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NASA NTRS2010

Composite Overwrapped Pressure Vessels (COPV) Stress Rupture Test: Part 2

One of the major concerns for the aging Space Shuttle fleet is the stress rupture life of composite overwrapped pressure vessels (COPVs). Stress rupture life of a COPY has been defined as the minimum time during which the composite maintains structural integrity considering the combined effects of stress levels and time. To assist in the evaluation of the aging COPVs in the Orbiter fleet an analytical reliability model was developed. The actual data used to construct this model was from testing of COPVs constructed of similar, but not exactly same materials and pressure cycles as used on Orbiter vessels. Since no actual Orbiter COPV stress rupture data exists the Space Shuttle Program decided to run a stress rupture test to compare to model predictions. Due to availability of spares, the testing was unfortunately limited to one 40" vessel. The stress rupture test was performed at maximum operating pressure at an elevated temperature to accelerate aging. The test was performed in two phases. The first phase, 130 F, a moderately accelerated test designed to achieve the midpoint of the model predicted point reliability. A more aggressive second phase, performed at 160 F, was designed to determine if the test article will exceed the 95% confidence interval ofthe model. In phase 3, the vessel pressure was increased to above maximum operating pressure while maintaining the phase 2 temperature. After reaching enough effectives hours to reach the 99.99% confidence level of the model phase 4 testing began when the temperature was increased to greater than 170 F. The vessel was maintained at phase 4 conditions until it failed after over 3 million effect hours. This paper will discuss the results of this test, it's implications and possible follow-on testing.

Russell, Richard↗

NASA NTRS2009

Composite Overwrapped Pressure Vessels (COPV) Stress Rupture Test

One of the major concerns for the aging Space Shuttle fleet is the stress rupture life of composite overwrapped pressure vessels (COPVs). Stress rupture life of a COPV has been defined as the minimum time during which the composite maintains structural integrity considering the combined effects of stress levels and time. To assist in the evaluation of the aging COPVs in the Orbiter fleet an analytical reliability model was developed. The actual data used to construct this model was from testing of COPVs constructed of similar, but not exactly same materials and pressure cycles as used on Orbiter vessels. Since no actual Orbiter COPV stress rupture data exists the Space Shuttle Program decided to run a stress rupture test to compare to model predictions. Due to availability of spares, the testing was unfortunately limited to one 40" vessel. The stress rupture test was performed at maximum operating pressure at an elevated temperature to accelerate aging. The test was performed in two phases. The first phase, 130 F, a moderately accelerated test designed to achieve the midpoint of the model predicted point reliability. The more aggressive second phase, performed at 160 F was designed to determine if the test article will exceed the 95% confidence interval of the model. This paper will discuss the results of this test, it's implications and possible follow-on testing.

Russell, Richard↗

NASA NTRS1971

Materials investigation and tests for the development of space compatible electrical connectors

A molding study of compounds based on copolymers of highly fluorinated olefins and of flame retardant silicone is reported. Both single cavity and four cavity molds having size 22 and 24 holes with three webs in each hole were used. Also covered are dielectric strength, arc resistance, Bashore rebound, and maintenance aging tests on the various materials that have been successfully molded.

Pomeroy, C.↗

NASA NTRS1986

Thermal aging effects in refractory metal alloys

The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.

Stephens, J. R.↗

NASA NTRS1987

Thermal aging effects in refractory metal alloys

Stephens, Joseph R.↗

NASA NTRS1944

Compressive Strength of Flat Panels with Z- and Hat-Section Stiffeners

Compression tests were conducted on 247 panels with Z-section stiffeners and 304 panels with hat-section stiffeners. Specimens were constructed from artificially aged Alclad 24S aluminum alloy with minimum guaranteed yield strengths of 64 and 57 ksi for stiffeners and sheet materials, respectively. Height, thickness, and spacing of stiffeners, sheet thickness, and length of specimens were varied systematically to show effects of changes in these dimensions on panel strength. Results show average stresses at buckling load and maximum load.

