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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Evolution of Indarch (EH4 Chondrite) at 1 GPa and High Temperature

The chondritic meteorites are materials that are as old as the solar system itself characterized by variations in bulk chemical and oxidation state, and have long been considered possible building blocks that accreted to form the terrestrial inner planets. Enstatite chondrites contain nearly FeO free enstatite, silicon-rich kamacite and various sulfides indicating formation under highly reducing conditions. These materials could have participated in the formation of the Earth. However, "fingerprinting" of meteoritic materials has shown that no known meteoritic class corresponds to a hypothetical bulk Earth composition in every aspect. To derive constraints on early accretion and differentiation processes and possibly resolve the debate on the formation of the Earth, it is required to study experimentally a variety of chondritic materials and investigate their melting relations and elemental partitioning behavior at variable pressure (P), temperature (T) and oxygen fugacities (fO2). Variations in fO2 can indeed change chemical features and phase equilibria dramatically. The P-T phase diagrams of peridotites and carbonaceous chondrites have been extensively studied experimentally up to pressures and temperatures corresponding to the transition zone and lower mantle. Even though partial melting experiments have been conducted at ambient pressure on the enstatite chondrite Indarch, enstatite meteorites have never been experimentally investigated at high PT. The following investigation focuses on the effect of the fO2 on the phase relations of Indarch, an EH4 chondrite.

Berthet, S.↗
NASA NTRS2014

Stardust Interstellar Preliminary Examination V: XRF Analyses of Interstellar Dust Candidates at ESRF ID13

Here, we report analyses by synchrotron X-ray fluorescence microscopy of the elemental composition of eight candidate impact features extracted from the Stardust Interstellar Dust Collector (SIDC). Six of the features were unambiguous tracks, and two were crater-like features. Five of the tracks are so-called midnight tracks that is, they had trajectories consistent with an origin either in the interstellar dust stream or as secondaries from impacts on the Sample Return Capsule (SRC). In a companion paper reporting synchrotron X-ray diffraction analyses of ISPE candidates, we show that two of these particles contain natural crystalline materials: the terminal particle of track 30contains olivine and spinel, and the terminal particle of track 34 contains olivine. Here, we show that the terminal particle of track 30, Orion, shows elemental abundances, normalized to Fe, that are close to CI values, and a complex, fine-grained structure. The terminal particle of track 34, Hylabrook, shows abundances that deviate strongly from CI, but shows little fine structure and is nearly homogenous. The terminal particles of other midnight tracks, 29 and 37, had heavy element abundances below detection threshold. A third, track28, showed a composition inconsistent with an extraterrestrial origin, but also inconsistent with known spacecraft materials. A sixth track, with a trajectory consistent with secondary ejecta from an impact on one of the spacecraft solar panels, contains abundant Ce and Zn. This is consistent with the known composition of the glass covering the solar panel. Neither crater-like feature is likely to be associated with extraterrestrial materials. We also analyzed blank aerogel samples to characterize background and variability between aerogel tiles. We found significant differences in contamination levels and compositions, emphasizing the need for local background subtraction for accurate quantification.

Stardust↗
NASA NTRS1995

Orbital atomic oxygen effects on materials: An overview of MSFC experiments on the STS-46 EOIM-3

The third Evaluation of Oxygen Interaction with Materials experiment was flown on Space Shuttle Mission STS-46 (July 31 - August 8, 1992), representing a joint effort of several NASA centers, universities, and contractors. This array of active instrumentation and material exposure sub-assemblies was integrated as a Shuttle cargo bay pallet experiment for investigating the effects of orbital atomic oxygen on candidate space materials. Marshall Space Flight Center contributed several passive exposure trays of material specimens, uniform stress and static stress material exposure fixtures, the Atomic Oxygen Resistance Monitor (AORM), and specimens of thermal coatings for the EOIM-3 variable exposure mechanisms. As a result of 42 hours of spacecraft velocity vector-oriented exposure during the later phases of the STS-46 mission in LEO, EOIM-3 materials were exposed to an atomic oxygen fluence of 2.2 x 10(exp 20) atoms/sq cm. In this paper, an overview is presented of the technical approaches and results from analyses of the MSFC flight specimens, fixtures, and the AORM. More detailed results from earlier EOIM missions, the LDEF, and from laboratory testing are included in associated papers of this conference session.

