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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 91 records · Page 5

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NASA NTRS1988

Durability of thermal barrier coatings in a high heat flux environment

Thermal shock is a significant factor in the limited service life of Space Shuttle Main Engine (SSME) high pressure, fuel turbopump (HPFTP) turbine blades. Addition of advanced thermal barrier coatings (TBCs) to the blades could serve to dampen the thermal shock, thereby increasing the life of the blades. However, testing and use of TBCs to date is performed primarily under moderate heat flux conditions which are typical of aircraft turbines. Only limited testing was conducted that addresses high heat flux and severe thermal shock conditions. Therefore, it is not clear if TBCs can survive severe thermal shocks or provide adequate thermal shock protection to the HPFTP turbine blades. The purpose is to experimentally evaluate the potential durability and protective capability of a variety of advanced TBCs in a cyclic thermal shock environment. A secondary goal is to identify significant parameters affecting TBC life during high heat flux testing. Parameters investigated include top coat thickness, bond coat thickness, substrate type, and substrate geometry.

Brindley, William J.↗

NASA NTRS1996

Thermomechanical Multiaxial Fatigue Testing Capability Developed

Structural components in aeronautical gas turbine engines typically experience multiaxial states of stress under nonisothermal conditions. To estimate the durability of the various components in the engine, one must characterize the cyclic deformation and fatigue behavior of the materials used under thermal and complex mechanical loading conditions. To this end, a testing protocol and associated test control software were developed at the NASA Lewis Research Center for thermomechanical axial-torsional fatigue tests. These tests are to be performed on thin-walled, tubular specimens fabricated from the cobalt-based superalloy Haynes 188. The software is written in C and runs on an MS-DOS based microcomputer.

Source record↗

NASA NTRS1987

Durability characterization of ceramic materials for gas turbines

The strength retention of ceramic materials during extended high-temperature cyclic exposure is critical to their widespread application in gas turbine engines. During a continuing NASA funded program initated in 1979, reaction bonded silicon nitride (RBSN), sintered silicon carbide (SSC), reaction sintered silicon carbide (RSSC), and sintered silicon nitride (SSN) materials were evaluated following simulated gas turbine engine exposures. Exposures were performed by cycling specimens five times per hour between a high velocity burner discharge and a rapid air quench. The retained flexural strengths were determined following up to 3500 hours of exposure at temperatures up to 1370 C. Post-exposure strengths have been correlated with fractography and surface examination using SEM. Results illustrate excellent strength retention of SSC materials after 3500 hours of exposure to 1370 C. At 1200 C, RBSN and RSSC also demonstrate significant strength retention. Although SSN materials typically suffer significant strength losses during exposures at 1200 C, a new composition, which has improved high-temperature strength, also shows improved durability. In the majority of the materials, strength loss is typically associated with flaw formation in the protective SiO2 layer.

Carruthers, W. D.↗

DOE OSTI2024

Analyzing the impact of design factors on solar module thermomechanical durability using interpretable machine learning techniques

Solar modules in utility-scale systems are expected to maintain decades of lifetime to rival conventional energy sources. However, cyclic thermomechanical loading often degrades their long-term performance, highlighting the importance of effective design to mitigate thermal expansion mismatches between module materials. Given the complex composition of solar modules, isolating the impact of individual components on overall durability remains a challenging task. In this work, we analyze a comprehensive data set that comprises bill-of-materials (BOM) and thermal cycling power loss from 251 distinct module designs to identify the predominant design factors and their impacts on the thermomechanical durability of modules. The methodology of our analysis combines machine learning modeling (random forest) and Shapley additive explanation (SHAP) to correlate design factors with power loss and interpret the model’s decision-making. The interpretation reveals that silicon type (monocrystalline or polycrystalline), encapsulant thickness, busbar numbers, and wafer thickness predominantly influence the degradation. With lower power loss of around 0.6% on average in the SHAP analysis, monocrystalline cells present better durability than polycrystalline cells. This finding is further substantiated by statistical testing on our raw data set. The SHAP analysis also demonstrates that while thicker encapsulants lead to reduced power loss, further increasing their thickness over around 0.6 to 0.7 mm does not yield additional benefits, particularly for the front side one. In addition, other important BOM features such as the number of busbars are analyzed. This study provides a blueprint for utilizing explainable machine learning techniques in a complex material system and can potentially guide future research on optimizing the design of solar modules.