STRESSED SKIN - SHEETS - STRENGTH, COMPRESSIVE↗

NASA NTRS2007

Novel Thin Film Sensor Technology for Turbine Engine Hot Section Components

Degradation and damage that develops over time in hot section components can lead to catastrophic failure of the turbine section of aircraft engines. A range of thin film sensor technology has been demonstrated enabling on-component measurement of multiple parameters either individually or in sensor arrays including temperature, strain, heat flux, and flow. Conductive ceramics are beginning to be investigated as new materials for use as thin film sensors in the hot section, leveraging expertise in thin films and high temperature materials. The current challenges are to develop new sensor and insulation materials capable of withstanding the extreme hot section environment, and to develop techniques for applying sensors onto complex high temperature structures for aging studies of hot propulsion materials. The technology research and development ongoing at NASA Glenn Research Center for applications to future aircraft, launch vehicles, space vehicles, and ground systems is outlined.

Wrbanek, John D.↗

NASA NTRS2006

Space Flight Qualification on a Multi-Fiber Ribbon Cable and Array Connector Assembly

NASA's Goddard Space Flight Center (GSFC) cooperatively with Sandia National Laboratories completed a series of tests on three separate configurations of multi-fiber ribbon cable and MTP connector assemblies. These tests simulate the aging process of components during launch and long-term space environmental exposure. The multi-fiber ribbon cable assembly was constructed of non-outgassing materials, with radiation-hardened, graded index 100/140-micron optical fiber. The results of this characterization presented here include vibration testing, thermal vacuum monitoring, and extended radiation exposure testing data.

Xiaodan, Linda Jin↗

NASA NTRS2016

Direct Determination of the Space Weathering Rates in Lunar Soils and Itokawa Regolith from Sample Analyses

Space weathering effects on airless bodies result largely from micrometeorite impacts and solar wind interactions. Decades of research have provided insights into space weathering processes and their effects, but a major unanswered question still remains: what is the rate at which these space weathering effects are acquired in lunar and asteroidal regolith materials? To determine the space weathering rate for the formation of rims on lunar anorthite grains, we combine the rim width and type with the exposure ages of the grains, as determined by the accumulation of solar flare particle tracks. From these analyses, we recently showed that space weathering effects in mature lunar soils (both vapor-deposited rims and solar wind amorphized rims) accumulate and attain steady state in 10(sup 6)-10(sup 7) y. Regolith grains from Itokawa also show evidence for space weathering effects, but in these samples, solar wind interactions appear to dominate over impactrelated effects such as vapor-deposition. While in our lunar work, we focused on anorthite, given its high abundance on the lunar surface, for the Itokawa grains, we focused on olivine. We previously studied 3 olivine grains from Itokawa and determined their solar flare track densities and described their solar wind damaged rims]. We also analyzed olivine grains from lunar soils, measured their track densities and rim widths, and used this data along with the Itokawa results to constrain the space weathering rate on Itokawa. We observe that olivine and anorthite have different responses to solar wind irradiation.

Keller, L. P.↗

NASA NTRS1993

Lifetime prediction of materials exposed to the natural space environment

The goal of this study is to model the lifetime of different types of seal materials based on results obtained from accelerated experiments. A semi-mechanistic approach was taken. Thermal aging data were taken from the literature whereas experiments were conducted at Auburn under this contract for selected environments. The seal materials of interest are Silicone 383, Silicone 650, Viton 835, and Viton 747. The relevant conditions include thermal, oxygen, inert gas, vacuum, and gamma radiation. Compression set data available from NASA were used to examine the thermal effect. Experiments were conducted at Auburn University and at NASA to isolate the role of thermal, oxygen, inert gas, vacuum, gamma irradiation, and proton irradiation. A simple discrete stress relaxation method was developed to determine the relaxation response of the elastomers. Dynamic mechanical thermal analysis was also used to characterize the mechanical response of the specimens. These provide a more meaningful correlation between mechanisms and degradation.

