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DOE OSTI2022

Development of Lightweight Structural Materials with Improved Properties for Fission Batteries

Fission batteries require lightweight structural materials that demonstrate structural resilience when subjected to repeated shutdown, transportation, startup cycles, and certain external conditions, including rare events such as seismic vibrations and tsunamis. The objectives of this project are (1) to produce lightweight structural materials whose strength-to-weight ratios and fatigue resistance exceed those of current widely used structural materials such as 316 stainless steels (SS316), and (2) to enhance radiation tolerance of structural materials over a suitable service temperature range. To achieve these, (1) a lattice structure will be produced, (2) advanced modeling and simulation tools will be employed to design lattice structures (e.g., a gyroid structure) that reduce stress concentrations and thus increase fatigue resistance, and (3) one-dimensional (1-D) carbon nanotubes will be added to enhance radiation resistance. To validate our solution, high-temperature tensile and fatigue testing, in combination with microstructure characterization, will be conducted on wrought materials, additively manufactured solid materials, and the designed lightweight lattice structure material. Ion irradiation, microstructure characterization, and nanoindentation will be carried out to investigate the effect of 1-D carbon nanotubes on radiation tolerance. Successful completion of this project will deliver a material to serve as a substitute for current SS316 using the same chemistry but with lighter weight and improved mechanical properties. In addition, a material with carbon nanotubes can be designed for improved radiation tolerance over a suitable service temperature range. This project will establish new techniques in innovative materials/lattice design, advanced macroscale properties prediction, and the application of state-of-the-art processes.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Evaluation of 304L stainless steel deformation and failure under cyclic loading

The motivation for this work came from the simulation of components subjected to impact. In these problems, repeated loading can be generated by vibrational motion between internal parts of the component or by the occurrence of multiple impacts. Graphs of tensile equivalent plastic strain $(\overline{\varepsilon}_T^\rho)$ versus time from such cases had the character shown in Fig. 1. The equivalent plastic strain grew by alternating periods of accumulation and hold. The periods of hold indicate times when $d\overline{\varepsilon}_T^\rho$ did not accumulate. This can be due to the material unloading into the elastic range, or actually plastically reverse loading with hydrostatic stress σ h < 0 as was demonstrated for an impact simulation. Similar observations were made from the simulation of a 2-degree-of-freedom mass-elastic-plastic-spring system subjected to impact.

36 MATERIALS SCIENCE↗

NASA NTRS1956

Interim Report on Fatigue Characteristics of a Typical Metal Wing

Constant amplitude fatigue tests of seventy-two P-51D "Mustang" wings are reported. The tests were performed by a vibrational loading system and by an hydraulic loading device for conditions with and without varying amounts of pre-load. The results indicate that: (a) the frequency of occurrence of fatigue at any one location is related to the range of the loads applied, (b) the rate of propagation of visible cracks is more or less constant for a large portion of the life of the specimen, (c) the fatigue strength of the structure is similar to that of notched material having a theoretical stress concentration factor of more than 3.0, (d) the frequency distribution of fatigue life is approximately logarithmic normal, (e) the relative increase in fatigue life for a given pre-load depends on the maximum load of the loading cycle only, while the optimum pre-load value is approximately 85 percent of the ultimate failing load, and (f) that normal design procedure will not permit the determination of local stress levels with sufficient accuracy to determine the fatigue strength of an element of a redundant structure.

LOADS AND STRESSES, STRUCTURAL - REPEATED DYNAMIC↗

NASA NTRS2003

Fabricating Composite-Material Structures Containing SMA Ribbons

An improved method of designing and fabricating laminated composite-material (matrix/fiber) structures containing embedded shape-memory-alloy (SMA) actuators has been devised. Structures made by this method have repeatable, predictable properties, and fabrication processes can readily be automated. Such structures, denoted as shape-memory-alloy hybrid composite (SMAHC) structures, have been investigated for their potential to satisfy requirements to control the shapes or thermoelastic responses of themselves or of other structures into which they might be incorporated, or to control noise and vibrations. Much of the prior work on SMAHC structures has involved the use SMA wires embedded within matrices or within sleeves through parent structures. The disadvantages of using SMA wires as the embedded actuators include (1) complexity of fabrication procedures because of the relatively large numbers of actuators usually needed; (2) sensitivity to actuator/ matrix interface flaws because voids can be of significant size, relative to wires; (3) relatively high rates of breakage of actuators during curing of matrix materials because of sensitivity to stress concentrations at mechanical restraints; and (4) difficulty of achieving desirable overall volume fractions of SMA wires when trying to optimize the integration of the wires by placing them in selected layers only.

