Plasma torch oxidation resistance and erosion evaluation of pyrolytic materials.
Oxidation tests of pyrolytic materials for use in free standing thrust chamber of liquid propellant rocket
OXIDATION RESISTANCE↗
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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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Monitoring crack extension in fracture toughness tests by ultrasonics
An ultrasonic method was used to observe the onset of crack extension and to monitor continued crack growth in fracture toughness specimens during three point bend tests. A 20 MHz transducer was used with commercially available equipment to detect average crack extension less than 0.09 mm. The material tested was a 300-grade maraging steel in the annealed condition. A crack extension resistance curve was developed to demonstrate the usefulness of the ultrasonic method for minimizing the number of tests required to generate such curves.
Klima, S. J.↗
Monitoring crack extension in fracture toughness tests by ultrasonics
An ultrasonic method was used to observe the onset of crack extension and to monitor continued crack growth in fracture toughness specimens during three-point bend tests. A 20-MHz transducer was used with commercially available equipment to detect average crack extension less than 0.09 mm. The material tested was a 300-grade maraging steel in the annealed condition. A crack extension resistance curve was developed to demonstrate the usefulness of the ultrasonic method for minimizing the number of tests required to generate such curves.
Klima, S. J.↗
Crystal growth of sulfide materials from alkali polysulfide liquids
The fluids experiment system was designed for low temperature solution growth, nominally aqueous solution growth. The alkali polysulfides, compositions in the systems Na2S-S and K2S-S form liquids in the temperature range of 190 C to 400 C. These can be used as solvents for other important classes of materials such as transition metal and other sulfides which are not soluble in aqueous media. Among these materials are luminescent and electroluminescent crystals whose physical properties are sensitive functions of crystal perfection and which could, therefore, serve as test materials for perfection improvement under microgravity conditions.
White, W. B.↗
Ablation of carbonaceous materials in a hydrogen-helium arc-jet flow
The stagnation-point ablation rates of a graphite, a carbon-carbon composite, and four carbon-phenolic materials are measured in an arc-jet wind tunnel with a 50 percent hydrogen-50 percent helium mixture as the test gas. Flow environments are determined through measurements of static and impact pressures, heat-transfer rates to a calorimeter, and radiation spectra, and through numerical calculation of the flow through the wind tunnel, spectra, and heat-transfer rates. The environments so determined are: impact pressure approximately equal to 3 atm, Mach number approximately equal to 2.1, convective heat-transfer rate approximately equal to 14 kW/sq cm, and radiative heat-transfer rate approximately equal to 7 kW/sq cm in the absence of ablation. Ablation rates are determined from the measured rates of mass loss and recession of the ablation specimens. Compared with the predicted ablation rates obtained by running RASLE and CMA codes, the measured rates are higher by about 15 percent for all tested materials.
Park, C.↗
Mass spectrometers and atomic oxygen
The likely role of atmospheric atomic oxygen in the recession of spacecraft surfaces and in the shuttle glow has revived interest in the accurate measurement of atomic oxygen densities in the upper atmosphere. The Air Force Geophysics Laboratory is supplying a quadrupole mass spectrometer for a materials interactions flight experiment being planned by the Johnson Space Center. The mass spectrometer will measure the flux of oxygen on test materials and will also identify the products of surface reactions. The instrument will be calibrated at a new facility for producing high energy beams of atomic oxygen at the Los Alamos National Laboratory. The plans for these calibration experiments are summarized.
Hunton, D. E.↗
Plastic Recycling Experiments in Materials Education
The objective of this project was to introduce a series of plastic recycling experiments to students in materials-related courses such as materials science, material technology and materials testing. With the plastic recycling experiments, students not only can learn the fundamentals of plastic processing and properties as in conventional materials courses, but also can be exposed to the issue of materials life cycle and the impact on society and environment.
Liu, Ping↗
Selective Laser Melting Inconel 718 Restart Study
Selective Laser Melting (SLM) machines can occasionally shut down (such as in the event of a power failure), which requires the SLM build to be restarted. It has been observed that machine restarts can produce visible "restart lines" in the part, and, in at least one instance, a test specimen containing a restart line exhibited poor mechanical properties. The goal of this study is to evaluate the effect of different machine restart factors on the mechanical properties of the produced SLM material. Test specimens were produced by varying time to restart, the number of re-sinters, and whether or not the build required re-levelling. These are build variables that are typically controlled by the machine operator. Test results indicate that re-leveling and using three re-sinters produces acceptable material. Statistical analysis indicates that re-leveling and re-sintering have strong effects on the resulting material properties. Additionally, the visibility of a restart line loosely correlates with material properties such that obvious restart lines tended to indicate worse material properties.