Linton, Roger C.↗
NASA NTRS1975

Discrete component bonding and thick film materials study

The results are summarized of an investigation of discrete component bonding reliability and a fundamental study of new thick film resistor materials. The component bonding study examined several types of solder bonded components with some processing variable studies to determine their influence upon bonding reliability. The bonding reliability was assessed using the thermal cycle: 15 minutes at room temperature, 15 minutes at +125 C 15 minutes at room temperature, and 15 minutes at -55 C. The thick film resistor materials examined were of the transition metal oxide-phosphate glass family with several elemental metal additions of the same transition metal. These studies were conducted by preparing a paste of the subject composition, printing, drying, and firing using both air and reducing atmospheres. The resulting resistors were examined for adherence, resistance, thermal coefficient of resistance, and voltage coefficient of resistance.

Kinser, D. L.↗
NASA NTRS1979

Reusable solid rocket motor case - Optimum probabilistic fracture control

A methodology for the reliability analysis of a reusable solid rocket motor case is discussed in this paper. The analysis is based on probabilistic fracture mechanics and probability distribution for initial flaw sizes. The developed reliability analysis can be used to select the structural design variables of the solid rocket motor case on the basis of minimum expected cost and specified reliability bounds during the projected design life of the case. Effects on failure prevention plans such as nondestructive inspection and the material erosion between missions can also be considered in the developed procedure for selection of design variables. The reliability-based procedure that has been discussed in this paper can easily be modified to consider other similar structures of reusable space vehicle systems with different fracture control plans.

Hanagud, S.↗
NASA NTRS1989

Tethered variable gravity laboratory study: Low gravity process identification report

Experiments are described performable in the variable gravity environment, and the related compatible/beneficial residual accelerations, both for pure and applied research in the fields of Fluid Mechanics (static and dynamic), Materials Sciences (Crystal Growth, Metal and Alloy Solidification, Glasses, etc.), and Life Sciences, so as to assess the relevance of a variable G-level laboratory.

Briccarello, M.↗
NASA NTRS1996

Parabolic aircraft solidification experiments

A number of solidification experiments have been utilized throughout the Materials Processing in Space Program to provide an experimental environment which minimizes variables in solidification experiments. Two techniques of interest are directional solidification and isothermal casting. Because of the wide-spread use of these experimental techniques in space-based research, several MSAD experiments have been manifested for space flight. In addition to the microstructural analysis for interpretation of the experimental results from previous work with parabolic flights, it has become apparent that a better understanding of the phenomena occurring during solidification can be better understood if direct visualization of the solidification interface were possible. Our university has performed in several experimental studies such as this in recent years. The most recent was in visualizing the effect of convective flow phenomena on the KC-135 and prior to that were several successive contracts to perform directional solidification and isothermal casting experiments on the KC-135. Included in this work was the modification and utilization of the Convective Flow Analyzer (CFA), the Aircraft Isothermal Casting Furnace (ICF), and the Three-Zone Directional Solidification Furnace. These studies have contributed heavily to the mission of the Microgravity Science and Applications' Materials Science Program.

Workman, Gary L.↗
NASA NTRS2019

A Design Methodology for Optimizing and Integrating Composite Materials in Gear Structures

The application of composite materials to gear structures is complex because of the gear shape, the need for precise dimensional tolerances, and the complex dynamic load condition. Methods are presented in this work to design and optimize an integrated composite hub-web structure that can be used as part of a hybrid composite-steel gear. The composite hub-web structure is a planar structure with a large decrease in thickness from the hub to the rim. Methods for design and optimization of this variable-thickness structure are presented along with a method for forming braided prepreg material to conform to the shape of this structure. A layered approach is presented that integrates cut plies or filler materials for thickness buildup with continuous-fiber layers for the primary load path. An additional gear design concept is presented that has an axially extended continuous-fiber composite structure that can be combined with the planar structure. A proposed optimization methodology is introduced where an optimized design is output for each type of optimization simulation. Through this process, composite knowledge can be incorporated in the optimization, and more control is given over the design during the process. The methods in this study provide a tool for designing and optimizing composite structures for gears and other high-power-density applications.

optimization↗
NASA NTRS1977

Probabilistic fracture mechanics and optimum fracture control of the solid rocket motor case of the shuttle

Development of a procedure for the reliability analysis of the solid rocket motor case of the space shuttle is described. The analysis is based on probabilistic fracture mechanics and consideration of a probability distribution for the initial flaw sizes. The reliability analysis can be used to select design variables, such as the thickness of the SRM case, projected design life and proof factor, on the basis of minimum expected cost and specified reliability bounds. Effects of fracture control plans such as the non-destructive inspections and the material erosion between missions can also be considered in the developed methodology for selection of design variables. The reliability-based procedure can be easily modified to consider other similar structures and different fracture control plans.