Turner, Travis L.↗

NASA NTRS1977

Study of changes in properties of solar sail materials from radiation exposure

Techniques for monitoring changes in preparation of solar sail materials resulting from space radiation simulation, stressing (e.g., thermal, mechanical) and exposure to terrestrial environments are developed. The properties of interest are: metallic coating deterioration, polymeric film deterioration, interfacial debonding and possible metallic coating diffusion into the polymeric film. Four accelerated tests were devised to simulate the possible degradation processes mentioned above. These four tests are: a thermal shock test to simulate the wide variation of temperature expected in space (260 C to -100 C), a cyclic temperature test to stimulate the 6 minute temperature cycle anticipated in space, a mechanical vibration test to simulate mechanical bonding, folding and handling, and a humidity test to simulate terrestrial environment effects. The techniques for monitoring property changes are: visual and microscopic examination, ellipsometry, surface potential difference (SPD), photoelectron emission (PEE), and water contact angles.

Smith, T.↗

NASA NTRS2004

Enhanced Damping for Capillary Bridge Oscillation Using Velocity Feedback

The stability of cylindrical liquid bridges in reduced gravity is affected by ambient vibrations of the spacecraft. Such vibrations are expected to excite capillary modes of the bridge. The lowest-order unstable mode is particularly susceptible to vibration as the length of the bridge approaches the stability limit. This low-order mode is known as the (2,0) mode and is an axisymmetric varicose mode of one wavelength in the axial direction. In this work, an optical system is used to detect the (2,0)-mode amplitude. The derivative of the error signal produced by this detector is used to produce the appropriate voltages on a pair of ring electrodes which are concentric with the bridge. A mode-coupled Maxwell stress profile is thus generated in proportional to the modal velocity. Depending on the sign of the gain, the damping of the capillary oscillation can be either increased or decreased. This effect has been demonstrated in Plateau-tank experiments. Increasing the damping of the capillary modes on free liquid surfaces in space could be beneficial for containerless processing and other novel technologies. [work supported by NASA]

Wei, Wei↗

NASA NTRS2004

Enhanced Damping for Capillary Bridge Oscillation Using Velocity Feedback

Wei, Wei↗

NASA NTRS1979

Experimental evaluation of the effect of inlet distortion on compressor blade vibrations

Compressor rotor strain gage data from an engine test conducted with an inlet screen distortion were reduced and analyzed. The data were compared to results obtained from the same engine without inlet pressure distortion to determine the net effect of the distortion on the vibratory response of the compressor blades. The effect of the distortion was found to be most prominent in the first three compressor stages, with the rotor speed establishing the period of the complex wave and, consequently, the frequencies of all the higher engine order excitations. At certain speeds it was observed that the complex pressure wave had the frequency content to excite a number of modes simultaneously, although the overall magnitudes were small and well within allowable stress limits.

Lubomski, J. F.↗

DOE OSTI2015

Vibrational modes of ultrathin carbon nanomembrane mechanical resonators

We report measurements of vibrational mode shapes of mechanical resonators made from ultrathin carbon nanomembranes (CNMs) with a thickness of approximately 1 nm. CNMs are prepared from electron irradiation induced cross-linking of aromatic self-assembled monolayers and the variation of membrane thickness and/or density can be achieved by varying the precursor molecule. Single- and triple-layer freestanding CNMs were made by transferring them onto Si substrates with square/rectangular orifices. The vibration of the membrane was actuated by applying a sinusoidal voltage to a piezoelectric disk on which the sample was glued. The vibrational mode shapes were visualized with an imaging Mirau interferometer using a stroboscopic light source. Several mode shapes of a square membrane can be readily identified and their dynamic behavior can be well described by linear response theory of a membrane with negligible bending rigidity. By applying Fourier transformations to the time-dependent surface profiles, the dispersion relation of the transverse membrane waves can be obtained and its linear behavior verifies the membrane model. By comparing the dispersion relation to an analytical model, the static stress of the membranes was determined and found to be caused by the fabrication process.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2003