Tilson, William G.↗
Petascale Orbital-Free Density Functional Theory Enabled by Small-Box Algorithms
Orbital-free density functional theory (OFDFT) is a quantum-mechanics-based method that utilizes electron density as its sole variable. The main computational cost in OFDFT is the ubiquitous use of the fast Fourier transform (FFT), which is mainly adopted to evaluate the kinetic energy density functional (KEDF) and electron–electron Coulomb interaction terms. We design and implement a small-box FFT (SBFFT) algorithm to overcome the parallelization limitations of conventional FFT algorithms. We also propose real-space truncation of the nonlocal Wang–Teter KEDF kernel. The scalability of the SBFFT is demonstrated by efficiently simulating one full optimization step (electron density, energies, forces, and stresses) of 1,024,000 lithium (Li) atoms on up to 65,536 cores. We perform other tests using Li as a test material, including calculations of physical properties of different phases of bulk Li, geometry optimizations of nanocrystalline Li, and molecular dynamics simulations of liquid Li. All of the tests yield excellent agreement with the original OFDFT results, suggesting that the OFDFT-SBFFT algorithm opens the door to efficient first-principles simulations of materials containing millions of atoms.
Chemistry↗
Advanced Materials Laboratory User Test Planning Guide
Test process, milestones and inputs are unknowns to first-time users of the Advanced Materials Laboratory. The User Test Planning Guide aids in establishing expectations for both NASA and non-NASA facility customers. The potential audience for this guide includes both internal and commercial spaceflight hardware/software developers. It is intended to assist their test engineering personnel in test planning and execution. Material covered includes a roadmap of the test process, roles and responsibilities of facility and user, major milestones, facility capabilities, and inputs required by the facility. Samples of deliverables, test article interfaces, and inputs necessary to define test scope, cost, and schedule are included as an appendix to the guide.
Advanced Materials Laboratory↗
Technical Guidance for Creation of 237 NP Irradiation Target Fabrication Packages
This document describes the process used to document the fabrication of irradiation targets that may be inserted into either the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL), or the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). The targets are being irradiated to produce 238 Pu (5.48Mev alpha decay, T1/2 = 87.7 y) used in the fabrication of radioisotope thermoelectric generators (RTGs). RTGs powered by 238 Pu are an established power source technology for National Aeronautics and Space Administration space missions where solar power is not viable. The documentation included in fabrication files demonstrates full traceability of all materials, components, and assemblies used to build 237 Np targets. To accomplish this, all documentation (e.g., certified material test reports, weld reports, leak test reports) will be maintained and reviewed throughout materials procurement, component fabrication, and target assembly.
07 ISOTOPE AND RADIATION SOURCES↗
Quantifying engineered nanomaterial toxicity: comparison of common cytotoxicity and gene expression measurements
When evaluating the toxicity of engineered nanomaterials (ENMS) it is important to use multiple bioassays based on different mechanisms of action. In this regard we evaluated the use of gene expression and common cytotoxicity measurements using as test materials, two selected nanoparticles with known differences in toxicity, 5 nm mercaptoundecanoic acid (MUA)-capped InP and CdSe quantum dots (QDs). We tested the effects of these QDs at concentrations ranging from 0.5 to 160 µg/mL on cultured normal human bronchial epithelial (NHBE) cells using four common cytotoxicity assays: the dichlorofluorescein assay for reactive oxygen species (ROS), the lactate dehydrogenase assay for membrane viability (LDH), the mitochondrial dehydrogenase assay for mitochondrial function, and the Comet assay for DNA strand breaks.
Biomarkers↗
Conductivity effects in high-voltage spacecraft insulating materials
Laboratory measurements were performed to assess the influence of various external parameters on the conductivity properties of several typical and potential spacecraft insulating materials in a simulated space environment. The materials tested include Kapton, Teflon, quartz, and polyvinylidene fluoride. The parameters measured comprise sample thickness, temperature, applied voltage, illumination intensity and wavelength, and electron beam energy and current density. All tests were conducted in a vacuum chamber at a pressure of about one millionth Torr both with conventional optically-transparent gold front-surface electrodes and with the front surfaces of the test samples exposed directly to an electron beam. The data presented illustrate some of the complexities in electrical characteristics exhibited by the materials as a result of interactions with various conditions of their environment.
Adamo, R. C.↗
A study of subsurface crack initiation produced by rolling contact fatigue
Results of subsurface crack initiation studies produced by pure rolling contact fatigue in 7075-T6 aluminum alloy are presented in this article. Microstructural changes and subsequent crack initiation below the contacting surface in cylindrical test specimens subjected to repeated rolling contact are illustrated. The rolling conditions are simulated in a three-dimensional elastic-plastic finite element model in order to estimate the plastic strains and residual stresses in the test material. The numerically estimated distribution of plastic strains in the model correlate well with the extent of microstructural changes observed in the test specimen. Results also indicate that a combination of plastic strains and low values of residual stresses is conducive to subsurface crack initiation and growth.
Kumar, Arun M.↗
Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design
A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. The near-net shape DMLS parts have been delivered and final machining is underway. Fabrication of the traditionally manufactured hardware is also proceeding. Testing in liquid oxygen is planned for Q2 of FY2017. This topic explores the design of the turbopump along with fabrication and material testing of the DMLS hardware.