Hanagud, S.↗
NASA NTRS2026

Benchmarking Bayesian Optimization Frameworks and Acquisition Strategies for Materials Discovery and Autonomous Laboratories

Bayesian optimization (BO) can accelerate materials discovery by guiding expensive experiments toward the most promising processing conditions. We systematically compare five BO surrogate and framework combinations (Gaussian processes in Ax, Gaussian processes and Monte-Carlo neural networks in BayBE, random forests in Lolopy, and tree-structured Parzen (TPE) estimators in Hyperopt) on three benchmarks that mimic common materials design tasks (a discrete solid-electrolyte composition space, a hybrid discrete/continuous laminate-composite design problem solved with micromechanics modeling, and the continuous Ishigami analytic function which is a standard optimization benchmark). Each BO surrogate is paired with posterior mean, probability of improvement, and expected improvement acquisition functions and run for 100 trials from randomized initial samples with uniform random search providing a control. Across five random seeds per setting, BayBE’s Gaussian-process surrogate with expected improvement consistently reached ≥95 % of the known optimum in the fewest evaluations, while Lolopy’s random forest matched or exceeded GP performance on purely categorical or mixed spaces at a higher computational cost. Posterior mean alone often stagnated at local optima, underscoring the need for exploration, whereas probability and expected improvement balanced exploration and exploitation leading to better optimization in fewer trials. Execution times ranged from milliseconds for TPE to minutes for neural-network and random-forest surrogates. These results establish baseline expectations for BO in automated materials laboratories and highlight expected improvement with Gaussian processes as a reliable first choice, with random forests offering a strong alternative when categorical variables dominate. The benchmark suite and code are released to facilitate future surrogate, acquisition, and constraint-handling research in data-driven materials optimization.

Bayesian optimization↗
NASA NTRS1995

Multiple rings around Wolf-Rayet evolution

We present optical narrow-band imaging of multiple rings existing around galactic Wolf-Rayet (WR) stars. The existence of multiple rings of material around Wolf-Rayet stars clearly illustrates the various phases of evolution that massive stars go through. The objects presented here show evidence of a three stage evolution. O stars produce an outer ring with the cavity being partially filled by ejecta from a red supergiant of luminous blue variable phase. A wind from the Wolf-Rayet star then passes into the ejecta materials. A simple model is presented for this three stage evolution. Using observations of the size and dynamics of the rings allows estimates of time scales for each stage of the massive star evolution. These are consistent with recent theoretical evolutionary models. Mass estimates for the ejecta, from the model presented, are consistent with previous ring nebula mass estimates from IRAS data, showing a number of ring nebulae to have large masses, most of which must in be in the form of neutral material. Finally, we illustrate how further observations will allow the determination of many of the parameters of the evolution of massive stars such as total mass loss, average mass loss rates, stellar abundances, and total time spent in each evolutionary phase.

Marston, A. P.↗
NASA NTRS2021

Hot Isostatic Pressing for Reduction of Defects in Additively Manufactured Inconel-718 Preliminary Simulation Approach and Results

Selective laser melting (SLM) of Inconel-718 (IN718) is a promising advanced manufacturing technology; however, challenges exist for fracture-critical parts where pores induced during the manufacturing process reduce fatigue life of the material. Hot isostatic pressing (HIP) is a common post processing technique used to reduce the part porosity by exposing parts to high temperature and pressures. Pore closure depends on the pore shape, trapped gas, and HIP parameters, and the process can only be optimized by understanding the effect of these variables. An analysis capability is described to better understand the conditions necessary for pore closure, and the effect of several variables on porosity are explored and compared to a baseline case. The importance of valid material response models is identified as a significant factor in model accuracy; especially the creep material response model which, in the baseline case, predicts that creep strain accounts for 87.7% of the total strain at the conclusion of the HIP cycle. Lessons learned are described, in addition to future work including model validation.

