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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 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Prater, Tracie↗
DOE OSTI2025

Electric dipole excitations near the neutron separation energies in 96 Mo

Electric dipole strength near the neutron separation energy significantly impacts nuclear structure properties and astrophysical scenarios. These excitations are complex in nature and may involve the so-called pygmy dipole resonance (PDR). Transition densities play a crucial role in understanding the nature of nuclear excited states, including collective excitations, as well as in constructing transition potentials in DWBA or coupled-channels equations. In this work, we focus on electric dipole excitations in spherical molybdenum isotopes, particularly 96 Mo, employing fully consistent Hartree-Fock-Bogoliubov (HFB) and Quasiparticle Random Phase Approximation (QRPA) methods. We analyze the dipole strength near the neutron separation energy, which represents the threshold for neutron capture processes, and examine the isospin characteristics of PDR states through transition density calculations. Examination of proton and neutron transition densities reveals distinctive features of each dipole state, indicating their isoscalar and isovector nature. We observe that the primary component in the enhanced low-energy region exhibits isovector character. The PDR displays a mixture of isoscalar and isovector nature, distinguishing it from the isovector giant dipole resonance (IVGDR). These findings lay the groundwork for future investigations into the role of transition densities in reaction models and for their application to inelastic scattering calculations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Hybrid data-driven cement-stabilized soil design: An integration of machine learning, multi-objective optimization, and life cycle assessment

Soil stabilization is crucial in geotechnical engineering, yet conventional methods are often time-consuming, resource-intensive, and environmentally unsustainable. Despite growing interest in Machine Learning (ML) and optimization tools for mix design, few studies integrate these methods with decision-making techniques and environmental assessment to support practical implementation. This study proposes a hybrid data-driven framework for predicting strength, optimizing mix compositions, and evaluating environmental impacts via life cycle assessment of cement-stabilized soft soils. Six ML models were evaluated, and the top-performing eXtreme Gradient Boosting (XGB) model was further improved using the Grey Wolf Optimizer (GWO). The optimized XGB-GWO model, integrated with a polynomial cost function, served as the objective function in a multi-objective optimization problem solved via the Non-Dominated Sorting Genetic Algorithm II (NSGA-II), with final mix selection guided by the entropy-weighted TOPSIS method. Validation through a case study produced mix designs offering superior strength-cost trade-offs, with the optimal mix achieving 2243.2 kPa unconfined compressive strength and a 16.07 % reduction in carbon emissions compared to the highest-cost design. In conclusion, this study offers a sustainable, scalable approach to soil stabilization and supports informed decision-making in construction.

Life cycle assessment↗
DOE OSTI2019

Effects of Multiple Laser Peening impacts on Mechanical Properties and Microstructure Evolution of 40CrNiMo Steel

The effects of multiple laser peening impacts on mechanical properties and microstructure of 40CrNiMo steel were investigated. The surface residual stress and microhardness of the samples with different treatments were measured. The surface morphologies, tensile behavior and microstructure of the samples before and after laser peening were compared and analyzed. The experimental results showed that laser peening, especially multiple laser peening impacts has significant effects on the microhardness, residual stress and microstructure of 40CrNiMo steel. The surface roughness and the depth of the pit increased with increasing the impact times. After 3 laser peening impacts, the surface microhardness, compressive residual stress, the strength and ductility were significantly improved. Meanwhile, some microstructures, such as sub-grains, the precipitation of carbide and dislocations were also induced in the surface layer. Additionally, the microscopic strengthening mechanism of multiple laser peening impacts on the mechanical properties of 40CrNiMo steel was analyzed in detail.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Impact resistance and interlaminar fracture toughness of through-the-thickness reinforced graphite/epoxy

Five through-the-thickness stitch configurations are analyzed to determine the effect of impact resistance and interlaminar fracture toughness on T3000/3501-6 graphite/epoxy. The test specimens were stitched with either polyester or Kevlar yarns and with various stitch parameters. Tension and compression mechanical, impact and compression-after-impact, and double cantilever beam tests were conducted. It is observed that the stitched laminates have tension and compression strengths 20-25 percent lower than the strengths of unstitched laminates, the tension strength of stitched laminates is reduced with increasing number of stitches, and the compression strength increases as the number of stitches are increased. The impact data reveal that the Kevlar stitched laminates have less damage than unstitched laminates; the most effective configuration for suppressing impact damage and improving interlaminar fracture toughness consists of Kevlar yarns 1/4 inch apart with eight stitches per inch. The mode 1 critical strain energy release rate for the 1/4 inch Kevlar eight stitch laminate was calculated as 30 times higher than that of the unstitched.