Effects of broad frequency vibration on cultured osteoblasts

Bone is subjected in vivo to both high amplitude, low frequency strain, incurred by locomotion, and to low amplitude, broad frequency strain. The biological effects of low amplitude, broad frequency strain are poorly understood. To evaluate the effects of low amplitude strains ranging in frequency from 0 to 50 Hz on osteoblastic function, we seeded MC3T3-E1 cells into collagen gels and applied the following loading protocols for 3 min per day for either 3 or 7 days: (1) sinusoidal strain at 3 Hz, with 0-3000 microstrain peak-to-peak followed by 0.33 s resting time, (2) "broad frequency vibration" of low amplitude strain (standard deviation of 300 microstrain) including frequency components from 0 to 50 Hz, and (3) sinusoidal strain combined with broad frequency vibration (S + V). The cells were harvested on day 4 or 8. We found that the S + V stimulation significantly repressed cell proliferation by day 8. Osteocalcin mRNA was up-regulated 2.6-fold after 7 days of S + V stimulation, and MMP-9 mRNA was elevated 1.3-fold after 3 days of vibration alone. Sinusoidal stimulation alone did not affect the cell responses. No differences due to loading were observed in alkaline phosphatase activity and in mRNA levels of type I collagen, osteopontin, connexin 43, MMPs-1A, -3, -13. These results suggest that osteoblasts are more sensitive to low amplitude, broad frequency strain, and this kind of strain could sensitize osteoblasts to high amplitude, low frequency strain. This suggestion implies a potential contribution of stochastic resonance to the mechanical sensitivity of osteoblasts. Copyright 2002 Elsevier Science Ltd.

Non-NASA Center↗

NASA NTRS2013

Environmental Qualification of a Single-Crystal Silicon Mirror for Spaceflight Use

This innovation is the environmental qualification of a single-crystal silicon mirror for spaceflight use. The single-crystal silicon mirror technology is a previous innovation, but until now, a mirror of this type has not been qualified for spaceflight use. The qualification steps included mounting, gravity change measurements, vibration testing, vibration- induced change measurements, thermal cycling, and testing at the cold operational temperature of 225 K. Typical mirrors used for cold applications for spaceflight instruments include aluminum, beryllium, glasses, and glass-like ceramics. These materials show less than ideal behavior after cooldown. Single-crystal silicon has been demonstrated to have the smallest change due to temperature change, but has not been spaceflight-qualified for use. The advantage of using a silicon substrate is with temperature stability, since it is formed from a stress-free single crystal. This has been shown in previous testing. Mounting and environmental qualification have not been shown until this testing.

Hagopian, John↗

NASA NTRS2005

Oscillating-Linear-Drive Vacuum Compressor for CO2

A vacuum compressor has been designed to compress CO2 from approximately equal to 1 psia (approximately equal to 6.9 kPa absolute pressure) to approximately equal to 75 psia (approximately equal to 0.52 MPa), to be insensitive to moisture, to have a long operational life, and to be lightweight, compact, and efficient. The compressor consists mainly of (1) a compression head that includes hydraulic diaphragms, a gas-compression diaphragm, and check valves; and (2) oscillating linear drive that includes a linear motor and a drive spring, through which compression force is applied to the hydraulic diaphragms. The motor is driven at the resonance vibrational frequency of the motor/spring/compression-head system, the compression head acting as a damper that takes energy out of the oscillation. The net effect of the oscillation is to cause cyclic expansion and contraction of the gas-compression diaphragm, and, hence, of the volume bounded by this diaphragm. One-way check valves admit gas into this volume from the low-pressure side during expansion and allow the gas to flow out to the high-pressure side during contraction. Fatigue data and the results of diaphragm stress calculations have been interpreted as signifying that the compressor can be expected to have an operational life of greater than 30 years with a confidence level of 99.9 percent.

