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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 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Fatigue Test Result for High Burnup Pressurized Water Reactor Rods

The High Burnup Spent Fuel Data Project, sponsored by DOE-NE, is focused on understanding the effects of long-term storage and transportation on high burnup (HBU) (>45 gigawatt days per metric ton uranium) light water reactor fuel. The experiment includes 32 HBU spent nuclear fuel (SNF) assemblies that will be stored in a typical Independent Spent Fuel Storage Installation (ISFSI) and 25 sister rods - nine SNF rods that were removed from the fuel assemblies prior to insertion to the ISFSI and 16 SNF rods removed from similar HBU assemblies. The sister rods provide a baseline of the condition of the HBU rods prior to loading, drying, and long-term dry storage. Destructive examinations of the sister rods are focused on understanding overall SNF rod strength and durability. Both composite fuel and empty cladding will be tested to derive material properties. While the data generated can be used for multiple purposes, a primary goal of the sister rod PIE data and associated measured mechanical properties is to support existing fuel storage licensing and relicensing activities by addressing identified knowledge gaps, and enhance the technical basis for post-storage transportation, handling, and consolidation activities. Fatigue tests of HBU M5-clad, ZIRLO-clad, Zircaloy-4, and low tin Zircaloy-4 segments have been completed using ORNL’s Cyclic Integral Reversible Fatigue Tester (CIRFT). This is the first time ZIRLO-clad rods have been tested. Some of the segments were heat-treated to understand the effects of thermal transients such as those encountered during dry storage vacuum drying on the fatigue lifetime. This paper presents results of the fatigue tests obtained to date and discusses planned future tests.

Montgomery, Rose↗
NASA NTRS1988

Fatigue testing and damage development in continuous fiber reinforced metal matrix composites

A general overview of the fatigue behavior of metal matrix composites (MMC) is presented. The first objective is to present experimental procedures and techniques for conducting a meaningful fatigue test to detect and quantify fatigue damage in MMC. These techniques include interpretation of stress-strain responses, acid etching of the matrix, edge replicas of the specimen under load, radiography, and micrographs of the failure surfaces. In addition, the paper will show how stiffness loss in continuous fiber reinforced metal matrix composites can be a useful parameter for detecting fatigue damage initiation and accumulation. Second, numerous examples of how fatigue damage can initiate and grow in various MMC are given. Depending on the relative fatigue behavior of the fiber and matrix, and the interface properties, the failure modes of MMC can be grouped into four categories: (1) matrix dominated, (2) fiber dominated, (3) self-similar damage growth, and (4) fiber/matrix interfacial failures. These four types of damage will be discussed and illustrated by examples with the emphasis on the fatigue of unnotched laminates.

Johnson, W. S.↗
NASA NTRS1989

Fatigue testing and damage development in continuous fiber reinforced metal matrix composites

A general overview of the fatigue behavior of metal matrix composites (MMC) is presented. The first objective is to present experimental procedures and techniques for conducting a meaningful fatigue test to detect and quantify fatigue damage in MMC. These techniques include interpretation of stress-strain responses, acid etching of the matrix, edge replicas of the specimen under load, radiography, and micrographs of the failure surfaces. In addition, the paper will show how stiffness loss in continuous fiber reinforced metal matrix composites can be a useful parameter for detecting fatigue damage initiation and accumulation. Second, numerous examples of how fatigue damage can initiate and grow in various MMC are given. Depending on the relative fatigue behavior of the fiber and matrix, and the interface properties, the failure modes of MMC can be grouped into four categories: (1) matrix dominated, (2) fiber dominated, (3) self-similar damage growth, and (4) fiber/matrix interfacial failures. These four types of damage will be discussed and illustrated by examples with the emphasis on the fatigue of unnotched laminates.

Johnson, W. S.↗
NASA NTRS1984

The drive for Aircraft Energy Efficiency

NASA's Aircraft Energy Efficiency (ACEE) program, which began in 1976, has mounted a development effort in four major transport aircraft technology fields: laminar flow systems, advanced aerodynamics, flight controls, and composite structures. ACEE has explored two basic methods for achieving drag-reducing boundary layer laminarization: the use of suction through the wing structure (via slots or perforations) to remove boundary layer turbulence, and the encouragement of natural laminar flow maintenance through refined design practices. Wind tunnel tests have been conducted for wide bodied aircraft equipped with high aspect ratio supercritical wings and winglets. Maneuver load control and pitch-active stability augmentation control systems reduce fuel consumption by reducing the drag associated with high aircraft stability margins. Composite structures yield lighter airframes that in turn call for smaller wing and empennage areas, reducing induced drag for a given payload. In combination, all four areas of development are expected to yield a fuel consumption reduction of 40 percent.