Joshua M Fody↗
NASA NTRS2026

Development, Characterization, and Validation of Elevated-Temperature Constitutive Models: Deformation and Damage

This report provides a brief review of experimentally observed hereditary and nonhereditary material behavior along with background information on standard as well as advanced internal state variable constitutive modeling at elevated temperature. A description of exploratory, characterization, and validation testing is presented along with a detailed outline of what constitutes “sufficient” data content (i.e., quality and quantity) for developing or enhancing, characterizing, and validating a particular sophisticated nonlinear time- and history-dependent (hereditary) class of constitutive models known as GVIPS (generalized viscoplasticity with potential structure). The tests described are necessary to reveal a material’s behavior in the reversible (or viscoelastic) and irreversible (or viscoplastic) regimes, for the identification of both deformation and damage model parameters. Results presented are primarily for metallic materials. In all cases, both uniaxial and multiaxial tests are described, and the linkage between the specific tests and the parameters within the model that can be characterized from the results of these tests are also discussed. Discussion is also provided relative to the role information management must play relative to material data collection, analysis, maintenance, and dissemination. The need for such an information system is particularly important as both analyst and designer move toward utilizations of sophisticated, nonlinear time- and history dependent (hereditary) constitutive models. Lastly, the concept of state space and its utility in understanding and establishing constitutive models is addressed throughout. The intent behind this document is to help both the modeler and experimentalist understand each other’s specific points of view and provide guidance for both model development and characterization. Emphasis has been placed on providing the mechanician with information regarding how tests are performed and what issues to be aware of when interpreting results. It is hoped that experimentalists will take away a new perspective on the types of information that modelers and analysts are looking for from them.

Constitutive Modeling↗
NASA NTRS2007

Characterization of Nonlinear Rate Dependent Response of Shape Memory Polymers

Shape Memory Polymers (SMPs) are a class of polymers, which can undergo deformation in a flexible state at elevated temperatures, and when cooled below the glass transition temperature, while retaining their deformed shape, will enter and remain in a rigid state. Upon heating above the glass transition temperature, the shape memory polymer will return to its original, unaltered shape. SMPs have been reported to recover strains of over 400%. It is important to understand the stress and strain recovery behavior of SMPs to better develop constitutive models which predict material behavior. Initial modeling efforts did not account for large deformations beyond 25% strain. However, a model under current development is capable of describing large deformations of the material. This model considers the coexisting active (rubber) and frozen (glass) phases of the polymer, as well as the transitions between the material phases. The constitutive equations at the continuum level are established with internal state variables to describe the microstructural changes associated with the phase transitions. For small deformations, the model reduces to a linear model that agrees with those reported in the literature. Thermomechanical characterization is necessary for the development, calibration, and validation of a constitutive model. The experimental data reported in this paper will assist in model development by providing a better understanding of the stress and strain recovery behavior of the material. This paper presents the testing techniques used to characterize the thermomechanical material properties of a shape memory polymer (SMP) and also presents the resulting data. An innovative visual-photographic apparatus, known as a Vision Image Correlation (VIC) system was used to measure the strain. The details of this technique will also be presented in this paper. A series of tensile tests were performed on specimens such that strain levels of 10, 25, 50, and 100% were applied to the material while it was above its glass transition temperature. After deforming the material to a specified applied strain, the material was then cooled to below the glass transition temperature (Tg) while retaining the deformed shape. Finally, the specimen was heated again to above the transition temperature, and the resulting shape recovery profile was measured. Results show that strain recovery occurs at a nonlinear rate with respect to time. Results also indicate that the ratio of recoverable strain/applied strain increases as the applied strain increases.