Izenson, Michael G.↗

NASA NTRS2001

Transient Reliability Analysis Capability Developed for CARES/Life

The CARES/Life software developed at the NASA Glenn Research Center provides a general-purpose design tool that predicts the probability of the failure of a ceramic component as a function of its time in service. This award-winning software has been widely used by U.S. industry to establish the reliability and life of a brittle material (e.g., ceramic, intermetallic, and graphite) structures in a wide variety of 21st century applications.Present capabilities of the NASA CARES/Life code include probabilistic life prediction of ceramic components subjected to fast fracture, slow crack growth (stress corrosion), and cyclic fatigue failure modes. Currently, this code can compute the time-dependent reliability of ceramic structures subjected to simple time-dependent loading. For example, in slow crack growth failure conditions CARES/Life can handle sustained and linearly increasing time-dependent loads, whereas in cyclic fatigue applications various types of repetitive constant-amplitude loads can be accounted for. However, in real applications applied loads are rarely that simple but vary with time in more complex ways such as engine startup, shutdown, and dynamic and vibrational loads. In addition, when a given component is subjected to transient environmental and or thermal conditions, the material properties also vary with time. A methodology has now been developed to allow the CARES/Life computer code to perform reliability analysis of ceramic components undergoing transient thermal and mechanical loading. This means that CARES/Life will be able to analyze finite element models of ceramic components that simulate dynamic engine operating conditions. The methodology developed is generalized to account for material property variation (on strength distribution and fatigue) as a function of temperature. This allows CARES/Life to analyze components undergoing rapid temperature change in other words, components undergoing thermal shock. In addition, the capability has been developed to perform reliability analysis for components that undergo proof testing involving transient loads. This methodology was developed for environmentally assisted crack growth (crack growth as a function of time and loading), but it will be extended to account for cyclic fatigue (crack growth as a function of load cycles) as well.

Nemeth, Noel N.↗

NASA NTRS1984

Analysis of potential helicopter vibration reduction concepts

Several recent helicopter vibration reduction research programs are described. Results of studies of blade design parameters in rotor vibratory response and of an advanced blade design for reduced vibration are examined. An optimization approach to develop a general automated procedure for rotor blade design is described, and analytical results for an articulated rotor operating at a steady 160 kt flight condition are reported. The use of a self-adaptive controller to implement higher harmonic control in closed-loop fashion is addressed, and a computer simulation used to evaluate and compare the performance of alternative algorithms included in the generic active controller is discussed. Results are presented for steady level flight conditions, short-duration maneuvers, blade stresses and rotor performance, blade-appended aeroelastic devices, vibratory airloads, wake-induced blade airloads, and airloads from blade motions, the interaction of rotor and fuselage, and the interaction of rotor and empennage.

Landgrebe, A. J.↗

DOE OSTI2012

Helium solubility in SON68 nuclear waste glass

Helium behavior in a sodium borosilicate glass (SON68) dedicated to the immobilization of high-level nuclear waste is examined. Two experimental approaches on nonradioactive glass specimens are implemented: pressurized helium infusion experiments and {sup 3}He ion implantation experiments. The temperature variation of helium solubility in SON68 glass was determined and analyzed with the harmonic oscillator model to determine values of the energy of interaction E(0) at the host sites (about -4000 J/mol), the vibration frequency (about 1.7 x 10{sup 11} s{sup -1}), and the density of solubility sites (2.2 x 10{sup 21} sites cm{sup -3}). The implantation experiments show that a non diffusive transport phenomenon (i.e., athermal diffusion) is involved in the material when the helium concentration exceeds 2.3 x 10{sup 21} He cm{sup -3}, and thus probably as soon as it exceeds the density of solubility sites accessible to helium in the glass. We propose that this transport mechanism could be associated with the relaxation of the stress gradient induced by the implanted helium profile, which is favored by the glass damage. Microstructural characterization by TEM and ESEM of glass specimens implanted with high helium concentrations showed a homogeneous microstructure free of bubbles, pores, or cracking at a scale of 10 nm. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2008