James, R. L., Jr.↗
NASA NTRS2009

Characterization of Damage in Triaxial Braid Composites Under Tensile Loading

Carbon fiber composites utilizing flattened, large tow yarns in woven or braided forms are being used in many aerospace applications. Their complex fiber architecture and large unit cell size present challenges in both understanding deformation processes and measuring reliable material properties. This report examines composites made using flattened 12k and 24k standard modulus carbon fiber yarns in a 0 /+60 /-60 triaxial braid architecture. Standard straight-sided tensile coupons are tested with the 0 axial braid fibers either parallel with or perpendicular to the applied tensile load (axial or transverse tensile test, respectively). Nonuniform surface strain resulting from the triaxial braid architecture is examined using photogrammetry. Local regions of high strain concentration are examined to identify where failure initiates and to determine the local strain at the time of initiation. Splitting within fiber bundles is the first failure mode observed at low to intermediate strains. For axial tensile tests splitting is primarily in the 60 bias fibers, which were oriented 60 to the applied load. At higher strains, out-of-plane deformation associated with localized delamination between fiber bundles or damage within fiber bundles is observed. For transverse tensile tests, the splitting is primarily in the 0 axial fibers, which were oriented transverse to the applied load. The initiation and accumulation of local damage causes the global transverse stress-strain curves to become nonlinear and causes failure to occur at a reduced ultimate strain. Extensive delamination at the specimen edges is also observed.

Littell, Justin D.↗
NASA NTRS1999

Stress Analysis and Permeability Testing of Cryogenic Composite Feed Line

For the next generation Single-Stage-To-Orbit (SSTO) Reusable Launch Vehicle (RLV), the use of advanced composite materials is highly desirable and critical to the success of the mission. NASA Marshall Space Flight Center (MSFC) has been working with the aerospace industry for many years to develop and demonstrate the cryogenic composite propellant tanks and feed lines technologies. A 50.8-mm diameter composite feed line for the Clipper Graham (DCY.A) was developed and tested. The purpose of the program is to demonstrate the LH2 permeability, composite to composite and metal joints, as well as composite flange interface of the composite feed line. Stress analysis and permeability testing have been performed on this article. Recently, a larger composite feed line design is being investigated and developed at MSFC for potential use in future RLV. The diameter of the feed line is 203 mm and the overall length is approximately 2.2 meters. This one piece unlined feed line consists of three straight tubular sections joined by two 90 degree elbows. The material chosen is IM7/977-3 prepreg fabric. The lay-up pattern is [0/90, plus or minus 45]s and is built up to 18 plies to the flanges at both ends. A preliminary stress analysis has been conducted to identify potential critical stresses and to develop the finite element analysis (FEA) capability of composite feed lines. As expected, the critical stresses occurred at the rims of some flange holes and the onset of the tapered tubular sections. Further analysis is required to determine the loads, flange deflection, vibration, and combined maximum loads. Two permeability-testing apparatuses were also designed for both flat panel specimens and curved feed line sections after impact damage. A larger permeant gas exposed area is required to accurately determine the effect of impact damage on the permeability of the feed line materials. The flat panel tester was fabricated and assembled. Three test coupons were made of graphite/epoxy plain weave prepreg and unidirectional prepreg. The flow rate was calculated by measuring the change of manometer fluid height per unit time. The permeability of the coupons is then calculated according to Darcy's Law. The pressure increase due to the head rise in the manometer was not considered for the initial estimation. The result of the unidirectional composite coupon agreed with that obtained from the DC-XA feed line testing of a similar material. Further improvement on the design may be required to improve the accuracy and efficiency of permeability testing.

