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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 541 records · Page 30

An Evaluation of Techroll Seal Flexible Joint Material

This study evaluated the materials utilized in the flexible joint for possible failure modes. Studies undertaken included effect of temperature on the strength of the system, effect of fatigue on the strength of the system, thermogravimetric analysis, thermochemical analysis, differential scanning calorimeter analysis, dynamic mechanical analysis, and peel test. These studies indicate that if the joint failed due to a materials deficiency, the most likely mode was excessive temperature in the joint. In addition, the joint material is susceptible to fatigue damage which could have been a contributing factor.

Hall, W. B.↗

Buffer strips in composites at elevated temperature

The composite material 'buffer strip' concept is presently investigated at elevated temperatures for the case of graphite/polyimide buffer strip panels using a (45/0/45/90)2S layup, where the buffer strip material was 0-deg S-glass/polyimide. Each panel was loaded in tension until it failed, and radiographs and crack opening displacements were recorded during the tests to determine fracture onset, fracture arrest, and the extent of damage in the buffer strip after crack arrest. At 177 + or - 3 C, the buffer strips increased the panel strength by at least 40 percent in comparison with panels without buffer strips. Compared to similar panels tested at room temperature, those tested at elevated temperature had lower residual strengths, but higher failure strains.

Bigelow, C. A.↗

Enhancement of superplastic formability in a high strength aluminum alloy

A 7475 aluminum alloy was developed for superplastic forming (SPF). By lowering the Fe and Si contents in this alloy significantly below their normal levels and optimizing the thermomechanical processing to produce sheet, over 2000 percent thickness strain to failure was obtained. The microstructure, elevated-temperature uniaxial and biaxial tension, and cavitation behavior of the alloy were determined. In addition, a constitutive model was used to form a generic structural shape from which mechanical test specimens were removed and post-SPF characteristics were evaluated. The constitutive model included both material strain hardening and strain rate hardening effects, and was verified by accurately predicting forming cycles which resulted in successful component forming. Stress-life fatigue, stress rupture, and room and elevated temperature tensile tests were conducted on the formed material.

Agrawal, S. P.↗

The procedure safety system

Telerobotic operations, whether under autonomous or teleoperated control, require a much more sophisticated safety system than that needed for most industrial applications. Industrial robots generally perform very repetitive tasks in a controlled, static environment. The safety system in that case can be as simple as shutting down the robot if a human enters the work area, or even simply building a cage around the work space. Telerobotic operations, however, will take place in a dynamic, sometimes unpredictable environment, and will involve complicated and perhaps unrehearsed manipulations. This creates a much greater potential for damage to the robot or objects in its vicinity. The Procedural Safety System (PSS) collects data from external sensors and the robot, then processes it through an expert system shell to determine whether an unsafe condition or potential unsafe condition exists. Unsafe conditions could include exceeding velocity, acceleration, torque, or joint limits, imminent collision, exceeding temperature limits, and robot or sensor component failure. If a threat to safety exists, the operator is warned. If the threat is serious enough, the robot is halted. The PSS, therefore, uses expert system technology to enhance safety thus reducing operator work load, allowing him/her to focus on performing the task at hand without the distraction of worrying about violating safety criteria.

Obrien, Maureen E.↗

A creep cavity growth model for creep-fatigue life prediction of a unidirectional W/Cu composite

A microstructural model was developed to predict creep-fatigue life in a (0)(sub 4), 9 volume percent tungsten fiber-reinforced copper matrix composite at the temperature of 833 K. The mechanism of failure of the composite is assumed to be governed by the growth of quasi-equilibrium cavities in the copper matrix of the composite, based on the microscopically observed failure mechanisms. The methodology uses a cavity growth model developed for prediction of creep fracture. Instantaneous values of strain rate and stress in the copper matrix during fatigue cycles were calculated and incorporated in the model to predict cyclic life. The stress in the copper matrix was determined by use of a simple two-bar model for the fiber and matrix during cyclic loading. The model successfully predicted the composite creep-fatigue life under tension-tension cyclic loading through the use of this instantaneous matrix stress level. Inclusion of additional mechanisms such as cavity nucleation, grain boundary sliding, and the effect of fibers on matrix-stress level would result in more generalized predictions of creep-fatigue life.

