybdenum (Mo), and Tungsten (W) reaction chamber and thrust stand-off as well as Iridium ultra-fine lattice catalysts for integration into 1 N green propulsion thrusters. Refractory AM is in development and like traditional AM alloys requires substantial post-processing to include powder heat treatment, surface finish enhancement, inspection, and machining before placed in service. The combination of limited feedstock sources, high temperature processing, oxygen sensitivity, fracture prone nature, and need for elevated temperature mechanical testing limit the number of qualified facilities capable of post-processing AM refractory materials, which add to cost and schedule constraints. However, properly implemented refractory metal AM can overcome existing manufacture limitations by greatly increasing design flexibility, new material options, reduced price, decreased lead-time, and leverage the ever growing AM commercial supply base.

Refractory metal additive manufacture↗

NASA NTRSDate not supplied

Additive Manufacture of Refractory Metals for Aerospace Applications

High temperature refractory metals are required for a number of high temperature propulsion applications. Refractory metals are expensive, difficult to manufacture with high buy-to-fly ratios, and few vendors. Additive manufacture (AM) is used to produce C103, Molybdenum (Mo), and Tungsten (W) reaction chamber and thrust stand-off as well as Iridium ultra-fine lattice catalysts for integration into 1 N green propulsion thrusters. Refractory AM is in development and like traditional AM alloys requires substantial post-processing to include powder heat treatment, surface finish enhancement, inspection, and machining before placed in service. The combination of limited feedstock sources, high temperature processing, oxygen sensitivity, fracture prone nature, and need for elevated temperature mechanical testing limit the number of qualified facilities capable of post-processing AM refractory materials, which add to cost and schedule constraints. However, properly implemented refractory metal AM can overcome existing manufacture limitations by greatly increasing design flexibility, new material options, reduced price, decreased lead-time, and leverage the ever growing AM commercial supply base.

Refractory metal additive manufacture↗

DOE OSTI2022

Machine learning prediction of the mechanical properties of refractory multicomponent alloys based on a dataset of phase and first principles simulation

In this work, a dataset including structural and mechanical properties of refractory multicomponent alloys was developed by fusing computations of phase diagram (CALPHAD) and density functional theory (DFT). The refractory multicomponent alloys, also named refractory complex concentrated alloys (CCAs) which contain 2–5 types of refractory elements were constructed based on Special Quasi-random Structure (SQS). The phase of alloys was predicted using CALPHAD and the mechanical property of alloys with stable and single body-centered cubic (BCC) at high temperature (over 1,500°C) was investigated using DFT-based simulation. As a result, a dataset with 393 refractory alloys and 12 features, including volume, melting temperature, density, energy, elastic constants, mechanical moduli, and hardness, were produced. To test the capability of the dataset on supporting machine learning (ML) study to investigate the property of CCAs, CALPHAD, and DFT calculations were compared with principal components analysis (PCA) technique and rule of mixture (ROM), respectively. It is demonstrated that the CALPHAD and DFT results are more in line with experimental observations for the alloy phase, structural and mechanical properties. Furthermore, the data were utilized to train a verity of ML models to predict the performance of certain CCAs with advanced mechanical properties, highlighting the usefulness of the dataset for ML technique on CCA property prediction.

36 MATERIALS SCIENCE↗

NASA NTRS1994

Fracture mechanics life analytical methods verification testing

Verification and validation of the basic information capabilities in NASCRAC has been completed. The basic information includes computation of K versus a, J versus a, and crack opening area versus a. These quantities represent building blocks which NASCRAC uses in its other computations such as fatigue crack life and tearing instability. Several methods were used to verify and validate the basic information capabilities. The simple configurations such as the compact tension specimen and a crack in a finite plate were verified and validated versus handbook solutions for simple loads. For general loads using weight functions, offline integration using standard FORTRAN routines was performed. For more complicated configurations such as corner cracks and semielliptical cracks, NASCRAC solutions were verified and validated versus published results and finite element analyses. A few minor problems were identified in the basic information capabilities of the simple configurations. In the more complicated configurations, significant differences between NASCRAC and reference solutions were observed because NASCRAC calculates its solutions as averaged values across the entire crack front whereas the reference solutions were computed for a single point.

Favenesi, J. A.↗

NASA NTRS2003

Software for Training in Pre-College Mathematics

The Intelligent Math Tutor (IMT) is a computer program for training students in pre-college and college-level mathematics courses, including fundamentals, intermediate algebra, college algebra, and trigonometry. The IMT can be executed on a server computer for access by students via the Internet; alternatively, it can be executed on students computers equipped with compact- disk/read-only-memory (CD-ROM) drives. The IMT provides interactive exercises, assessment, tracking, and an on-line graphing calculator with algebraic-manipulation capabilities. The IMT provides an innovative combination of content, delivery mechanism, and artificial intelligence. Careful organization and presentation of the content make it possible to provide intelligent feedback to the student based on performance on exercises and tests. The tracking and feedback mechanisms are implemented within the capabilities of a commercial off-the-shelf development software tool and are written in the Unified Modeling Language to maximize reuse and minimize development cost. The graphical calculator is a standard feature of most college and pre-college algebra and trigonometry courses. Placing this functionality in a Java applet decreases the cost, provides greater capabilities, and provides an opportunity to integrate the calculator with the lessons.

