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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 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Accelerating Ground-Test Cycle Time: The Six-Minute Model Change and Other Visions for the 21st Century

The advantage of managing organizations to minimize product development cycle time has been well established. This paper provides an overview of the wind tunnel testing cycle time reduction activities at Langley Research Center (LaRC) and gives the status of several improvements in the wind tunnel productivity and cost reductions that have resulted from these activities. Processes have been examined and optimized. Metric data from monitoring processes provides guidance for investments in advanced technologies. The most promising technologies under implementation today include the use of formally designed experiments, a diverse array of quick disconnect technology and the judicious use of advanced electronic and information technologies.

Kegelman, Jerome T.↗
NASA NTRS2010

Nondestructive Evaluation and Monitoring Results from COPV Accelerated Stress Rupture Testing, NASA White Sands Test Facility (WSTF)

Develop and demonstrate NDE techniques for real-time characterization of CPVs and, where possible, identification of NDE capable of assessing stress rupture related strength degradation and/or making vessel life predictions (structural health monitoring or periodic inspection modes). Secondary: Provide the COPV user and materials community with quality carbon/epoxy (C/Ep) COPV stress rupture progression rate data. Aid in modeling, manufacturing, and application of COPVs for NASA spacecraft.

Saulsberry Regor↗
NASA NTRS2018

NEPP Evaluation of Automotive Grade Tantalum Chip Capacitors

Automotive grade tantalum (Ta) chip capacitors are available at lower cost with smaller physical size and higher volumetric efficiency compared to military/space grade capacitors. Designers of high reliability aerospace and military systems would like to take advantage of these attributes while maintaining the high standards for long-term reliable operation they are accustomed to when selecting military-qualified established reliability tantalum chip capacitors (e.g., MIL-PRF-55365). The objective for this evaluation was to assess the long-term performance of off-the-shelf automotive grade Ta chip capacitors (i.e., manufacturer self-qualified per AEC Q-200). Two (2) lots of case size D manganese dioxide (MnO2) cathode Ta chip capacitors from 1 manufacturer were evaluated. The evaluation consisted of construction analysis, basic electrical parameter characterization, extended long-term (2000 hours) life testing and some accelerated stress testing. Tests and acceptance criteria were based upon manufacturer datasheets and the Automotive Electronics Council's AEC Q-200 qualification specification for passive electronic components. As-received a few capacitors were marginally above the specified tolerance for capacitance and ESR. X-ray inspection found that the anodes for some devices may not be properly aligned within the molded encapsulation leaving less than 1 mil thickness of the encapsulation. This evaluation found that the long-term life performance of automotive grade Ta chip capacitors is generally within specification limits suggesting these capacitors may be suitable for some space applications.

Automotive↗
NASA NTRSDate not supplied

Infant Mortality and Wear-Out Failures in Polymer and MnO2 Tantalum Capacitors

Reliability testing of modern tantalum capacitors shows the presence of both types, infant mortality (IM) and wearout (WO) failures. To assure reliable operation, the probability of IM failures should be reduced to below the specified level, and the time of WO inception should be greater than the required useful life of the parts at operation conditions. In this work, several types of MnO2 and polymer cathode tantalum capacitors have been tested at highly accelerated conditions to assess voltage acceleration factors, determine adequate burn-in conditions, and assess the useful life. A modified time dependent dielectric breakdown (TDDB) model has been suggested to explain both types of failure, and a physical mechanism of degradation that is based on migration and reactions of oxygen vacancies explains increase of the defect related, IM failures with the level of stress.

tantalum capacitors↗
DOE OSTI2024

Mesoscale Modeling of the Effects of Accelerated Burnup on UO2 Microstructural Evolution