14 SOLAR ENERGY↗

NASA NTRS1991

A high temperature fatigue life prediction computer code based on the Total Strain Version of Strainrange Partitioning (SRP)

A recently developed high-temperature fatigue life prediction computer code is presented, based on the Total Strain version of Strainrange Partitioning (TS-SRP). Included in this code are procedures for characterizing the creep-fatigue durability behavior of an alloy according to TS-SRP guidelines and predicting cyclic life for complex cycle types for both isothermal and thermomechanical conditions. A reasonably extensive materials properties database is included with the code.

Mcgaw, Michael A.↗

NASA NTRS1993

A high temperature fatigue life prediction computer code based on the total strain version of StrainRange Partitioning (SRP)

A recently developed high-temperature fatigue life prediction computer code is presented and an example of its usage given. The code discussed is based on the Total Strain version of Strainrange Partitioning (TS-SRP). Included in this code are procedures for characterizing the creep-fatigue durability behavior of an alloy according to TS-SRP guidelines and predicting cyclic life for complex cycle types for both isothermal and thermomechanical conditions. A reasonably extensive materials properties database is included with the code.

Mcgaw, Michael A.↗

DOE OSTI2025

Studying the Durability of Molybdenum Carbide Aerogel as an Electrocatalyst Support for Proton Exchange Membrane Fuel Cells

Carbon-supported platinum nanoparticles (Pt/C) are currently the state-of-the-art catalyst in proton exchange membrane fuel cells (PEMFCs). Unfortunately, the carbon support lacks the ability to stabilize the metal catalyst, as platinum tends to dissolve and agglomerate, significantly compromising the durability. Herein, we synthesized a ceramic material, molybdenum carbide aerogel (MCAG), and utilized it as a Pt support for PEMFCs, as an alternative for conventional carbon supports. N 2 adsorption and XRD analysis showed that the MCAG possesses a combination of high porosity and a well-defined ceramic crystalline structure. The Pt/MCAG system was studied for its electrocatalytic activity toward ORR in a half-cell and demonstrated satisfactory reaction kinetics and electrochemical active surface area, comparable to the commercial Pt/C. For durability examination, an accelerated stress test (AST) in a single cell was conducted with the Pt/MCAG catalyst at the cathode, following the U.S. DOE electrocatalyst AST protocol. Intermediate polarization curves and cyclic voltammograms were recorded over the course of the AST to monitor the aging process. The results indicated that the MCAG support exhibited superior durability in long-term fuel cell operation compared to a carbon support. The Pt/MCAG system demonstrated stable behavior during the progressive stages of the AST, retaining more than 50% of its initial performance by the end of the test, whereas carbon-supported Pt preserved only 30%.

25 ENERGY STORAGE↗

NASA NTRS2014

NASA's Advanced Environmental Barrier Coatings Development for SiC/SiC Ceramic Matrix Composites: Understanding Calcium Magnesium Alumino-Silicate (CMAS) Degradations and Resistance

