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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Ares I-X Upper Stage Simulator Residual Stress Analysis

The structural analyses described in the present report were performed in support of the NASA Engineering and Safety Center (NESC) Critical Initial Flaw Size (CIFS) assessment for the Ares I-X Upper Stage Simulator (USS) common shell segment. An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. The results of this effort served as one of the critical load inputs required to perform a CIFS assessment of the same segment.

Raju, Ivatury S.↗
NASA NTRS2017

A Numerical Study on the Edgewise Compression Strength of Sandwich Structures with Facesheet-Core Disbonds

Damage tolerant design approaches require determination of critical damage modes and flaw sizes in order to establish nondestructive evaluation detection requirements. A finite element model is developed to assess the effect of circular facesheet-core disbonds on the strength of sandwich specimens subjected to edgewise compressive loads for the purpose of predicting the critical flaw size for a variety of design parameters. Postbuckling analyses are conducted in which an initial imperfection is seeded using results from a linear buckling analysis. Both the virtual crack closure technique (VCCT) and cohesive elements are considered for modeling disbond growth. Predictions from analyses using the VCCT and analyses using cohesive elements are in good correlation. A series of parametric analyses are conducted to investigate the effect of core thickness and material, facesheet layup, facesheet-core interface properties, and curvature on the criticality of facesheet-core disbonds of various sizes. The results from these analyses provide a basis for determining the critical flaw size for facesheet-core disbonds subjected to edgewise compression loads and, therefore, nondestructive evaluation flaw detection requirements for this configuration.

Bergan, Andrew C.↗
NASA NTRS1996

Study Thermographic Flaw Detection

The development of thermographic inspection methods for use on aerospace structures is under investigation. Several different material systems, structural geometries and defect types have been included in this study so as to establish a baseline from which future IRT testing can be made. This study examines various thermal loading techniques in an attempt to enhance the likelihood of capturing and identifying critically sized flaws under 'non-laboratory' actual working conditions. Qualification techniques and calibration standards are also being investigated to standardize the thermographic method. In conjunction with the thermographic inspections, advanced image processing techniques including digital filtering and neural networks have been investigated to increase the ability of 91 detecting and sizing flaws. Here, the digitized thermographic images are mathematically manipulated through various filtering techniques and/or artificial neural mapping schemes to enhance its overall quality, permitting accurate flaw identification even when the signal-to-noise ratio is low.

Walker, James L.↗
NASA NTRS1996

Study Thermographic Flaw Detection

The development of thermographic inspection methods for use on aerospace structures is under investigation. Several different material systems, structural geometries and defect types have been included in this study so as to establish a baseline from which future Infrared Thermography(IRT) testing can be made. This study examines various thermal loading techniques in an attempt to enhance the likelihood of capturing and identifying critically sized flaws under 'non laboratory' actual working conditions. Qualification techniques and calibration standards are also being investigated to standardize the thermographic method. In conjunction with the thermographic inspections, advanced image processing techniques including digital filtering and neural networks have been investigated to increase the ability of detecting and sizing flaws. Here, the digitized thermographic images are mathematically manipulated through various filtering techniques and/or artificial neural mapping schemes to enhance its overall quality, permitting accurate flaw identification even when the signal-to-noise ratio is low.

Walker, James L.↗
NASA NTRS2005

Acoustic Emission Weld Monitoring in the 2195 Aluminum-Lithium Alloy

Due to its low density, the 2195 aluminum-lithium alloy was developed as a replacement for alloy 2219 in the Space Shuttle External Tank (ET). The external tank is the single largest component of the space shuttle system. It is 154 feet long and 27.6 feet in diameter, and serves as the structural backbone for the shuttle during launch, absorbing most of the 7 million plus pounds of thrust produced. The almost 4% decrease in density between the two materials provides an extra 7500 pounds of payload capacity necessary to put the International Space Station components into orbit. The ET is an all-welded structure; hence, the requirement is for up to five rewelds without hot cracking. Unfortunately, hot cracking during re-welding or repair operations was occurring and had to be dealt with before the new super lightweight tank could be used. Weld metal porosity formation was also of concern because it leads to hot cracking during weld repairs. Accordingly, acoustic emission (AE) nondestructive testing was employed to monitor the formation of porosity and hot cracks in order to select the best filler metal and optimize the weld schedule. The purpose of this work is to determine the feasibility of detecting hot cracking in welded aluminum-lithium (Al-Li) structures through the analysis of acoustic emission data. By acoustically characterizing the effects of reheating during a repair operation, the potential for hidden flaws coalescing and becoming "unstable" as the panel is repaired could be reduced. Identification of regions where microcrack growth is likely to occur and the location of active flaw growth in the repair weld will provide the welder with direct feedback as to the current weld quality enabling adjustments to the repair process be made in the field. An acoustic emission analysis of the source mechanisms present during welding has been conducted with the goals of locating regions in the weld line that are susceptible to damage from a repair operation, identifying the formation of critically sized flaws and providing accept/reject criteria for the quality of a weld as it is performed.