Chu, Tsuchin Philip↗
NASA NTRS1985

Large deflection behavior of quasi-isotropic laminates under low-velocity impact type point loading

Eight-ply quasi-isotropic circular composite plates of Thornel 300 graphite in Narmco 5208 epoxy resin (T300/5208) were analyzed to obtain the large deformation behavior under low-velocity impact type point loads. A simple plate-membrane coupling model was developed. The impact type point loads were replaced by equivalent quasi-static point loads. The plate-membrane coupling model was used to obtain the large deformation shapes for the thin circular composite laminates. The analyses indicated that the large deformation shapes of the composite plates under point loads vary with the center point displacements, and hence are different for different load levels. Quasi-isotropic plates were analyzed by replacing anisotropic bending stiffness components with the equivalent flexural stiffness for the isotropic plates. The plate-membrane coupling model was verified by conducting a series of tests on clamped circular quasi-isotropic laminates. Deflected shapes for the thin composite plates were experimentally obtained. These shapes agreed well with the analytically predicted shapes.

Kelkar, A.↗
DOE OSTI2020

Crushing behaviors of unidirectional carbon fiber reinforced plastic composites under dynamic bending and axial crushing loading

The dynamic crushing characteristics of unidirectional carbon fiber reinforced plastic composites under two loading types, dynamic three-point bending and axial crushing, are investigated by experiment and finite element simulation. Hat section samples with two different layup orientations are tested at various impact velocities to investigate its effects. The experiment results show that delamination plays a critical role in dynamic bending deformation. Different layup orientations lead to similar crushing bending behaviors, but remarkable variations in delamination pattern evolutions. In contrast, layup orientation exerts more significant effects on failure modes and energy absorption in axial crushing. A finite element model with multiple layers of thick shell element and cohesive element is established, and simulations are performed for both dynamic three-point bending and axial crushing. The model can capture the crushing behaviors in the two loading types reasonably well. The damage evolution and energy absorption through various mechanisms at different loading conditions are discussed.

42 ENGINEERING↗
NASA NTRS2013

Process Optimization of Bismaleimide (BMI) Resin Infused Carbon Fiber Composite

Bismaleimide (BMI) resins are an attractive new addition to world-wide composite applications. This type of thermosetting polyimide provides several unique characteristics such as excellent physical property retention at elevated temperatures and in wet environments, constant electrical properties over a vast array of temperature settings, and nonflammability properties as well. This makes BMI a popular choice in advance composites and electronics applications [I]. Bismaleimide-2 (BMI-2) resin was used to infuse intermediate modulus 7 (IM7) based carbon fiber. Two panel configurations consisting of 4 plies with [+45deg, 90deg]2 and [0deg]4 orientations were fabricated. For tensile testing, a [90deg]4 configuration was tested by rotating the [0deg]4 configirration to lie orthogonal with the load direction of the test fixture. Curing of the BMI-2/IM7 system utilized an optimal infusion process which focused on the integration of the manufacturer-recommended ramp rates,. hold times, and cure temperatures. Completion of the cure cycle for the BMI-2/IM7 composite yielded a product with multiple surface voids determined through visual and metallographic observation. Although the curing cycle was the same for the three panellayups, the surface voids that remained within the material post-cure were different in abundance, shape, and size. For tensile testing, the [0deg]4 layup had a 19.9% and 21.7% greater average tensile strain performance compared to the [90deg]4 and [+45deg, 90deg, 90deg,-45degg] layups, respectively, at failure. For tensile stress performance, the [0deg]4 layup had a 5.8% and 34.0% greater average performance% than the [90deg]4 and [+45deg, 90deg, 90deg,-45deg] layups.

Ehrlich, Joshua W.↗
NASA NTRS2005

Unitized Regenerative Fuel Cell System Gas Storage-Radiator Development

High-energy-density regenerative fuel cell systems that are used for energy storage require novel approaches to integrating components in order to preserve mass and volume. A lightweight unitized regenerative fuel cell (URFC) energy storage system concept is being developed at the NASA Glenn Research Center. This URFC system minimizes mass by using the surface area of the hydrogen and oxygen storage tanks as radiating heat surfaces for overall thermal control of the system. The waste heat generated by the URFC stack during charging and discharging is transferred from the cell stack to the surface of each tank by loop heat pipes, which are coiled around each tank and covered with a thin layer of thermally conductive carbon composite. The thin layer of carbon composite acts as a fin structure that spreads the heat away from the heat pipe and across the entire tank surface. Two different-sized commercial-grade composite tanks were constructed with integral heat pipes and tested in a thermal vacuum chamber to examine the feasibility of using the storage tanks as system radiators. The storage tank-radiators were subjected to different steady-state heat loads and varying heat load profiles. The surface emissivity and specific heat capacity of each tank were calculated. In the future, the results will be incorporated into a model that simulates the performance of similar radiators using lightweight, spacerated carbon composite tanks.