Kim, Young-Suk↗

Fast Risetime Reverse Bias Pulse Failures in SiC PN Junction Diodes

SiC-based high temperature power devices are being developed for aerospace systems which will require high reliability. One behavior crucial to power device reliability. To date, it has necessarily been assumed to date is that the breakdown behavior of SiC pn junctions will be similar to highly reliable silicon-based pn junctions. Challenging this assumption, we report the observation of anomalous unreliable reverse breakdown behavior in moderately doped (2-3 x 10(exp 17) cm(exp -3)) small-area 4H- and 6H-SiC pn junction diodes at temperatures ranging from 298 K (25 C) to 873 K (600 C). We propose a mechanism in which carrier emission from un-ionized dopants and deep level defects leads to this unstable behavior. The fundamental instability mechanism is applicable to all wide bandgap semiconductors whose dopants are significantly un-ionized at typical device operating temperatures.

Neudeck, Philip G.↗

Prognostics of Power MOSFET

This paper demonstrates how to apply prognostics to power MOSFETs (metal oxide field effect transistor). The methodology uses thermal cycling to age devices and Gaussian process regression to perform prognostics. The approach is validated with experiments on 100V power MOSFETs. The failure mechanism for the stress conditions is determined to be die-attachment degradation. Change in ON-state resistance is used as a precursor of failure due to its dependence on junction temperature. The experimental data is augmented with a finite element analysis simulation that is based on a two-transistor model. The simulation assists in the interpretation of the degradation phenomena and SOA (safe operation area) change.

Celaya, Jose Ramon↗

Support of LAVA Integration and Testing

The Lunar Advanced Volatile Analysis (LAVA) subsystem is a part of the Regolith and Environment Science & Oxygen and Lunar Volatile Analysis (RESOLVE) Payload that will fly to the lunar pole on the Resource Prospector Mission (RPM) in 2019. The purpose of the mission is to characterize the water on the surface and subsurface of the moon in various locations in order to map the distribution. This characterization of water will help to understand how feasible water is as a resource that can be used for drinking water, breathable air, and propellants in future missions. This paper describes the key support activities performed during a 10 week internship; specifically, troubleshooting the Near Infrared Spectrometer for the Surge Tank (NIRST) instrument count loss, contributing to a clamp to be used in the installation of Resistive Temperature Detectors (RTDs) to tubing, performing a failure analysis of the LAVA Fluid Subsystem (FSS), and finalizing trade studies for release.

Trade Study↗

Mechanical Tensile Testing of Titanium 15-3-3-3 and Kevlar 49 at Cryogenic Temperatures

Titanium 15-3-3-3 and Kevlar 49 are highly desired materials for structural components in cryogenic applications due to their low thennal conductivity at low temperatures. Previous tests have indicated that titanium 15-3-3-3 becomes increasingly brittle as the temperature decreases. Furthermore, little is known regarding the mechanical properties of Kevlar 49 at low temperatures, most specifically its Young's modulus. This testing investigates the mechanical properties of both materials at cryogenic temperatures through cryogenic mechanical tensile testing to failure. The elongation, ultimate tensile strength, yield strength, and break strength of both materials are provided and analyzed here.

James, Bryan L.↗

ENG 572 Final Report

Thermo-electric coolers (TECs) provide an essential function in many high-powered applications by diverting heat away from a temperature-sensitive load. This summer I have worked with Sandia National Laboratories in exploring the failure mechanisms behind said devices. I have been tasked with determining a plan of action for two TECs manufactured by two different companies labeled A and B respectively. Prior to my involvement in the project, the former has displayed failures during normal operation within its packaging. The latter was subsequently chosen to resolve these issues. Thermal cycling between the extreme expected operating temperatures (-40°C to 80°C) was applied to 5 unmounted TECAs over a period of 5 hours with 1-hour soaks at each extreme. The unmounted TECBs are currently undergoing the same process, and the task is expected to be completed over the next few weeks. The results of the TECA characterization have indicated no failure has occurred, which indicates that failure will need to be induced through either higher temperature extremes or additional mechanical stress.