Environmental barrier coatings (EBCs) and SiCSiC ceramic matrix composites (CMCs) systems will play a crucial role in next generation turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures with improved efficiency, reduce engine weight and cooling requirements. The development of prime-reliant environmental barrier coatings is essential to the viability and reliability of the envisioned CMC engine component applications, ensuring integrated EBC-CMC system durability and designs are achievable for successful applications of the game-changing component technologies and lifing methodologies.This paper will emphasize recent NASA environmental barrier coating developments for SiCSiC turbine airfoil components, utilizing advanced coating compositions, state-of-the-art processing methods, and combined mechanical and environment testing and durability evaluations. The coating-CMC degradations in the engine fatigue-creep and operating environments are particularly complex; one of the important coating development aspects is to better understand engine environmental interactions and coating life debits, and we have particularly addressed the effect of Calcium-Magnesium-Alumino-Silicate (CMAS) from road sand or volcano-ash deposits on the durability of the environmental barrier coating systems, and how the temperature capability, stability and cyclic life of the candidate rare earth oxide and silicate coating systems will be impacted in the presence of the CMAS at high temperatures and under simulated heat flux conditions. Advanced environmental barrier coating systems, including HfO2-Si with rare earth dopant based bond coat systems, will be discussed for the performance improvements to achieve better temperature capability and CMAS resistance for future engine operating conditions.

Environmental barrier coatings↗

NASA NTRS2004

Durability and Design Issues of Thermal/environmental Barrier Coatings on Sic/sic Ceramic Matrix Composites Under 1650 C Test Conditions

Ceramic thermal/environmental barrier coatings for SiC-based ceramics will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability remains a major concern with the ever-increasing temperature requirements. Currently, advanced T/EBC systems, which typically include a high temperature capable zirconia- (or hahia-) based oxide top coat (thermal barrier) on a less temperature capable mullite/barium-strontium-aluminosilicate (BSAS)/Si inner coat (environmental barrier), are being developed and tested for higher temperature capability Sic combustor applications. In this paper, durability of several thermal/environmental barrier coating systems on SiC/SiC ceramic matrix composites was investigated under laser simulated engine thermal gradient cyclic, and 1650 C (3000 F) test conditions. The coating cracking and delamination processes were monitored and evaluated. The effects of temperature gradients and coating configurations on the ceramic coating crack initiation and propagation were analyzed using finite element analysis (FEA) models based on the observed failure mechanisms, in conjunction with mechanical testing results. The environmental effects on the coating durability will be discussed. The coating design approach will also be presented.

Zhu, Dong-Ming↗

NASA NTRS1983

Burner liner thermal/structural load modelling

The objective of this program is to develop a thermal data transfer computer program module for the burner liner thermal structural load modeling program. This will be accomplished by (1) reviewing existing methodologies for thermal data transfer and selecting three heat transfer codes for application in this program; (2) evaluating the selected codes to establish criteria for developing a computer program module to transfer thermal data from the heat transfer codes to selected stress analysis codes; (3) developing the automated thermal load transfer module; and (4) verifying and documenting the module. In aircraft turbine engine hot section components, cyclic thermal stresses are the most important damage mechanism. Consequently, accurate and reliable prediction of thermal loads is essential to improving durability. To achieve this goal, a considerable effort over the past 20 years has been devoted to the acquisition of engine temperature test data, as well as the development of accurate, reliable, and efficient computer codes for the prediction of steady state and transient temperatures and for the calculation of elastic and inelastic cyclic stresses and strains in hot section components. There is a need for continued development of these codes, because the availability of more accurate analysis techniques for complex configurations has enabled engine designers to use more sophisticated designs to achieve higher cycle efficiency and reduce weight.

Maffeo, R. J.↗

NASA NTRS1999

Cyclic Cryogenic Thermal-Mechanical Testing of an X-33/RLV Liquid Oxygen Tank Concept

An important step in developing a cost-effective, reusable, launch vehicle is the development of durable, lightweight, insulated, cryogenic propellant tanks. Current cryogenic tanks are expendable so most of the existing technology is not directly applicable to future launch vehicles. As part of the X-33/Reusable Launch Vehicle (RLV) Program, an experimental apparatus developed at the NASA Langley Research Center for evaluating the effects of combined, cyclic, thermal and mechanical loading on cryogenic tank concepts was used to evaluate cryogenic propellant tank concepts for Lockheed-Martin Michoud Space Systems. An aluminum-lithium (Al 2195) liquid oxygen tank concept, insulated with SS-1171 and PDL-1034 cryogenic insulation, is tested under simulated mission conditions, and the results of those tests are reported. The tests consists of twenty-five simulated Launch/Abort missions and twenty-five simulated flight missions with temperatures ranging from -320 F to 350 F and a maximum mechanical load of 71,300 lb. in tension.