Burke, Kenneth A.↗
DOE OSTI2024

Low-Cost, High-Performance Carbon Fiber for Compressed Natural Gas Storage Tanks (Final Technical Report – Down Select Report)

The aim of this project is to reduce the cost of Type IV, carbon fiber (CF) composite overwrap compressed gas storage tanks by reducing the cost of CF and CF composites. The project team worked to reduce the cost of CF by exploring and testing opportunities for a low-cost alternative precursor material for CF production to supplant market-dominant and costly polyacrylonitrile (PAN). Concurrently, the team aimed to reduce the cost of the tanks at the composite level by improving the interfacial adhesion between the fibers and the matrix resin through the incorporation of low-cost nanoparticles recycled from waste materials, which would reduce the volume of costly CF required to achieve the same tank performance. At the end of the first year, the project team selected mesophase pitch as the primary precursor candidate from a field of materials based on the superior mechanical performance and cost-saving potential. During the second year, the team produced CFs derived from mesophase pitch achieving an average tensile strength of 365.6 ksi and average tensile modulus of 40.74 Msi. Facility availability for spinning and converting these fibers at greater scale has hindered scale-up demonstration, but the team has identified opportunities to conduct this work in the near term. Cost modeling shows that these mesophase pitch-derived CFs can be up to 40% less expensive than PAN-derived CFs due to the lower cost of the feedstock material, higher throughput, greater conversion yield, and lower cost spinning method and compared to PAN. Additionally, the team has demonstrated at lab-scale that nanoparticle coating CFs can significantly increase the interfacial shear strength and load transfer efficiency of CFs in a matrix. Single filament pull-out testing showed a 27% average increase in max interfacial shear strength due to this coating. A continuous method of applying these coatings to a tow of CF has been developed for scale-up. 26 m tows of coated CFs were produced using this system and formed into composite ring samples for ASTM ring burst testing. Issues with the testing protocol have limited assessment of these results. A prototype Type IV tank was designed to meet ANSI HGV2 standards, and the design criteria set out by DOE, using the CF properties developed by the team paired with a proprietary resin matrix, a polyamide liner, and aluminum end bosses. The tank weighs 153.1 kg and with a total capacity of 5.8 kg H2 (5.6 kg usable), which yields a gravimetric capacity of 1.17 kWh/kg. Cost modeling predicts that the tank will have a projected cost of $15.73/kWh. Tank performance modeling does not include considerations for fiber-matrix load transfer efficiency improvements offered by nanoparticle coating method.

08 HYDROGEN↗
NASA NTRS1972

Development of lightweight graphite/polyimide sandwich panels, phases 3, 4 and 5

Work performed in the last three phases of the program included: (1) face sheet processing; (2) honeycomb core manufacture; (3) face sheet-to-core bonding development; and (4) sandwich panel fabrication and testing. Resin cure studies were a major portion of this effort since processing problems traced to the polyimide matrix resin had to be resolved before quality core and face sheets could be fabricated. Honeycomb core fabrication and testing were conducted by Hexcel Corporation. A total of four graphite/polyimide resin composite cores were fabricated, tested, and reported. Two sandwich panels weighing .48 and .58 lb/sq ft, respectively were designed and fabricated which meet the support structure loads for the shuttle orbiter thermal protection system.

Merlette, J. B.↗
NASA NTRS1978

CODSTRAN: Composite durability structural analysis

CODSTRAN (COmposite Durability STRuctural ANalysis) is an integrated computer program being developed for the prediction of defect growth and fracture of composite structures subjected to service loads and environments. CODSTRAN is briefly described with respect to organization, capabilities and present status. Application of CODSTRAN current capability to a flat composite laminate with a center slit which was subjected to axial tension loading predicted defect growth which is in good agreement with C-scan ultrasonic test records.