Shelton, Robert O.↗

NASA NTRSDate not supplied

Hybrid-Electric Aero-Propulsion Controls Testbed Results with Energy Storage

Electrified aircraft propulsion (EAP) research is a priority of the National Aeronautics and Space Administration (NASA) for its potential to increase propulsion system efficiency, performance, and operability at the subsystem and vehicle levels while decreasing emissions. These EAP systems demand more advanced control algorithms due to increased complexity. NASA has developed a reconfigurable, hardware-in-the-loop rig to verify control algorithm performance using a sub-scale electro-mechanical system. A novel capability of this rig is the ability to test full scale EAP control algorithms on a sub-scale representation of the electro-mechanical system without turbomachinery/rotors. A novel feature is the use of a physical energy storage device within the electro-mechanical system. A dual spool, parallel hybrid-electric turbofan architecture and energy management control system is tested with the goal of verifying the ability to obtain turbomachinery model operability benefits while controlling sub-scale electro-mechanical hardware. Pre-test predictions of the turbofan model, control, and rig performance were obtained through simulation using a software model of the rig. Theoretical results showing the true performance of the turbofan model were obtained through a software simulation using full-scale mechanical shaft models. The paper compares theoretical, predicted, and actual test results from the turbofan model, energy management control and rig perspectives. The results show that the presence of sub-scale electro-mechanical hardware did not inhibit the energy management algorithm from achieving turbomachinery operability benefits.

hybrid↗

NASA NTRSDate not supplied

Hybrid-Electric Aero-Propulsion Controls Testbed Results with Energy Storage

Electrified aircraft propulsion (EAP) research is a priority of the National Aeronautics and Space Administration (NASA) for its potential to increase propulsion system efficiency, performance, and operability at the subsystem and vehicle levels while decreasing emissions. These EAP systems demand more advanced control algorithms due to increased complexity. NASA has developed a reconfigurable, hardware-in-the-loop rig to verify control algorithm performance using a sub-scale electro-mechanical system. A novel capability of this rig is the ability to test full scale EAP control algorithms on a sub-scale representation of the electro-mechanical system without turbomachinery/rotors. A novel feature is the use of a physical energy storage device within the electro-mechanical system. A dual spool, parallel hybrid-electric turbofan architecture and energy management control system is tested with the goal of verifying the ability to obtain turbomachinery model operability benefits while controlling sub-scale electro-mechanical hardware. Pre-test predictions of the turbofan model, control, and rig performance were obtained through simulation using a software model of the rig. Theoretical results showing the true performance of the turbofan model were obtained through a software simulation using full-scale mechanical shaft models. The paper compares theoretical, predicted, and actual test results from the turbofan model, energy management control and rig perspectives. The results show that the presence of sub-scale electro-mechanical hardware did not inhibit the energy management algorithm from achieving turbomachinery operability benefits.

hybrid↗

DOE OSTI2022

MPACT Software Management Plan (V.4.3)

The MPACT code solves a discretized form of the Boltzmann transport equation on a wide variety of geometries and is distributed with a multigroup neutron cross section library. MPACT provides an advanced geometrically resolved neutral-particle transport capability to solve the flux distribution throughout the entire problem geometry, and it can model the isotopic depletion, decay, and activation of materials. The flux solution in MPACT is provided using a 2D/1D synthesis method within the framework of the 3D coarse mesh finite difference (CMFD) method for which axial and radial correction factors are obtained from 2D method of characteristics (MOC) and 1D nodal expansion method (NEM), PN, or SN. Other key characteristics of the MPACT code include the subgroup method and the embedded self-shielding method (ESSM) for resonance treatment, depletion capability based on the ORIGEN exponential matrix method, and a simplified thermal-hydraulics method for temperature/fluid feedback. The sole purpose of the simplified feedback model is to provide a mechanism for testing during code development and to provide a limited capability for educational applications. Work performed at the code level supports the VERA-QA-001, quality assurance program plan (QAPP) and VERA-QA-002, VERA Software Quality Assurance Plan.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2006

JWST NIRSpec Cryogenic Light Shield Mechanism

The focal plane detectors for the Near-Infrared Spectrometer (NIRSpec) instrument on the James Webb Space Telescope (JWST) require a light tight cover for calibration along with an open field-of-view during ground performance testing within a cryogenic dewar. In order to meet the light attenuation requirements and provide open and closed fields of view without breaking vacuum, a light shield mechanism was designed. This paper describes the details of the light shield mechanism design and test results. Included is information on the labyrinth light path design, motor capability and performance, dry film lubrication, mechanism control, and mechanism cryogenic performance results.

Hale, Kathleen↗

NASA NTRS2014

Damage Characterization of EBC-SiCSiC Ceramic Matrix Composites Under Imposed Thermal Gradient Testing

Due to their high temperature capabilities, Ceramic Matrix Composite (CMC) components are being developed for use in hot-section aerospace engine applications. Harsh engine environments have led to the development of Environmental Barrier Coatings (EBCs) for silicon-based CMCs to further increase thermal and environmental capabilities. This study aims at understanding the damage mechanisms associated with these materials under simulated operating conditions. A high heat-flux laser testing rig capable of imposing large through-thickness thermal gradients by means of controlled laser beam heating and back-side air cooling is used. Tests are performed on uncoated composites, as well as CMC substrates that have been coated with state-of-the-art ceramic EBC systems. Results show that the use of the EBCs may help increase temperature capability and creep resistance by reducing the effects of stressed oxidation and environmental degradation. Also, the ability of electrical resistance (ER) and acoustic emission (AE) measurements to monitor material condition and damage state during high temperature testing is shown; suggesting their usefulness as a valuable health monitoring technique. Micromechanics models are used to describe the localized stress state of the composite system, which is utilized along with ER modeling concepts to develop an electromechanical model capable of characterizing material behavior.

protective coatings (nonmetallic)↗