Zee, Ralph↗

DOE OSTI2020

Development of a heterogeneous nanostructure through abnormal recrystallization of a nanotwinned Ni superalloy

This work explores the development of a heterogeneous nanostructured material through leveraging abnormal recrystallization, which is a prominent phenomenon in coarse-grained Ni-based superalloys. Additionally, through synthesis of a sputtered Inconel 725 film with a heterogeneous distribution of stored energy and subsequent aging treatments at 730°C, a unique combination of grain sizes and morphologies was observed throughout the thickness of the material. Three distinct domains are formed in the aged microstructure, where abnormally large grains are observed in-between a nanocrystalline and a nanotwinned region. In order to investigate the transitions towards a heterogeneous structure, crystallographic orientation and elemental mapping at interval aging times up to 8 h revealed the microstructural evolution and precipitation behavior. From the experimental observations and the detailed analysis of this study, the current methodology can be utilized to further expand the design space of current heterogeneous nanostructured materials.

36 MATERIALS SCIENCE↗

NASA NTRS2008

Cryogenic Moisture Uptake in Foam Insulation for Space Launch Vehicles

Rigid polyurethane foams and rigid polyisocyanurate foams (spray-on foam insulation), like those flown on Shuttle, Delta IV, and will be flown on Ares-I and Ares-V, can gain an extraordinary amount of water when under cryogenic conditions for several hours. These foams, when exposed for eight hours to launch pad environments on one side and cryogenic temperature on the other, increase their weight from 35 to 80 percent depending on the duration of weathering or aging. This effect translates into several thousand pounds of additional weight for space vehicles at lift-off. A new cryogenic moisture uptake apparatus was designed to determine the amount of water/ice taken into the specimen under actual-use propellant loading conditions. This experimental study included the measurement of the amount of moisture uptake within different foam materials. Results of testing using both aged specimens and weathered specimens are presented. To better understand cryogenic foam insulation performance, cryogenic moisture testing is shown to be essential. The implications for future launch vehicle thermal protection system design and flight performance are discussed.

Fesmire, James E.↗

NASA NTRS1988

Long-life assurance for Space Station - Is it an issue?

Various issues related to the long-life assurance (LLA) of the Space Station (SS) are discussed. The effects of exposure to atomic oxygen, radiation, thermal cycling, micrometeoroid and debris damage, and the physical aging of polymers on the SS materials are examined. The proper design of the SS truss system and pressure vessels, electronic systems, mechanical systems, and software for LLA is addressed.

Cruse, T. A.↗

NASA NTRS2006

Fire-Resistant Reinforcement Makes Steel Structures Sturdier

Built and designed by Avco Corporation, the Apollo heat shield was coated with an ablative material whose purpose was to burn and, thus, dissipate energy. The material charred to form a protective coating which blocked heat penetration beyond the outer surface. Avco Corporation subsequently entered into a contract with Ames Research Center to develop spinoff applications of the heat shield in the arena of fire protection, specifically for the development of fire-retardant paints and foams for aircraft. This experience led to the production of Chartek 59, manufactured by Avco Specialty Materials (a subsidiary of Avco Corporation eventually acquired by Textron, Inc.) and marketed as the world s first intumescent epoxy material. As an intumescent coating, Chartek 59 expanded in volume when exposed to heat or flames and acted as an insulating barrier. It also retained its space-age ablative properties and dissipated heat through burn-off. Further applications were discovered, and the fireproofing formulation found its way into oil refineries, chemical plants, and other industrial facilities working with highly flammable products.

Source record↗

NASA NTRS1975

Electron microscopy of irradiation effects in space

The paper discusses several discoveries made in the study of lunar material. In the examination of the effects of solar wind implantations the topics covered include (1) solar wind radiation damage parameters and their aging characteristics, (2) the theory of the ancient solar wind, (3) the solar wind sputtering erosion rate, (4) the physicochemical properties of amorphous coatings, (5) maturity indexes and the macroscopic properties of the lunar regolith, (6) solar wind gas bubbles, (7) the composition of very heavy nuclei in the contemporary solar wind, and (8) track aging processes. Conclusions are drawn from the results about other extraterrestrial features such as the parent bodies of the meteorites, early solar nebulas, and interstellar clouds.