Volk, Brent↗
NASA NTRS1994

Multidisciplinary design optimization using genetic algorithms

Multidisciplinary design optimization (MDO) is an important step in the conceptual design and evaluation of launch vehicles since it can have a significant impact on performance and life cycle cost. The objective is to search the system design space to determine values of design variables that optimize the performance characteristic subject to system constraints. Gradient-based optimization routines have been used extensively for aerospace design optimization. However, one limitation of gradient based optimizers is their need for gradient information. Therefore, design problems which include discrete variables can not be studied. Such problems are common in launch vehicle design. For example, the number of engines and material choices must be integer values or assume only a few discrete values. In this study, genetic algorithms are investigated as an approach to MDO problems involving discrete variables and discontinuous domains. Optimization by genetic algorithms (GA) uses a search procedure which is fundamentally different from those gradient based methods. Genetic algorithms seek to find good solutions in an efficient and timely manner rather than finding the best solution. GA are designed to mimic evolutionary selection. A population of candidate designs is evaluated at each iteration, and each individual's probability of reproduction (existence in the next generation) depends on its fitness value (related to the value of the objective function). Progress toward the optimum is achieved by the crossover and mutation operations. GA is attractive since it uses only objective function values in the search process, so gradient calculations are avoided. Hence, GA are able to deal with discrete variables. Studies report success in the use of GA for aircraft design optimization studies, trajectory analysis, space structure design and control systems design. In these studies reliable convergence was achieved, but the number of function evaluations was large compared with efficient gradient methods. Applicaiton of GA is underway for a cost optimization study for a launch-vehicle fuel-tank and structural design of a wing. The strengths and limitations of GA for launch vehicle design optimization is studied.

Unal, Resit↗
NASA NTRS1993

Fuzzy sets predict flexural strength and density of silicon nitride ceramics

In this work, we utilize fuzzy sets theory to evaluate and make predictions of flexural strength and density of NASA 6Y silicon nitride ceramic. Processing variables of milling time, sintering time, and sintering nitrogen pressure are used as an input to the fuzzy system. Flexural strength and density are the output parameters of the system. Data from 273 Si3N4 modulus of rupture bars tested at room temperature and 135 bars tested at 1370 C are used in this study. Generalized mean operator and Hamming distance are utilized to build the fuzzy predictive model. The maximum test error for density does not exceed 3.3 percent, and for flexural strength 7.1 percent, as compared with the errors of 1.72 percent and 11.34 percent obtained by using neural networks, respectively. These results demonstrate that fuzzy sets theory can be incorporated into the process of designing materials, such as ceramics, especially for assessing more complex relationships between the processing variables and parameters, like strength, which are governed by randomness of manufacturing processes.

Cios, Krzysztof J.↗
NASA NTRS2013

Unit-Sphere Multiaxial Stochastic-Strength Model Applied to Anisotropic and Composite Materials

Models that predict the failure probability of brittle materials under multiaxial loading have been developed by authors such as Batdorf, Evans, and Matsuo. These "unit-sphere" models assume that the strength-controlling flaws are randomly oriented, noninteracting planar microcracks of specified geometry but of variable size. This methodology has been extended to predict the multiaxial strength response of transversely isotropic brittle materials, including polymer matrix composites (PMCs), by considering (1) flaw-orientation anisotropy, whereby a preexisting microcrack has a higher likelihood of being oriented in one direction over another direction, and (2) critical strength, or K (sub Ic) orientation anisotropy, whereby the level of critical strength or fracture toughness for mode I crack propagation, K (sub Ic), changes with regard to the orientation of the microstructure. In this report, results from finite element analysis of a fiber-reinforced-matrix unit cell were used with the unit-sphere model to predict the biaxial strength response of a unidirectional PMC previously reported from the World-Wide Failure Exercise. Results for nuclear-grade graphite materials under biaxial loading are also shown for comparison. This effort was successful in predicting the multiaxial strength response for the chosen problems. Findings regarding stress-state interactions and failure modes also are provided.

Nemeth, Noel, N.↗
NASA NTRS1951

Plastic Stress-strain Relations for 75S-T6 Aluminum Alloy Subjected to Biaxial Tensile Stresses

In this investigation, the material tested was a 75S-T6 aluminum alloy and the stresses were essentially biaxial and tensile. The biaxial tensile stresses were produced in a specially designed testing machine by subjecting a thin-walled tubular specimen to axial tension and internal pressure. Plastic stress-strain relations for various biaxial stress conditions were obtained using a clip-type SR-4 strain gage. Three types of tests were made: Constant-stress-ratio tests, variable-stress-ratio tests, and special tests. The constant-stress-ratio test results gave control data and showed the influence of biaxial stresses on the yield, fracture, and ultimate strength of the material. By means of the variable-stress-ratio tests, it is possible to determine whether there is any significant difference between the flow and deformation type of theory. Finally, special tests were conducted to check specific assumptions made in the theories of plastic flow. The constant-stress-ratio tests show that the deformation theory based on the octahedral, effective; or significant stress-strain relations is in approximate agreement with the test results. The variable-stress-ratio tests show that both the deformation and flow theory are in equally good agreement with the test results.

Marin, Joseph↗