Walker, James L.↗
NASA NTRS2008

Weld Residual Stress and Distortion Analysis of the ARES I-X Upper Stage Simulator (USS)

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. While the main focus of this paper is a discussion of the weld modeling procedures and results for the USS, a short summary of the CIFS assessment is provided.

Raju, Ivatury↗
NASA NTRS1989

Effects of various consolidation techniques on microstructure, strength, and reliability of alpha-SiC

The effects of slurry pressing, HIP, and sinter-HIP on the strength, microstructure, and critical processing flaws in alpha-SiC are examined. Also, the feasibility of glass encapsulation is determined. Baseline strength was improved by about 25 percent by using slurry pressing instead of dry pressing. HIP further improved average strength to as high as 655 MPa. Sinter-HIP did not noticeably improve average strength. Although process-related flaws such as shrinkage cracks and large voids were not seen in HIPed alpha-SiC, surface-related flaws were observed. It is suggested that surface finishing by lapping, polishing, and heat treating might reduce the effect of surface-related flaws, improving the Weibull modulus in HIPed alpha-SiC.

Dutta, Sunil↗
NASA NTRS2006

Advanced Damage Tolerance Analysis of International Space Station Pressure Wall Welds

EM20/MSFC has sponsored technology in the area of advanced damage tolerance analysis tools used to analyze the International Space Station (ISS) pressure wall welds. The ISS European modules did not receive non-destructive evaluation (NDE) inspection after proof test. In final assembly configuration, most welds could only be inspected from one side, and some welds were uninspectible. Therefore, advanced damage tolerance analysis was required to determine the critical initial flaw sizes and predicted safe life for the pressure wall welds. EM20 sponsored the development of a new finite element tools using FEA-Crack and WARP3D to solve the problem. This presentation gives a brief overview of the new analytical tools and the analysis results.

Allen, Phillip A.↗
NASA NTRS2007

In-Plane Cracking Behavior and Ultimate Strength for 2D Woven and Braided Melt-Infiltrated SiC/SiC Composites Tensile Loaded in Off-Axis Fiber Directions

The tensile mechanical properties of ceramic matrix composites (CMC) in directions off the primary axes of the reinforcing fibers are important for architectural design of CMC components that are subjected to multi-axial stress states. In this study, 2D-woven melt-infiltrated (MI) SiC/SiC composite panels with balanced fiber content in the 0 degree and 90 degree directions were tensile loaded in-plane in the 0 degree direction and at 45 degree to this direction. In addition, a 2D triaxially-braided MI composite panel with balanced fiber content in the plus or minus 67 degree bias directions and reduced fiber content in the axial direction was tensile loaded perpendicular to the axial direction tows (i.e., 23 degrees from the bias fibers). Stress-strain behavior, acoustic emission, and optical microscopy were used to quantify stress-dependent matrix cracking and ultimate strength in the panels. It was observed that both off-axis loaded panels displayed higher composite onset stresses for through-thickness matrix cracking than the 2D-woven 0/90 panels loaded in the primary 0 degree direction. These improvements for off-axis cracking strength can in part be attributed to higher effective fiber fractions in the loading direction, which in turn reduces internal stresses on critical matrix flaws for a given composite stress. Also for the 0/90 panel loaded in the 45 degree direction, an improved distribution of matrix flaws existed due to the absence of fiber tows perpendicular to the loading direction. In addition, for the +67/0/-67 braided panel, the axial tows perpendicular to the loading direction were not only low in volume fraction, but were also were well separated from one another. Both off-axis oriented panels also showed relatively good ultimate tensile strength when compared to other off-axis oriented composites in the literature, both on an absolute strength basis as well as when normalized by the average fiber strength within the composites. Initial implications are discussed for constituent and architecture design to improve the directional cracking of SiC/SiC CMC components with MI matrices.