Dexter, H. B.↗
DOE OSTI2024

Adhesion in thermomechanically processed seaweed-lignocellulosic composite materials

The increasing concerns associated with petroleum-derived polymers motivate the development of sustainable, renewably sourced alternatives. In ubiquitous applications such as structural materials for infrastructure, the built environment as well as packaging, where natural materials such as wood are used, we rely on nonrenewable and nondegradable polymers to serve as adhesives. In wood panels, such as medium density fiberboards (MDFs), formaldehyde-based resins are predominantly used to bond wood fibers and to provide strength to the materials. To further mitigate the environmental impact of construction materials, more sustainable adhesives need to be investigated. Here, in this article, we introduce Ulva seaweed as an adhesive to enable cohesion and strength in hot-pressed wood panels. Upon hot-pressing, powdered Ulva flows in between the wood particles, generating a matrix, which provides strong binding. We show that the flexural strength of Ulva-bonded wood biocomposites increases with increasing Ulva concentrations. At an Ulva concentration of 40 wt%, our composites reach an average elastic modulus of 6.1 GPa, and flexural strength of 38.2 MPa (compared to 4.7 GPa and 22.6 MPa, respectively, for pure wood compressed at the same pressing conditions). To highlight the bonding mechanisms, we performed infrared and x-ray photoelectron spectroscopy and identified indications of fatty acid mobility during hot-pressing. In addition, we demonstrate that the presence of Ulva improves other properties of the composites such as water resistance and fame retardancy. Ulva is also shown to behave as an excellent adhesive agent between two prepressed beams. Finally, we perform an in-depth analysis of the environmental impact of wood-Ulva biocomposites.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Scaling of impact damage in fiber composites

Impact damage in fiber composite structures remains of much concern, and is often the limiting factor in establishing allowable strain levels. The complexity of impact damage formation usually dictates that experiments are required, but scaling of results from small laboratory scale specimens to large structures introduces additional uncertainty into the analysis. This presentation gives the results of an analytical and experimental investigation intended to develop procedures for prediction of damage formation and subsequent strength loss, with particular emphasis on scaling of results with respect to structure size. The experimental investigation involved both drop-weight and airgun impact on carbon/epoxy plates and cylinders. Five sizes of plates ranging from 50 by 50 by 1.072 mm to 250 by 250 by 5.36 mm, and two sizes of cylinders with diameters of 96.5 and 319 mm, were employed in the experimental program. Impact tests were carried out over a range of impact conditions, and specimens were inspected for damage by C-scan and deplying. Analysis procedures were developed for both quasistatic and dynamic impacts for both the plates and cylinders. As has been reported previously, comparison of predicted structural response and measured surface strains was quite good over the entire range of sizes employed in the program. The damage formation and strength loss after impact showed a number of interesting features that are significant with respect to scaling of size. The extent of delamination was observed to increase with specimen size more than would be expected if stresses controlled the delamination extent. This was explained on the basis that delamination is controlled by energy release rates, and thus incorporates the usual dependence on the absolute size characteristic of fracture mechanics. Additionally, the experiments indicated that delamination initiated at matrix cracks and is dependent on the absolute size of the ply group thicknesses. Both the initiation and propagation of delamination are seen to be controlled by fracture mechanics parameters, and thus show specific dependence on size that must be accounted for in extrapolating results from laboratory scale tests to full size structures.

Swanson, Stephen R.↗
NASA NTRS1992

Hypervelocity impact damage tolerance of fused silica glass

A test program was conducted at the NASA/Johnson Space Center (JSC) concerning hypervelocity impact damage in fused silica glass. The objectives of this test program were: to expand the penetration equation data base in the velocity range between 2 and 8 km/s; to determine how much strength remains in a glass pane that has sustained known impact damage; and to develop a relationship between crater measurements and residual strength predictions that can be utilized in the Space Shuttle and Space Station programs. The results and conclusions of the residual strength testing are discussed below. Detailed discussion of the penetration equation studies will follow in future presentations.