Accelerating the nuclear fuel qualification process will rely on some combination of advanced modeling and simulation techniques with accelerated irradiation testing and separate effects experiments to enable the development of new fuel concepts in a shorter time frame. One of the key challenges to successfully leveraging accelerated irradiation tests will be understanding the artifacts that may be introduced with accelerated accumulation of dose and/or burnup. This work presents phase field (MARMOT) simulations of the evolution of representative 2D UO2 microstructures up to 40 MWd/kgU. Simulations were performed under both commercial light water reactor fuel conditions as well as those that would be expected for highly accelerated (~10x) burnup conditions similar to those used in the MiniFuel irradiations in Oak Ridge National Laboratory’s High Flux Isotope Reactor. The phase field model was coupled with a discrete nucleation algorithm to model re- structuring at high burnup. The effect of the different fission rates in both microstructures was investigated at two temperatures: 650?C and 800?C. The lower temperature simulations both showed an onset of restructuring at nearly 60 MWd/kgU. More extensive restructuring was obtained in the MiniFuel microstructure compared with that of the PWR fuel. At 800?C, no restructuring was obtained as a result of the thermally activated diffusion of Xe atoms and U vacancies to fission gas bubbles, which reduces the nucleation driving force. These results highlight the importance of using modeling and simulation tools to inform the environmental conditions during targeted accelerated irradiation tests to extract the most useful fuel performance data.

accelerated fuel qualification, Phase Field, Restr↗
NASA NTRS1977

Ferrographic analysis of wear debris generated in accelerated rolling element fatigue tests

The types and quantities of wear particles generated during accelerated ball rolling contact fatigue tests were determined. Ball specimens were made of AMS 5749, a corrosion resistant, high-temperature bearing steel. The lubricant was a super-refined naphthenic mineral oil. Conditions included a maximum Hertz stress of 5.215 times 10 to the 9th power Pa and a shaft speed of 10,000 rpm. Four types of wear particles were observed; normal rubbing wear particles, fatigue spall particles, spheres, and friction polymer.

Jones, W. R., Jr.↗
DOE OSTI2023

Performance and durability of electrically conductive tape for shingled Si heterojunction technology cells

We report electrically conductive tape (ECT) was characterized and used to assemble shingled cell strings at low temperature to achieve high reliability Pb- and Ag-free interconnections. The volume resistivity for two considered ECTs are 0.13 ± 0.06 mΩ·cm and 0.47 ± 0.20 mΩ·cm and specific contact resistances, 6.85± 2.00 mΩ·cm 2 and 6.30 ± 0.37 mΩ·cm 2 using the emerging IEC 62788-8-1 Technical Specification for assessment of electrically conductive adhesives (ECA). Durability and performance of the technology in glass–glass mini modules were evaluated with temperature cycling, damp heat testing, and combined-accelerated stress testing (CAST). Through temperature cycling (-40°C to 85°C) applying five times the mini module short-circuit current in forward bias and in the multi climate CAST protocol, there was negligible degradation of fill factor after replacing connectors at the modules' cable leads; however, CAST resulted in short circuit current loss attributed to degradation in light collection by the cells, not the ECT. The IEC 61215-2 85°C, 85% relative humidity damp heat testing showed susceptibility of the HJT cells to effects of humidity in the electroluminescence intensity around the module perimeter that degraded power performance by 4% (relative). Contrasting the IEC 61215-2 qualification testing-based damp heat testing with CAST, factors such as the optical stress of CAST may precipitate the degradation of the modules whereas the humidity levels and duration of IEC 61215-2 damp heat testing may lead to excessive levels of humidity diffused into the modules, potentially resulting in degradation that is unrepresentative of the field.

14 SOLAR ENERGY↗
NASA NTRS1982

Investigation of reliability attributes and accelerated stress factors on terrestrial solar cells

The accelerated stress test results obtained on all terrestrial solar cells since the inception of the program are summarized. Tested cells were grouped according to the method used to form the conductive metallization layer: solder dipped, vacuum deposited, screen printed, and copper plated. Although metallization systems within each group were quite similar, they differed in numerous details according to the procedures employed by each manufacturer. Test results were summarized for all cells according to both electrical degradation and catastrophic mechanical changes. These results indicated a variability within each metallization category which was dependent on the manufacturer. Only one manufacturer was represented in the copper plated category and, although these showed no signs of detrimental copper diffusion during high temperature testing, their metallization was removed easily during high humidity pressure cooker testing. Preliminary testing of encapsulated cells showed no major differences between encapsulated and unencapsulated cells when subjected to accelerated testing.