Morscher, Gregory N.↗
NASA NTRS2008

Ares I-X USS Material Testing

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). Material characterization tests were conducted to quantify the material behavior for use in the CIFS analyses. Fatigue crack growth rate, Charpy impact, and fracture tests were conducted on the parent and welded A516 Grade 70 steel. The crack growth rate tests confirmed that the material behaved in agreement with literature data and that a salt water environment would not significantly degrade the fatigue resistance. The Charpy impact tests confirmed that the fracture resistance of the material did not have a significant reduction for the expected operational temperatures of the vehicle.

Dawicke, David S.↗
NASA NTRS2008

Assessment of the LC-2 Prelaunch Fatigue Spectra of the CM-to-SM Flange Weld

The pad stay and rollout components of the Ares I-X life cycle can generate cyclic stress oscillations to the vehicle that could initiate and grow fatigue cracks from weld defects. The Ares I-X Project requested that a study be performed to determine if stabilization of the vehicle is required to reduce the stresses that could initiate and grow fatigue cracks at the flange-to-skin weld of the Command Module (CM) and Service Module (SM) interface. A fatigue crack growth analysis was conducted that used loads (LC-2) and stress analyses developed by the Ares I-X Project and utilized material data and analysis methods developed by a critical initial flaw size (CIFS) analysis conducted by NASA Engineering and Safety Center (NESC) for the Upper Stage Simulator (USS) of the Ares I-X vehicle. A full CIFS analysis for the CM-to-SM flange-to-skin weld was not performed because the full flight spectrum was not provided and was not necessary to answer the question posed by the Ares I-X Project. Instead, an approach was developed to determine if the crack growth due to the pad stay and rollout components of the flight spectrum would adversely influence the CIFS. The approach taken used a number of conservative assumptions that eliminated the need for high-fidelity analyses and additional material testing, but still provided a bounding solution for the uncertainties of the problem. The results from this analysis indicate that the LC-2 pad stay and rollout spectrum components would not produce significant fatigue crack growth on the CM-to-SM flange-to-skin weld. Thus, from a fatigue crack growth standpoint, no stabilization is required to reduce the LC-2 pad stay and rollout cyclic stresses on the CM-to-SM flange-to-skin weld.

Dawicke, David S.↗
NASA NTRS2008

ARES I-X USS Fracture Analysis Loads Spectra Development

This report describes the development of a set of bounding load spectra for the ARES I-X launch vehicle. These load spectra are used in the determination of the critical initial flaw size (CIFS) of the welds in the ARES I-X upper stage simulator (USS).

Larsen, Curtis↗
NASA NTRS2009

Stress Analysis of Bolted, Segmented Cylindrical Shells Exhibiting Flange Mating-Surface Waviness

Bolted, segmented cylindrical shells are a common structural component in many engineering systems especially for aerospace launch vehicles. Segmented shells are often needed due to limitations of manufacturing capabilities or transportation issues related to very long, large-diameter cylindrical shells. These cylindrical shells typically have a flange or ring welded to opposite ends so that shell segments can be mated together and bolted to form a larger structural system. As the diameter of these shells increases, maintaining strict fabrication tolerances for the flanges to be flat and parallel on a welded structure is an extreme challenge. Local fit-up stresses develop in the structure due to flange mating-surface mismatch (flange waviness). These local stresses need to be considered when predicting a critical initial flaw size. Flange waviness is one contributor to the fit-up stress state. The present paper describes the modeling and analysis effort to simulate fit-up stresses due to flange waviness in a typical bolted, segmented cylindrical shell. Results from parametric studies are presented for various flange mating-surface waviness distributions and amplitudes.

Knight, Norman F., Jr.↗
NASA NTRS2018

Improving Scientific Payload Communication Over Multiple, Low-Capacity Links

Communication is an important part of every airborne science mission. It provides a means for a large group of ground-based scientists to monitor and adjust experiments aboard aircraft that often cannot support a large number of passengers. In some cases, such as unmanned aircraft, communication becomes critical to a successful mission. Existing communication systems require the use of multiple, low-capacity channels, or links, to handle the capacity requirements of the scientists. Current communication solutions attempt to balance performance and reliability, but ultimately suffer from some critical design flaws that limit the ability of the system to handle additional links. We show how adding resources to the current system results in decreased performance and reliability. We explore the use of a new communication protocol, MultiPath Transmission Control Protocol, to make better use of multiple communication links and propose a total system capable of scaling to any number of channels efficiently and dynamically. The tools developed to support and measure this solution are also detailed.