Edelstein, K. S.↗
DOE OSTI2021

Back Cover: Influence of Intracrystalline Ionic Strength in MFI Zeolites on Aqueous Phase Dehydration of Methylcyclohexanols (Angew. Chem. Int. Ed. 47/2021)

Here the impact of the concentration of hydrated hydronium ions and in turn of the local ionic strength in MFI zeolites has been investigated for the aqueous phase dehydration of 4-methylcyclohexanol (E1 mechanism) and cis-2-methylcyclohexanol (E2 mechanism). The E2 pathway with the latter alcohol led to a 2.5-fold higher activity. The catalytic activity normalized to the hydronium ions (turnover frequency, TOF) passed through a pronounced maximum, which is attributed to the increasing excess chemical potential of the alcohols in the pores, increasing in parallel with the ionic strength and the additional work caused by repulsive interactions and charge separation induced by the bulky alcohols. While the maximum in rate observed is invariant with the mechanism or substitution, the reaction pathway is influencing the activation parameters differently.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2001

Impact Cratering Calculations

We examined the von Mises and Mohr-Coulomb strength models with and without damage effects and developed a model for dilatancy. The models and results are given in O'Keefe et al. We found that by incorporating damage into the models that we could in a single integrated impact calculation, starting with the bolide in the atmosphere produce final crater profiles having the major features found in the field measurements. These features included a central uplift, an inner ring, circular terracing and faulting. This was accomplished with undamaged surface strengths of approximately 0.1 GPa and at depth strengths of approximately 1.0 GPa. We modeled the damage in geologic materials using a phenomenological approach, which coupled the Johnson-Cook damage model with the CTH code geologic strength model. The objective here was not to determine the distribution of fragment sizes, but rather to determine the effect of brecciated and comminuted material on the crater evolution, fault production, ejecta distribution, and final crater morphology.

Ahrens, Thomas J.↗
DOE OSTI2024

Experiments and Simulations of the Dusty Properties of Hypervelocity Impact Plasmas

Hypervelocity impacts, referring to impacts occurring at several times the speed of sound in the target, result in inertial stresses greatly exceeding the material strength and produce behavior that is not fully understood. These impact phenomena are seen in space through impacts of orbital debris and meteoroids on spacecraft and airless natural bodies but can also be produced in laboratory environments using light-gas guns and electrostatic dust accelerators. When a hypervelocity impact occurs, plasma is generated both from thermal ionization and from pressure ionization, producing a wide range of plasma densities depending on the impactor’s velocity. This plasma is initially formed in the warm dense matter (WDM) regime and governed by high energy density (HED) hydrodynamics before it rapidly expands and dissipates, spanning many orders of magnitude in density and length scale. The plasma can also contain a dust component, which is particularly relevant for the lower-velocity range of hypervelocity impacts with parameters that are particularly relevant to Tokamak plasmas. Therefore, the properties and dynamics of these plasmas cannot be fully characterized without considering dusty plasma effects, which are ubiquitous but poorly understood.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2020

Durability Characterization of Low Ice Adhesion and Impact Resistance Coatings

Glaze, rime and mixed icing conditions can cause significant variation in aerodynamic performance, fuel efficiency, and flight safety. For commercial aircraft, active icing mitigation strategies are utilized to enable safe flight within icing conditions according to the FAR Part 25/29 Appendix C icing envelope. For general aviation and unmanned aerial vehicles that cannot support active anti-icing technologies, avoidance is the only recourse. Passive approaches have been investigated to reduce weight and energy consumption for active systems and to expand the operational envelope for smaller aircraft. Coatings are one passive method to reduce or mitigate ice accretion on frontal surfaces of commercial aircraft with the greatest region of interest being wing leading edges. Aircraft wing leading edges represent an extreme environment. Durability must be considered for any material to be applied as a coating in this area. Currently, there are no specifications regarding coating durability of a low ice adhesion material applied on the wing leading edge. Therefore, a reasonable starting point is to use the durability specifications put forth for an aircraft external coating. Besides the tests called out in these specifications, others were included such as Taber abrasion to simulate wear and erosion. Beyond durability, performance metrics with regards to adhesion strength of accreted in-flight (i.e., impact) icing are central to determine coating usefulness. Determination of this property though is particularly challenging and only a few facilities have the capability to quantify this. An instrument at NASA Langley Research Center [Adverse Environment Rotary Test Stand Jr., (AERTS Jr.)], based on the AERTS system at The Pennsylvania State University, allows for screening numerous coatings subjected to the icing environment. To establish a benchmark for comparison with research coatings, a state-of-the-art (SOA) commercial aircraft coating was subjected to an array of salient durability and performance experiments. The same tests were conducted using a baseline epoxy (BE) resin formulation that demonstrated some initial promising results for comparison. Results from this initial screening will be discussed herein.