Lathrop, J. W.↗
DOE OSTI2018

Beam Diagnostic Challenges for FACET-II

FACET-II, the Facility for Advanced Accelerator Experimental Tests II, is a new accelerator R&D test facility to be constructed at SLAC. It will provide high-energy, high-density electron and positron beams to advance the development of beam driven plasma wakefield acceleration and support a broad range of experiments. The FACET-II beams are expected to have 10 GeV energy, contain 2 nC of charge, have a transverse normalized emittance of 7 microns, be compressed to about 1 micron long and focused to about 6 micron wide at the interaction point. Additionally, the nominal peak current is 20 kA and is expected to fluctuate up to 200 kA. Most experiments desire complete knowledge of the incoming beam parameters on a pulse-to-pulse basis. However, the extreme beam densities and strong fields of the beam current will destroy any diagnostics intercepting the beam in a single shot and impose unique challenges for beam diagnostics. Moreover, non-intercepting diagnostics are desirable to provide feedback for machine setup and characterization. Finally, we need to look beyond conventional diagnostics to seek new solutions for measurements of the high charge, small beam size, short bunch length, and low emittance.

43 PARTICLE ACCELERATORS↗
NASA NTRS1991

Corrosion of metal particle and metal evaporated tapes

Very high coercivity metal particle (MP) and metal evaporated (ME) tapes are being used in 8mm video and digital audio tape applications, and more recently in digital data recording applications. In view of the inherent susceptibility of such media to environmental corrosion, a number of recent studies have addressed their long term stability and archivability. These studies have used an accelerated corrosion test based either on elevated temperature-humidity or polluting gas atmospheres known as Battelle tests. A comparison of the Battelle test results performed at different laboratories reveals a large variation from one location to another, presumably due to incorrect replication of the Battelle condition. Furthermore, when the Battelle tests are performed on enclosed cartridges, it is quite possible that diffusion limits the penetration of the extremely low concentration polluting gaseous species to the inner layers of the tapes during the short time of the accelerated test, whereas in real life these diffusion limitations may not apply. To avoid this uncertainty, the corrosion behavior of commercial 8mm MP and ME tapes when cassettes without their external plastic cases were exposed to 50 deg C and 80 percent RH for 7.5 weeks is investigated.

Speliotis, Dennis E.↗
NASA NTRS1977

Ferrographic analysis of wear debris generated in accelerated rolling element fatigue tests

Ferrographic analysis was used to determine the types and quantities of wear particles generated during accelerated rolling contact fatigue tests. The NASA five-ball rolling contact fatigue tester was used. Ball specimens were made of AMS 5749, a corrosion-resistant high-temperature bearing steel. The lubricant was a super-refined naphthenic mineral oil. Conditions included a maximum Hertz stress of 5.52 billion Pa and a shaft speed of 10,000 rpm. Four types of wear particles were observed: normal rubbing wear particles, fatigue spall particles, spheres, and friction polymer.

Jones, W. R., Jr.↗
NASA NTRSDate not supplied

Creep Testing of Vectran Yarn

NASA and industry are developing inflatable space structures to provide deployable habitable volumes for future exploration missions in space and on the surface of the Moon and Mars. These structures must withstand the constant pressure loading of multi-year missions. These missions therefore require excellent creep resistance in the constituent cordage and webbings that provide the primary structure of the vessel, which is typically constructed using high-strength synthetic materials such as Vectran. Real-time and accelerated creep testing of Vectran webbings has been performed at NASA Langley Research Center (LaRC), however, acceptable correlation between the results of the two approaches has not yet been achieved. Given the additional complexity of the webbing architecture, creep testing at the yarn level is being studied to reduce the number of interacting properties and focus on the core creep behavior to see if better correlation can be achieved between real-time and accelerated tests. To achieve this objective a creep test stand that is able to support simultaneous testing of five Vectran yarns had been previously designed and built. The test stand utilizes two clamp-wrap grips to mount the yarn and has a 10:1 load ratio, via a lever-arm, henceforth, known as the lever-arm test stand. Real-time creep testing (without measuring the strain of the yarn) in this fixture produces yarn ruptures in the gauge section. However, a large scatter in the times to failure was seen in the results across multiple loading conditions. For example, a test at 70% of the ultimate tensile strength (UTS) was found to have specimens that failed within a matter of hours and others that took over 6 weeks to fail. Prior test data on Vectran webbings had indicated high variability in the material strength, leading to higher than average scatter in the creep testing of webbings, which could translate to the scatter in creep behavior at the yarn level as well. However, there was still the possibility that the lever-arm test stand was causing the high scatter in data; specifically, due to potential variability in the loading of each specimen. Therefore, an additional creep test setup was designed and built to attempt to determine if the large scatter in the results was due to inherent material properties, the lever-arm test stand, or both. The newly designed creep test stand, henceforth known as the conventional test stand, utilized the more typical method for creep testing which involved hanging a weight from the yarn with no additional load amplification. The conventional test stand was designed and fabricated in-house at LaRC. High speed cameras were used to validate that the specimens in the conventional test stand failed in the gauge section. Once it was determined that the conventional test stand would provide valid failures in the gauge section, creep tests on the Vectran yarns were run to compare to the lever-arm test stand results. Preliminary results for a 70% UTS creep test have some specimens failing within a number of hours and some failing in excess of 6 weeks. These results are similar to those seen on the lever-arm test stand, pointing towards a large variability inherent in the material. The poster/presentation will focus on the design, fabrication, and validation of the conventional test stand as well as present preliminary results comparing the creep data from the conventional and lever-arm test stands