MPTCP↗
NASA NTRS1975

Fracture control method for composite tanks with load sharing liners

The experimental program was based on the premise that the plastic sizing cycle, which each pressure vessel is subjected to prior to operation, acts as an effective proof test of the liner, screening out all flaws or cracks larger than a critical size. In doing so, flaw growth potential is available for cyclic operation at pressures less than the sizing pressure. Static fracture and cyclic life tests, involving laboratory type specimens and filament overwrapped tanks, were conducted on three liner materials: (1) 2219-T62 aluminum, (2) Inconel X750 STA, and (3) cryoformed 301 stainless steel. Variables included material condition, thickness, flaw size, flaw shape, temperature, sizing stress level, operating stress level and minimum-to-maximum operating stress ratio. From the empirical data base obtained, a procedure was established by which the service life of composite tanks with load sharing liners could be guaranteed with a high degree of confidence.

Bixler, W. D.↗
DOE OSTI2022

Initial Refinement and Optimization of the Image Reconstruction (U-MBIR) Algorithm to Optimize its Performance in Detecting Damage and Flaws

Concrete is a critical component of nuclear power plants; thus, its safety and reliability must be thoroughly examined throughout the life cycle of the structural system. During the life cycle of this infrastructure, monitoring of the concrete for signs of degradation should be performed through nondestructive evaluation (NDE). Ultrasonic measurements have been an industry standard for both surface and subsurface inspections. As such, Oak Ridge National Laboratory (ORNL) is developing advanced image reconstruction algorithms to overcome the limitations of traditional ultrasonic NDE methodologies. The results and discussion presented herein summarize the current state of the ultrasonic model–based iterative reconstruction (U-MBIR) algorithm developed at ORNL.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

An Eddy Current Case Study using NASA’s Transfer Function and Limited-Sample Probability of Detection Guidebooks

Probability of detection (POD) requirements for NASA fracture-critical human-rated systems can be met by (1) claiming ‘similarity’ to NASA Standard Nondestructive Evaluation (NDE) flaw sizes or (2) by inspector-specific POD demonstration, known as NASA Special NDE. Standard NDE flaw sizes are intended to represent the detection capability of most qualified inspectors, and were primarily based on POD studies in the development of the Space Shuttle Program Orbiter fracture control plan. However, these Standard NDE flaw sizes were based on fatigue cracks in flat panels of one material alloy over a limited range of panel thicknesses. While the POD study was comprehensive, the inspection conditions are relatively narrow. An evaluation of similarity between the Standard NDE POD study and flight component conditions is required to apply Standard NDE to specific flight component inspections. A similarity evaluation may include differences in materials, surface finish, component geometry (e.g., curvature, corners, welds), and inspection access. Similarity is typically based on a qualitative engineering evaluation. Recently, NASA published a quantitative methodology to assess similarity. If similarity is not supported by test and analysis, then the methodology provides a transfer function of flaw size for Special NDE POD demonstration. NASA recommends that Special POD demonstrations use flaws that are flight-like or more difficult to detect than flight component flaws, which are commonly induced fatigue cracks. Often, it is not feasible to induce fatigue cracks in flight component geometry, and therefore, a simpler representative geometry is used, commonly a flat panel, for POD demonstration. Inducing cracks in simple geometry specimens can be time-consuming and expensive, and thus, minimizing the number of flawed specimens is desired. Traditionally, NASA Special NDE demonstration was limited to MIL-HDBK-1823A methods or the binomial point-estimate method (PEM), commonly known as 29/29. Recently, NASA published a limited-sample POD (LS-POD) methodology for signal-response NDE techniques (e.g., eddy current) that provides POD demonstration with fewer specimens than previous approaches. LS-POD suggests a minimum of 10 flawed specimens, compared to 29 in the PEM and the suggested minimum of 40 from MIL-HDBK-1823A. The methodology also includes new guidance on evaluating the probability of false calls. In this presentation, these new transfer function and LS-POD methodologies are described and illustrated through an eddy current detection capability of far-side flaws on thin welded panels. A geometry-based transfer function is developed using electro-discharge machined (EDM) notches in flight component and simple geometry to estimate the Special NDE flaw size that is representative of the critical initial flaw size required by the fracture analysis. Then, fatigue cracks are induced in simple flat panels of the transferred flaw size, and the LS-POD methodology is used for Special NDE demonstration.

P. A. Parker↗