Miranda L Beaudry↗
NASA NTRS1981

Low-velocity impact tests on fibrous composite sandwich structures

The effect of low-velocity projectile impact on the load-carrying ability of the composite sandwich structural components is investigated experimentally, the impact simulating the damage caused by runway debris and the accidental dropping of hand tools during servicing on secondary aircraft structures made with composites. The sandwich-type beam specimens were fabricated with graphite/epoxy face sheets, aluminum honeycomb core, and a steel (back) plate. A four-point beam-loading apparatus was used, and the ultimate strength, ultimate strain, and residual strength of the composites were determined. A faired curve is presented indicating the lower bound of the failure threshold for each of the laminate configurations tested in compression and tension as a function of the projectile impact energy. It is shown that strength degradation due to impact is dependent on the laminate configuration and the fiber/matrix combination. The laminates having more angle plies near the impact surface and unidirectional plies elsewhere seem to show extensive interply and intraply fiber delaminations at failure relative to the laminates with a cross-ply on the impact surface.

Sharma, A. V.↗
DOE OSTI2021

Effect of rice husk ash-derived activator on the structural build-up of alkali activated materials

Highlights: • Filtered and unfiltered sodium silicate solutions were synthesised from RHA. • The dissolution efficiency of RHA in NaOH solution was 76.3%. • RHA-derived activator showed a structural build-up comparable to the commercial activator in AAM pastes. • The undissolved residues in the unfiltered RHA-derived activator increased the yield stress. • Comparable compressive strength and early age gel formation were observed from both commercial and RHA-derived solutions. Waste-derived sodium silicates (SSs) were synthesised from rice husk ash (RHA) to produce alkali activated materials (AAMs) using fly ash and slag as precursors. The effects of these SSs on the structural build-up were investigated by monitoring the evolution of the viscoelasticity, ultrasonic pulse waves, setting time, and infrared spectra. Two types of RHA derived SSs (filtered SS and unfiltered SS) were prepared to investigate the effect of the undissolved residue on the hardening process. The derived SS contained a large portion of monomer silicate species. The results showed that the structural build-up mechanism was comparable between the AAMs activated by the filtered SS and a commercial SS. The unfiltered SS increased the yield stress of the paste by up to 10 times. However, the residues in the unfiltered SS had insignificant impacts on the gel formation and compressive strength when using identical SiO{sub 2}/Na{sub 2}O and Na{sub 2}O/binder ratios in the mix design.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Influence of weakening minerals on ensemble strength and slip stability of faults: Influence of Weakening Minerals on Fault

We explore the impact of phyllosilicate (weak but velocity strengthening) in a majority tectosilicate (strong but velocity weakening) matrix on bulk shear strength and slip stability of faults. Numerical simple shear experiments using a distinct element model (DEM) are conducted on both uniform mixtures of quartz and talc analogs and on textured mixtures consisting of a talc layer embedded in a quartz matrix. The mechanical response of particles is represented by a linear elastic contact model with a slip-weakening constitutive relation representing the essence of rate-state friction. The weight percentage of the talc in the uniform mixtures and the relative thickness of the talc layer in the textured mixtures are varied to investigate the transitional behavior of shear strength and slip stability. Specifically, for uniform mixtures, ~50% reduction on bulk shear strength is observed with 25% talc present, and a dominant influence of talc occurs at 50%; for textured mixtures, a noticeable weakening effect is shown at a relative layer thickness of 1 particle, ~50% shear strength reduction is observed with 3-particles, and a dominant influence occurs at 5 particles. In terms of slip stability, a transition from velocity weakening to velocity strengthening is observed with 10% to 25% talc present in the uniform mixtures or with 3 particles to 5 particles in the textured mixtures. In addition, further analysis suggests that quartz has a high tendency toward dilation, potentially promoting permeability; while talc dilates with increased slip rate but compacts rapidly when slip rate is reduced, potentially destroying permeability. The simulation results match well with previous laboratory observations.