Rivers, H. Kevin↗

NASA NTRS2001

Durability and Damage Development in Woven Ceramic Matrix Composites

Damage development in woven SiC/SiNC ceramic matrix composites (CMC's) under tensile and cyclic loading both at room and elevated temperatures have been investigated for the exhaust nozzle of high-efficient turbine engines. The ultimate strength, failure strain, proportional limit and modulus data at a temperature range of 23 to 1250 C are generated. The tensile strength of SiC/SiNC woven composites have been observed to increase with increased temperatures up to 1000 C. The stress/strain plot shows a pseudo-yield point at 25 percent of the failure strain (epsilon(sub r)) which indicates damage initiation in the form of matrix cracking. The evolution of damage beyond 0.25 epsilon(sub f), both at room and elevated temperature comprises multiple matrix cracking, interfacial debonding, and fiber pullout. Although the nature of the stress/strain plot shows damage-tolerant behavior under static loading both at room and elevated temperature, the life expectancy of SiC/SiNC composites degrades significantly under cyclic loading at elevated temperature. This is mostly due to the interactions of fatigue damage caused by the mechanically induced plastic strain and the damage developed by the creep strain. The in situ damage evolutions are monitored by acoustic event parameters, ultrasonic C-scan and stiffness degradation. Rate equations for modulus degradation and fatigue life prediction of ceramic matrix composites both at room and elevated temperatures are developed. These rate equations are observed to show reasonable agreement with experimental results.

Haque, A.↗

NASA NTRS2020

Durability of YSZ coated Ti2AlC in 1300°C high velocity burner rig tests

A thermal barrier coating system survived 500 h in cyclic burner rig tests at 1300°C, exceeding the life of all previous systems. An yttria stabilized zirconia (7YSZ) thermal barrier coating (TBC) was plasma sprayed on the oxidation resistant Ti2AlC MAX phase and tested in a jet fuel burner. No coating spallation or recession was observed, only a 2.4 mg/sq.cm mass gain due to typical cubic Al2O3 oxidation kinetics. The modest weight gain contrasted with large TBC spallation or oxide volatility losses that might occur under cyclic, high velocity (~100 m/s) burner conditions. The coating surface exhibited colonies of [111]flourite fiber-textured columns separated by craze crack patterns, but with no visible moisture attack. The thickness of the alumina scale under the YSZ face was >20 μm, more than twice that formed on TBC/superalloy systems at failure. TiO2 nodules, initially formed on the uncoated backside, were then removed as volatile hydroxides formed in high temperature, high velocity water vapor (~10%). Overall, the test indicated the exceptional stability of the YSZ/Ti2AlC system under turbine conditions, due in large part to good thermal expansion matching.

alumina, MAX phases, thermal barrier coatings (TBC↗

NASA NTRS2018

Cyclic Symmetry Finite Element Forced Response Analysis of a Distortion-Tolerant Fan with Boundary Layer Ingestion

Accurate prediction of the blade vibration stress is required to determine overall durability of fan blade design under Boundary Layer Ingestion (BLI) distorted flow environments. Traditional single blade modeling technique is incapable of representing accurate modeling for the entire rotor blade system subject to complex dynamic loading behaviors and vibrations in distorted flow conditions. A particular objective of our work was to develop a high-fidelity full-rotor aeromechanics analysis capability for a system subjected to a distorted inlet flow by applying cyclic symmetry finite element modeling methodology. This reduction modeling method allows computationally very efficient analysis using a small periodic section of the full rotor blade system. Experimental testing by the use of the 8-foot by 6-foot Supersonic Wind Tunnel Test facility at NASA Glenn Research Center was also carried out for the system designated as the Boundary Layer Ingesting Inlet/Distortion-Tolerant Fan (BLI2DTF) technology development. The results obtained from the present numerical modeling technique were evaluated with those of the wind tunnel experimental test, toward establishing a computationally efficient aeromechanics analysis modeling tool facilitating for analyses of the full rotor blade systems subjected to a distorted inlet flow conditions. Fairly good correlations were achieved hence our computational modeling techniques were fully demonstrated. The analysis result showed that the safety margin requirement set in the BLI2DTF fan blade design provided a sufficient margin with respect to the operating speed range.