47 OTHER INSTRUMENTATION↗

Mitigating the Effects of Au-Al Intermetallic Compounds Due to High-Temperature Processing of Surface-Electrode Ion Traps

Stringent physical requirements need to be met for the high-performing surface-electrode ion traps used in quantum computing and timekeeping. In particular, these traps must survive a high-temperature environment for vacuum chamber preparation and support high RF voltage on closely spaced electrodes. Due to the use of gold wire bonds on aluminum pads, intermetallic growth can lead to wire bond failure via breakage or high resistance, limiting the lifetime of a trap assembly to a single multiday bake at 200 ° C. Using traditional thick metal stacks to prevent intermetallic growth, however, can result in trap failure due to RF breakdown events. Through high-temperature experiments, we conclude that an ideal metal stack for ion traps is Ti/Pt/Au (20/100/250 nm), which allows for a cumulative bakeable time of roughly 86 days without compromising the trap voltage performance. This increase in the bakeable lifetime of ion traps will remove the need to discard otherwise functional ion traps when vacuum hardware is upgraded, which will greatly benefit ion trap experiments.

Haltli, Raymond A.↗

Thermomechanical and bithermal fatigue behavior of cast B1900 + Hf and wrought Haynes 188

A thermomechanical fatigue (TMF) high-temperature life prediction method has been evaluated using the experimental data. Bithermal fatigue (BTF), bithermal creep-fatigue (BTC-F), and TMF experiments were performed using two aerospace structural alloys, cast B1900 + Hf and wrought Haynes 188. The method which is based on the total strain version of strain range partitioning and unified cyclic constitutive modeling requires, as an input, information on the flow and failure behavior of the material of interest. Bithermal temperatures of 483 and 871 C were used for the cast B1900 + Hf nickel-base alloy and 316 and 760 C for the wrought Haynes 188 cobalt-base alloy. Maximum and minimum temperatures were also used in both TMF and BTF tests. Comparisons were made between the results of these tests and isothermal tensile and fatigue test data obtained previously. Qualitative correlations were observed between tensile and isothermal fatigue tests.

Halford, G. R.↗

Constitutive model development of aluminum alloy 1100 for elevated temperature forming process

Commercially pure aluminum alloy, AA1100, presents good electrical and thermal conductivity, high formability, and low cost. Those favorable characteristics have the potential to enable bipolar plates with improved economics and enhanced performance compared to current stainless steel bipolar plates for proton exchange membrane fuel cells. An accurate constitutive model is essential to develop and optimize processing parameters and effectively control the forming process. Here, the objective of this work is to develop a constitutive model of AA1100 that is able to simulate stress-strain relation, formed geometry, and predict the onset of fracture strain to avoid forming failure. Initially, a set of tensile tests at temperature between 300 and 500°C and strain rate between 0.005 and 1.0/s were conducted to examine the deformation behavior. Then, a set of damage-based unified visco-plastic constitutive equations is proposed and calibrated based on the results of stress-strain data. A genetic algorithm optimization method is applied to search for best fitting material constants in constitutive equations. The proposed model shows good predictability of both the stress-strain relation and fracture strain at low strain rate and high temperature conditions. The accuracy of proposed model is also evaluated statistically. A comparison of the proposed model with three popular models (Arrhenius-type mode, Johnson-Cook model and Zerilli-Armstrong model) was made. The proposed model shows the best experimental agreement with correlation coefficient of 0.96 in contrast to 0.25, 0.38 and 0.75 for the popular models, respectively. The proposed model can help to optimize the elevated temperature forming process and guide die design to enable optimal geometric features in the formed components.