58 GEOSCIENCES↗
DOE OSTI2022

Characterization of a 1D-imaging high-energy x-ray backlighter driven by the National Ignition Facility Advanced Radiographic Capability laser

Plastic deformation of samples compressed to Mbar pressures at high strain rates at the National Ignition Facility (NIF) forms the basis of ongoing material strength experiments in conditions relevant to meteor impacts, geophysics, armor development, and inertial confinement fusion. Hard x-ray radiography is the primary means of measuring the evolution of these samples, typically employing a slit-collimated high-Z microdot driven by the NIF laser to generate >40 keV x rays [E. Gumbrell et al., Rev. Sci. Instrum. 89, 10G118 (2018) and C. M. Huntington et al., Rev. Sci. Instrum. 89, 10G121 (2018)]. Alternatively, a dysprosium “micro-flag” target driven by the Advanced Radiographic Capability laser (~2 kJ, 10 ps) can deliver significantly higher spatiotemporal resolution [M. P. Hill et al., Rev. Sci. Instrum. 92, 033535 (2021)], especially in high-opacity samples. Here, initial experiments revealed problematic brightness and spectral gradients from this source, but by radiographing a set of diamond-turned, 105 µm-thick Pb test objects and supported by simulations using the 3D Monte Carlo code GEANT4, these geometry-dependent gradients across the field of view are quantified and mitigation strategies are assessed. In addition to significantly enhancing the modulation transfer function compared to the existing system, image stacking from multiple layers of image plate is shown to almost double the signal to noise ratio that will reduce uncertainties in future dynamic strength experiments.

47 OTHER INSTRUMENTATION↗
NASA NTRS1998

Global Failure Modes in High Temperature Composite Structures

Composite materials have been considered for many years as the major advance in the construction of energy efficient aerospace structures. Notable advances have been made in understanding the special design considerations that set composites apart from the usual "isotropic" engineering materials such as the metals. As a result, a number of significant engineering designs have been accomplished. However, one shortcoming of the currently favored composites is their relatively unforgiving behavior with respect to failure (brittleness) under seemingly mild impact conditions and large efforts are underway to rectify that situation, much along the lines of introducing thermoplastic matrix materials. Because of their relatively more pronounced (thermo) viscoelastic behavior these materials respond with "toughness" in fracture situations. From the point of view of applications requiring material strength, this property is highly desirable. This feature impacts several important and distinct engineering problems which have been' considered under this grant and cover the 1) effect of impact damage on structural (buckling) stability of composite panels, the 2) effect of time dependence on the progression of buckling instabilities, and the 3) evolution of damage and fracture at generic thickness discontinuities in structures. The latter topic has serious implications for structural stability problems (buckling failure in reinforced shell structures) as well as failure progression in stringer-reinforced shell structures. This grant has dealt with these issues. Polymer "toughness" is usually associated with uncrosslinked or thermo-plastic polymers. But, by comparison with their thermoset counterparts they tend to exhibit more pronounced time dependent material behavior; also, that time dependence can occur at lower temperatures which places restriction in the high temperature use of these "newer and tougher" materials that are not quite so serious with the thermoset matrix materials. From a structural point of view the implications of this material behavior are potentially severe in that structural failure characteristics are no longer readily observed in short term qualification tests so characteristic for aerospace structures built from typical engineering metals.

Knauss, W. G.↗
NASA NTRS1998

Cross Sections for Electron Impact Excitation of Ions Relevant to Planetary Atmospheres Observation

The goal of this research grant was to calculate accurate oscillator strengths and electron collisional excitation strengths for inelastic transitions in atomic species of relevance to Planetary Atmospheres. Large scale configuration-interaction atomic structure calculations have been performed to obtain oscillator strengths and transition probabilities for transitions among the fine-structure levels and R-matrix method has been used in the calculations of electron-ion collision cross sections of C II, S I, S II, S III, and Ar II. A number of strong features due to ions of sulfur have been detected in the spectra of Jupiter satellite Io. The electron excitation cross sections for the C II and S II transitions are studied in collaboration with the experimental atomic physics group at the Jet Propulsion Laboratory. There is excellent agreement between experiment and theory which provide an accurate and broad-base test of the ability of theoretical methods used in the calculation of atomic processes. Specifically, research problems have been investigated for: electron impact excitation cross sections of C II: electron impact excitation cross sections of S III; energy levels and oscillator strengths for transitions in S III; collision strengths for electron collisional excitation of S II; electron impact excitation of inelastic transitions in Ar II; oscillator strengths of fine-structure transitions in neutral sulfur; cross sections for inelastic scattering of electrons from atomic nitrogen; and excitation of atomic ions by electron impact.

Tayal, Swaraj S.↗