forced response analysis↗

NASA NTRS1978

CODSTRAN - Composite durability structural analysis

CODSTRAN (COmposite Durability STRucture ANalysis) a NASA Lewis Center computer program for the prediction of defect growth and fracture of composite structures when subjected to service loads is presented. Organization, capabilities and present status are discussed. Organizational aspects include executive, input, output, analysis and composite mechanics modules. Capabilities include: durability assessment of large structures and complex structural parts from composites, structural response due to static, cyclic, transient impact and thermal loads, and criteria for static, cyclic, and dynamic fracture. At the present state of development some of CODSTRAN's analysis capabilities include composite mechanics, static failures, and lamination residual stresses. An application in which CODSTRAN is used to predict the defect growth in a flat specimen, with a center through-slit under tension is studied. When completed, CODSTRAN will account for geometry and material nonlinearities, environmental effects as well as static, cyclic and dynamic fracture.

Chamis, C. C.↗

NASA NTRS1981

Survey of long-term durability of fiberglass reinforced plastic structures

Included are fluid containment vessels, marine structures, and aircraft components with up to 19 years of service. Correlations were obtained for the variation of static fatigue strength, cyclic fatigue strength, and residual burst strength for pressure vessels. In addition, data are presented for the effects of moisture on strength retention. Data variations were analyzed, and relationships and implications for testing are discussed. Change in strength properties for complete structures was examined for indications of the effects of environmental conditions such as moisture and outdoor exposure (ultraviolet radiation, weathering) on long term durability.

Lieblein, S.↗

NASA NTRS1979

Cyclic tests of P-bulb end-seal designs for a shuttle-type wing-elevon cove membrane seal

Four P-bulb end seal designs were tested at room temperature in a cyclic seal test apparatus. Test results show that all the P-bulb end seals have the durability required for a 100 mission life (neglecting possible elevated-temperature effects) and three of the four P-bulbs provide an adequate seal against a 7.0-kPa air pressure differential. Antifriction material attached to the P-bulb rub surface reduced friction slightly but could degrade the sealing effectiveness. A flat rub surface molded into the P-bulb discouraged wrinkling and rolling and thereby reduced leakage. However, the P-bulbs lacked resilience, as indicated by increased leakage when P-bulb compression was reduced. The best P-bulb design tested included an antifriction interface bonded to a flat surface molded into the P-bulb.

Hunt, L. R.↗

NASA NTRS1986

Strength of graphite/epoxy bolted wing-skin splice specimens subjected to outdoor exposure under constant load and yearly fatigue loading

The results of an experimental study to provide long-term durability data on detailed full-scale graphite/epoxy wing-skin joint designs under environmental exposure and cyclic loading associated with commercial transport aircraft are reported. The specimens consisted of a single-row bolt configuration fabricated from T300/5208 and a double-row bolt configuration fabricated from T300/5209. The unpainted specimens were exposed to the outdoor environment under a sustained tensile load, and at yearly intervals, they were subjected to fatigue loading. Experimental results showed a slight reduction in residual tensile strength for both graphite/epoxy joints under the exposure times and fatigue loadings reported. A 7.5-percent decrease in residual strength was observed for the T300/5208 single-row joint after 5 years exposure and two lifetimes of fatigue loading. A 5.3-percent decrease in residual strength was observed for the T300/5209 double-row joint after 7 years exposure and 2.8 lifetimes of fatigue loading. The 5208 epoxy material was more susceptible to degradation by ultraviolet radiation than the 5209 epoxy material.

Wichorek, G. R.↗