O'Neal, Derek↗
Variance Decomposition of MEDLI2 Reconstructed Heating Using Neural Networks
The Mars Entry, Descent, and Landing Instrumentation (MEDLI2) sensor suite collected data during entry of the Mars 2020 Perseverance rover into Mars’ atmosphere. This suite included a network of MEDLI2 Instrumented Sensor Plugs (MISPs). Each MISP was comprised of a cylinder made of Thermal Protection System (TPS) material with 1-3 embedded thermocouples (TCs), and it was flush mounted into the heatshield or backshell. Data from these in-depth TCs were used to reconstruct the aeroheating environment of the vehicle throughout entry. Surface heating was posed as an inverse problem, with the goal of estimating the surface heating by minimizing an objective function of the difference between MISP temperature measurements during flight and the temperature predictions derived from the Fully Implicit Ablation and Thermal response (FIAT) program. Given an aerothermal environment, FIAT calculates the material response and provides in-depth temperatures throughout the TPS material. To achieve the reverse, an internal tool called FIAT_Opt runs through multiple different environments until the output temperature at the TC depth closely matches the flight data. 95% confidence intervals on the reconstructed surface heating were obtained using Monte Carlo analysis, in which uncertainties in the thermocouple depth and the TPS material properties (e.g., density, thermal conductivity, heat capacity, emissivity) based on flight-lot material testing were included. A variance decomposition method using Sobol indices was employed to assess the sensitivity of the reconstructed peak heating to the TC placement and material property uncertainties. Variance decomposition was found to require tens of thousands of FIAT_Opt runs in order for the Sobol indices to converge. With a single FIAT_Opt run taking on the order of 40 minutes, the required number of computations would take months to complete, even if using multiple CPUs. To mitigate this problem, three machine learning models (ridge regression with cross-validation, random forest regression, and a deep neural network) were trained and tested using the 2000 Monte Carlo runs that were already completed. A subset of 1600 runs were used to train the model (i.e., training set), while the remaining 400 runs were used as the test set. The predictions from the deep neural network (DNN) on the test set showed nearly perfect agreement to the actual values computed with FIAT_Opt (R2 > 0.99). Using the DNN as a surrogate model, the variance decomposition using 50,000 runs was completed within minutes. The resulting Sobol indices showed that the reconstructed peak surface heating was most sensitive to the uncertainties in the thermal conductivity (ST = 0.37) and heat capacity (ST = 0.26). This method can be leveraged to provide requirements for material property measurements needed to improve the accuracy of surface heating prediction and ultimately lead to the reduction of design margins in the future. This presentation will include background on the MEDLI2 suite; the method used for inverse heating estimation; the way that material property uncertainties were accounted for using Monte Carlo analysis; a brief background on variance decomposition; the motivation for using machine learning in this context; how a neural network was trained on the data to enable variance decomposition in a fraction of the time; and the variance decomposition results for one of the MISPs.
Hannah Alpert↗
Program definition and preliminary results of a long-term evaluation program of advanced composites for supersonic cruise aircraft applications
Advanced composites will play a key role in the development of the technology required for the design and fabrication of future supersonic vehicles. A program is in progress to determine the time-temperature-stress capabilities of several high-temperature composite materials. Tests included in this study are thermal aging, ambient aging, fatigue, creep, fracture, tensile, and real-time flight-simulation exposure. The program has two parts. The first includes all the material-property determinations and aging and simulation exposures up through 10,000 h. The second continues these tests up to 50,000 cumulative h. The program is currently in the midst of the 10,000-h phase. Some of the results obtained to date and the status of the various tests are discussed.
Kerr, J. R.↗
Performance of cross-flow turbines with varying blade materials and unsupported blade span
Cross-flow turbines could play a larger role in the diversification of the global energy supply if the impact of more cost-competitive design choices on performance and rotor dynamics was better understood. This study focuses on rotor performance and blade strain measurements while varying the following parameters: blade materials and blade free end length by changing strut support position. Towing tank experiments were performed with a modular 1-meter diameter cross-flow turbine consisting of three NACA 0018 blades with two support struts. One strut was fixed at the lower end of the turbine, while the second strut was adjustable, thereby changing the length of the free end. The blade materials tested were carbon, E-glass, and hollow E-glass fiber composites, in decreasing order of stiffness and cost. High-resolution distributed fiber optic sensors were embedded in two of the three rotor blades for each material and provided hundreds of strain measurements per blade. Turbine performance and blade strain were measured while varying tow speed and tip speed ratio. Performance tests were conducted at towing speeds sufficiently high for the performance to be independent of Reynolds number. E-glass blades and carbon blades performed similarly for the most rigid strut configurations. Higher strain was measured on the E-glass blades, and their performance was reduced for less rigid configurations compared to the carbon fiber blades. The performance of the highly deflective hollow E-glass blades was lower overall and became even more degraded for longer unsupported blade span. Furthermore, the results provide insight into the use of various blade materials in cross-flow turbines and guidance on allowable free end length for each material type.
16 TIDAL AND WAVE POWER↗