Assessment of Proper Bonding Methods and Mechanical Characterization FPGA CQFPs

This presentation discusses fractured leads on field-programmable gate array (FPGA) during flight vibration. Actions taken to determine root cause and resolution of the failure include finite element analysis (FEA) and vibration testing and scanning electron microscopy (with X-ray microanalysis) and energy dispersive spectrometry (SEM/EDS) failure assessment. Bonding methods for surface mount parts is assessed, including critical analysis and assessment of random fatigue damage. Regarding ceramic quad flat pack (CQFP) lead fracture, after disassembling the attitude control electronics (ACE) configuration, photographs showed six leads cracked on FPGA RTSX72SU-1 CQ208B package located on the RWIC card. An identical package (FPGA RTSX32SU-1 CQ208B) mounted on the RWIC did not results in cracked pins due to vibration. FPGA lead failure theories include workmanship issues in the lead-forming, material defect in the leads of the FPGA packages, and the insecure mounting of the board in the card guides, among other theories. Studies were conducted using simple calculations to determine the response and fatigue life of the package. Shorter packages exhibited more response when loaded by out-of-plane displacement of PCB while taller packages exhibit more response when loaded by in-plane acceleration of PCB. Additionally, under-fill did not contribute to reducing stress in leads due to out-of-plane PCB loading or from component twisting, as much as corner bonding. The combination of corner bond and under-fill is best to address mechanical and thermal S/C environment. Test results of bonded parts showed reduced (dampened) amplitude and slightly shifted peaks at the un-bonded natural frequency and an additional response at the bonded frequency. Stress due to PCBB out-of-plane loading was decreased on in the corners when only a corner bond was used. Future work may address CQFP fatigue assessment, including the investigation of discrepancy in predicted fatigue damage, as well as comparing fatigue life and fatigue damage cycle ration computed using FEA and Miner's rule to results from a fatigue assessment software program.

Davis, Milton C.↗

NASA NTRS1998

Effects of microgravity on osteoblast growth

Studies from space flights over the past two decades have demonstrated that basic physiological changes occur in humans during space flight. These changes include cephalic fluid shifts, loss of fluid and electrolytes, loss of muscle mass, space motion sickness, anemia, reduced immune response, and loss of calcium and mineralized bone. The cause of most of these manifestations is not known and until recently, the general approach was to investigate general systemic changes, not basic cellular responses to microgravity. Recently analyzed data from the 1973-1974 Skylabs disclose that there is a rise in the systemic hormone, cortisol, which may play a role in bone loss in flight. In two flights where bone growth was measured (Skylabs 3 and 4), the crew members had a significant loss of calcium accompanied by a rise in 24 hour urinary cortisol during the entire flight period. In ground-based work on osteoblasts, we have demonstrated that equivalent amounts of glucocorticoids can inhibit osteoblast cell growth. In addition, this laboratory has recently studied gene growth and activation of mouse osteoblasts (MC3T3-E1) during spaceflight. Osteoblast cells were grown on glass coverslips, loaded in the Biorack plunger boxes 18 hours before launch and activated 19 hours after launch in the Biorack incubator under microgravity conditions. The osteoblasts were launched in a serum deprived state, activated and collected in microgravity. Samples were collected at 29 hours after sera activation (0-g, n=4; 1-g, n=4). The osteoblasts were examined for changes in gene expression and cell morphology. Approximately one day after growth activation, remarkable differences were observed in gene expression in 0-g and 1-g flight samples. The 0-g activated cells had increased c-fos mRNA when compared to flight 1-g controls. The message of immediate early growth gene, cox-2 was decreased in the microgravity activated cells when compared to ground or 1-g flight controls. Cox-1 was not detected in any of the samples. There were no significant differences in the expression of actin mRNA between the 0-g and 1-g samples. These data indicate that quiescent osteoblasts are slower to enter the cell cycle in microgravity, suggesting that the force of gravity itself may be a significant factor in bone loss in spaceflight. Preliminary data from our STS 76 flight experiment support our hypothesis that a basic biological response occurs at the tissue, cellular, and molecular level in 0-g. Here we examine ground-based and space flown data on osteoblast growth in ground-based experiments mimicking space flight conditions and in microgravity to simulate lack of gravity stress to help us understand the mechanism of bone loss by experiments.

NASA Experiment Number 9403056↗

NASA NTRS1972

Study of effects of design details on structural response to acoustic excitation

The normal mode vibration characteristics of one-dimensional and two-dimensional panel arrays were investigated analytically and experimentally. The finite element displacement method was used to formulate the structural models. The structural models include a stiffness and consistent mass matrix for thin-walled open-section beams not previously reported, and a modification of a rectangular plate bending element to include a fundamental interior mode for the element as a generalized coordinate. Provision for adding lumped masses to represent accelerometers is also included. For the one-dimensional panel, the normal mode stress resultants are obtained by integrating the equilibrium equations directly. For the two-dimensional panel arrays, the solution for the stress resultants in the cover sheet was attempted by introducing stress functions dependent upon the displacement field of the plate element. This approach, although incomplete, is a natural extension of the one-dimensional analysis for plate elements. The exerimental program which was used to verify the analysis is described and experimental results are compared with the analysis.

Rudder, F. F., Jr.↗