08 HYDROGEN↗

An anisotropic damage model based on dislocation-mediated nucleation of cracks under high-rate compression

In this report, we developed a thermodynamically-consistent, rate-dependent micromechanics model for brittle damage nucleated by dislocation plasticity applicable for large deformations. Dislocation substructure evolution was used to inform a nucleation criterion for a microcrack. Under global compression, the sliding of a microcrack induces formation of wing cracks. Effective stress drives dynamic growth of these cracks under a 3D stress state, resulting in an anisotropic material stiffness. The model was also advanced to predict grain size dependence of a polycrystalline solid. Internal variables were constrained based on the laws of thermodynamics. Material constants were calibrated for polycrystalline beryllium to demonstrate the applicability of the model to simulate dynamic failure under compression. We demonstrate the versatility of the model to capture brittle to ductile transition governed by temperature and strain rate. The predictive capability of the model to simulate failure stress and failure strain is compared with dynamic and quasistatic data on beryllium.

36 MATERIALS SCIENCE↗

Cyclic stress analysis of an air-cooled turbine vane

The effects of gas pressure level, coolant temperature, and coolant flow rate on the stress-strain history and life of an air-cooled vane were analyzed using measured and calculated transient metal temperatures and a turbine blade stress analysis program. Predicted failure locations were compared to results from cyclic tests in a static cascade and engine. The results indicate that a high gas pressure was detrimental, a high coolant flow rate somewhat beneficial, and a low coolant temperature the most beneficial to vane life.

Kaufman, A.↗

Rocket engine diagnostics using qualitative modeling techniques

Researchers at NASA Lewis Research Center are presently developing qualitative modeling techniques for automated rocket engine diagnostics. A qualitative model of a turbopump interpropellant seal system was created. The qualitative model describes the effects of seal failures on the system steady state behavior. This model is able to diagnose the failure of particular seals in the system based on anomalous temperature and pressure values. The anomalous values input to the qualitative model are generated using numerical simulations. Diagnostic test cases include both single and multiple seal failures.

Binder, Michael↗

Rocket engine diagnostics using qualitative modeling techniques

Researchers at NASA Lewis Research Center are presently developing qualitative modeling techniques for automated rocket engine diagnostics. A qualitative model of a turbopump interpropellant seal system has been created. The qualitative model describes the effects of seal failures on the system steady-state behavior. This model is able to diagnose the failure of particular seals in the system based on anomalous temperature and pressure values. The anomalous values input to the qualitative model are generated using numerical simulations. Diagnostic test cases include both single and multiple seal failures.

Binder, Michael↗

Effect of NO on DME-Methanol HCCI Experimental Observations

Methanol is an attractive fuel for the maritime sector due to its wide availability. Its direct use as a fuel, however, is accompanied by challenges such as high latent heat of vaporization and low cetane number. A potential solution to overcome the ignition properties of methanol could be through on-board generation of dimethyl ether (DME) via catalytic dehydration of methanol. The resulting mixture from dehydration can be mixed in with the intake air to generate a homogenous charge compression ignition (HCCI) preburn for subsequent direct injection (DI) and successful ignition methanol at diesel–like timescales. However, if the preburn species are treated separately from the complete methanol MCCI approach the preburn heat release rate (HRR) phasing and behavior do not replicate the preburn behavior of the complete approach. Thus, the presence of the main methanol mixing controlled compression ignition (MCCI) combustion event influences the DME/methanol preburn kinetics. Specifically, it was found that trapped residual temperature alone was insufficient alone to be responsible for the observed differences, and that trace species concentrations of NO in the trapped residual gas also influenced DME/methanol kinetics increasing low temperature heat release (LTHR) magnitude and advancing high temperature heat release (HTHR) phasing. NO is not present in HCCI combustion of neat DME or DME/methanol blends nor is elevated gas temperature in the trapped residuals; both of which result in failure to accurately predict the HCCI combustion of DME/methanol blends when coupled with subsequent DI methanol MCCI. This work experimentally explores the effect of trapped residual temperature and NO on DME and DME/methanol HCCI combustion.

Jatana, Gurneesh [ORNL] (ORCID:0000000288903225)↗