Maurette, M.↗

NASA NTRS2012

Revitalization of the NASA Langley Research Center's Infrastructure

The NASA Langley Research Center (Langley) was founded in 1917 as the nation's first civilian aeronautical research facility and NASA's first field center. For nearly 100 years, Langley has made significant contributions to the Aeronautics, Space Exploration, and Earth Science missions through research, technology, and engineering core competencies in aerosciences, materials, structures, the characterization of earth and planetary atmospheres and, more recently, in technologies associated with entry, descent, and landing. An unfortunate but inevitable outcome of this rich history is an aging infrastructure where the longest serving building is close to 80 years old and the average building age is 44 years old. In the current environment, the continued operation and maintenance of this aging and often inefficient infrastructure presents a real challenge to Center leadership in the trade space of sustaining infrastructure versus not investing in future capabilities. To address this issue, the Center has developed a forward looking revitalization strategy that ties future core competencies and technical capabilities to the Center Master Facility Plan to maintain a viable Center well into the future. This paper documents Langley's revitalization strategy which integrates the Center's missions, the Langley 2050 vision, the Center Master Facility Plan, and the New Town repair-by-replacement program through the leadership of the Vibrant Transformation to Advance Langley (ViTAL) Team.

Weiser, Erik S.↗

NASA NTRS2008

Cryogenic Moisture Analysis of Spray-On Foam Insulation (SOFI)

The NASA Cryogenics Test Laboratory at Kennedy Space Center conducted long-term testing of SOFI materials under actual-use cryogenic conditions. The lab tested NCFI 24-124 (acreage foam), BX-265 (close-out foam, including intertank flange and bipod areas), and a potential alternate material, NCFI 27-68 (acreage foam with the flame retardant removed). Specimens of all three materials were placed at a site that simulated aging (the Vehicle Assembly Building [VAB]) and a site that simulated weathering (Atmospheric Exposure Test Site [beach site]). After aging/ weathering intervals of 3, 6, and 12 months, the samples were retrieved and tested for their ability to absorb moisture under conditions similar to those experienced by the Space Shuttle External Tank (ET) during the loading of cryogenic propellants.

Source record↗

NASA NTRS2007

Condition Assessment of Kevlar Composite Materials Using Raman Spectroscopy

This viewgraph presentation includes the following main concepts. Goal: To evaluate Raman spectroscopy as a potential NDE tool for the detection of stress rupture in Kevlar. Objective: Test a series of strand samples that have been aged under various conditions and evaluate differences and trends in the Raman response. Hypothesis: Reduction in strength associated with stress rupture may manifest from changes in the polymer at a molecular level. If so, than these changes may effect the vibrational characteristics of the material, and consequently the Raman spectra produced from the material. Problem Statement: Kevlar composite over-wrapped pressure vessels (COPVs) on the space shuttles are greater than 25 years old. Stress rupture phenomena is not well understood for COPVs. Other COPVs are planned for hydrogen-fueled vehicles using Carbon composite material. Raman spectroscopy is being explored as an non-destructive evaluation (NDE) technique to predict the onset of stress rupture in Kevlar composite materials. Test aged Kevlar strands to discover trends in the Raman response. Strength reduction in Kevlar polymer will manifest itself on the Raman spectra. Conclusions: Raman spectroscopy has shown relative changes in the intensity and FWHM of the ~1613 cm(exp -1) peak. Reduction in relative intensity for creep, fleet leader, and SIM specimens compared to the virgin strands. Increase in FWHM has been observed for the creep and fleet leader specimens compared to the virgin strands. Changes in the Raman spectra may result from redistributing loads within the material due to the disruption of hydrogen bonding between crystallites or defects in the crystallites from aging the Kevlar strands. Peak shifting has not been observed to date. Analysis is ongoing. Stress measurements may provide a tool in the short term.

Washer, Glenn↗