Chamis, C. C.↗
NASA NTRS1988

The viscoplastic behavior of SCS6/Ti-15-3 metal matrix composite materials at elevated temperatures

Titanium-based metal matrix composite materials (MMC'S) are being considered for use in the National Aerospace Plane. It is expected that these materials will be subjected to temperatures ranging up to about 820 C (1500 F). The present study was a preliminary investigation intended to quantify the level of viscoplastic behavior exhibited by SCS6/Ti-15-3 MMC's at elevated temperatures. The study consisted of a series of uniaxial creep/creep recovery tests. These tests were conducted in air at a temperature of 535 C (1000 F). Three distinct types of specimens were tested: Ti-15-3 heat matrix specimens (O2/plus or minus 45) sub s composite specimens, and (90 sub 2/plus or minus 45) sub s composite specimens. Tensile loads were applied to the specimens using a lever-arm creep frame equipped with a high temperature furnace. Specimen creep stains were monitored using an LVDT-based extensometer.

Tuttle, Mark E.↗
NASA NTRS1989

Sustained load behavior of graphite/epoxy metal-lined pressure vessels for long-life space applications

Tests were performed on candidate graphite yarns for the overwraps to be used on the Space Station Freedom's pressure vessels. The objective was to determine the performance and ranking of these overwraps to ensure that sustained loads would not be a problem during their 30-yr life in space. Tests were conducted at high stress levels for short time periods on subscale composite bottles. The average delivered fiber stresses were determined from the measured burst pressures via SCI analysis that accounts for both geometry and the properties of the resin and yarn.

Babel, H. W.↗
NASA NTRS2018

Composite Technology for Exploration (CTE)

Technology Product Capability: The CTE (Composite Technology for Exploration) project will develop and demonstrate critical composites technologies with a focus on weight-saving, performance-enhancing bonded joint technology for Space Launch System (SLS)-scale composite hardware to support future NASA exploration missions - Improve the analytical capabilities required to predict failure modes in composite structures; - and, Support SLS payload adapters and fittings by maturing composite bonded joint technology and analytical tools to enable risk reduction. Exploration & Science Impact: Lighter weight structures; Improved material predictive capabilities; Improved bonded joint failure load and mode predictions to help reduce knockdown factors; and improve predictability and reliability; Increase confidence of all bonded joint composite structures; Reduce reliance on expensive testing.

CTE↗
NASA NTRS1992

Effect of contact stresses in four-point bend testing of graphite/epoxy and graphite/PMR-15 composite beams

The results of in-plane four-point bend experiments on unidirectionally reinforced composite beams are presented for graphite/epoxy (T300/934) and graphite/polyimide (G30-500/PMR-15) composites. The maximum load and the location of cracks formed during failure were measured for testpieces with fibers oriented at various angles to the beam axis. Since most of the beams failed near one or more of the load points, the strength of the beams was evaluated in terms of a proposed model for the local stress distribution. In this model, an exact solution to the problem of a localized contact force acting on a unidirectionally reinforced half plane is used to describe the local stress field. The stress singularity at the load points is treated in a manner similar to the stress singularity at a crack tip in fracture mechanisms problems. Using this approach, the effect of fiber angle and elastic material properties on the strength of the beam is described in terms of a load intensity factor. For fiber angles less than 45 deg from the beam axis, a single crack is initiated near one of the load points at a critical value of the load intensity factor. The critical load intensity factor decreases with increasing fiber angle. For larger fiber angles, multiple cracks occur at locations both near and away from the load points, and the load intensity factor at failure increases sharply with increasing fiber angle.

Binienda, W. K.↗
NASA NTRS1992

The effect of contact stresses in four-point bend testing of graphite/epoxy and graphite/PMR-15 composite beams

The results of in-plane four-point bend experiments on unidirectionally reinforced composite beams are presented for graphite/epoxy (T300/934) and graphite/polyimide (G30-500/PMR-15) composites. The maximum load and the location of cracks formed during failure were measured for testpieces with fibers oriented at various angles to the beam axis. Since most of the beams failed near one or more of the load points, the strength of the beams was evaluated in terms of a proposed model, for the local stress distribution. In this model, an exact solution to the problem of a localized contact force acting on a unidirectionally reinforced half plane is used to describe the local stress field. The stress singularity at the load points is treated in a manner similar to the stress singularity at a crack tip in fracture mechanisms problems. Using this approach, the effect of fiber angle and elastic material properties on the strength of the beam is described in terms of a load intensity factor. For fiber angles less than 45 deg from the beam axis, a single crack is initiated near one of the load points at a critical value of the load intensity factor. The critical load intensity factor decreases with the increasing fiber angle. For larger fiber angles, multiple cracks occur at locations both near and away from the load points, and the load intensity factor at failure increases sharply with increasing fiber angle.

Binienda, Wieslaw K.↗