creep testing↗
NASA NTRS1982

Preliminary analysis of accelerated space flight ionizing radiation testing

A preliminary analysis shows that radiation dose equivalent to 30 years in the geosynchronous environment can be accumulated in a typical composite material exposed to space for 2 years or less onboard a spacecraft orbiting from perigee of 300 km out to the peak of the inner electron belt (approximately 2750 km). Future work to determine spacecraft orbits better tailored to materials accelerated testing is indicated. It is predicted that a range of 10 to the 9th power to 10 to the 10th power rads would be accumulated in 3-6 mil thick epoxy/graphite exposed by a test spacecraft orbiting in the inner electron belt. This dose is equivalent to the accumulated dose that this material would be expected to have after 30 years in a geosynchronous orbit. It is anticipated that material specimens would be brought back to Earth after 2 years in the radiation environment so that space radiation effects on materials could be analyzed by laboratory methods.

Wilson, J. W.↗
DOE OSTI2019

Use of indentation to study the degradation of photovoltaic backsheets

The ability of electrical insulating materials within a module to act as insulators is a key safety requirement for photovoltaic (PV) technology. Presently, however, the durability of backsheets may not be readily assessed. For example, the mechanical tensile test continues to be developed, and its use has not been validated such that a technically based pass/fail criteria may be established. This study examines the use of simple indentation methods, including durometer hardness and instrumented indentation, as a means to quantitively assess the degradation of PV backsheets. Characteristics including: hardness, modulus, load/displacement profile, creep hold response, and residual impression are explored in an empirical study. Glass/encapsulant/backsheet mini-modules constructed using backsheets including: polyamide (PA), poly(ethylene terephthalate) (PET), polyvinyl fluoride (PVF) laminate ('TPE'), and polyvinylidene fluoride (PVDF) were examined. An M-type durometer as well as Berkovich and cube-corner tips were used in the indentation experiments. Additional characterizations were performed to interpret the indentation measurements including: surface roughness measurements using atomic force microscopy (AFM), a chemical integrity study using Fourier-transform infrared spectroscopy (FTIR), and phase-transition measurements using differential scanning calorimetry (DSC). The results are analyzed in the context of the combined accelerated stress test (C-AST) also explored in this study. Instrumented indentation (i.e., using a Berkovich tip) was able to distinguish between backsheets and quantify the effects of accelerated testing (including up to 60%, 25%, and 20% change in hardness, modulus, and creep displacement, respectively). The embrittlement of the backsheets was not readily assessable using cube-corner indentation. Cracking of the known-bad polyamide backsheet was observed from the C-AST, which was not observed to result from steady state UV weathering.

14 SOLAR ENERGY↗
NASA NTRS1978

Characterization of wear debris generated in accelerated rolling-element fatigue tests

A ferrographic analysis was used to determine the types and quantities of wear debris generated during accelerated rolling contact fatigue tests. The five-ball rolling contact fatigue tester was used. Ball specimens were made of a corrosion resistant, high-temperature bearing steel. The lubricant was a superrefined naphthenic mineral oil. Conditions included a maximum Hertz stress of 5.52 10 to the 9th power Pa and a shaft speed of 10,000 rpm. Four types of wear debris were observed: (1) normal rubbing wear particles, (2) fatigue microspall particles, (3) spheres, and (4) friction polymer deposits. The characterization of wear debris as a function of time was of limited use in predicting fatigue failures in these accelerated tests.

Jones, W. R., Jr.↗