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NASA NTRS2007

Testing of Full Scale Flight Qualified Kevlar Composite Overwrapped Pressure Vessels

Many decades ago NASA identified a need for low-mass pressure vessels for carrying various fluids aboard rockets, spacecraft, and satellites. A pressure vessel design known as the composite overwrapped pressure vessel (COPV) was identified to provide a weight savings over traditional single-material pressure vessels typically made of metal and this technology has been in use for space flight applications since the 1970's. A typical vessel design consisted of a thin liner material, typically a metal, overwrapped with a continuous fiber yarn impregnated with epoxy. Most designs were such that the overwrapped fiber would carry a majority of load at normal operating pressures. The weight advantage for a COPV versus a traditional singlematerial pressure vessel contributed to widespread use of COPVs by NASA, the military, and industry. This technology is currently used for personal breathing supply storage, fuel storage for auto and mass transport vehicles and for various space flight and aircraft applications. The NASA Engineering and Safety Center (NESC) was recently asked to review the operation of Kevlar 2 and carbon COPVs to ensure they are safely operated on NASA space flight vehicles. A request was made to evaluate the life remaining on the Kevlar COPVs used on the Space Shuttle for helium and nitrogen storage. This paper provides a review of Kevlar COPV testing relevant to the NESC assessment. Also discussed are some key findings, observations, and recommendations that may be applicable to the COPV user community. Questions raised during the investigations have revealed the need for testing to better understand the stress rupture life and age life of COPVs. The focus of this paper is to describe burst testing of Kevlar COPVs that has been completed as a part of an the effort to evaluate the effects of ageing and shelf life on full scale COPVs. The test articles evaluated in this discussion had a diameter of 22 inches for S/N 014 and 40 inches for S/N 011. The time between manufacture and burst was 28 and 22 years. Visual inspection, shearography, heat soak thermography and borescope inspection were performed on vessel S/N 011 and all but shearography was performed on S/N 014 before they were tested and details of this work can be found in a companion paper titled, "Nondestructive Methods and Special Test Instrumentation Supporting NASA Composite Overwrapped Pressure Vessel Assessments." The vessels were instrumented so that measurements could be made to aid in the understanding of vessel response. Measurements made on the test articles included girth, boss displacement, internal volume, multiple point strain, full field strain, eddy current, acoustic emission (AE) pressure and temperature. The test article before and during burst is shown with the pattern used for digital image correlation full field strain measurement blurring as the vessel fails.

Greene, Nathanael↗

NASA NTRS2026

AC and DC Fault Management for Megawatt Electrified Aircraft Electrical Powertrains Task 3: Lifetime and Reliability of Electrical Insulators

This research project was a collaborative investigation between researchers at the RTX Technology Research Center (RTRC) and the University of Texas at Austin and made a significant contribution to enabling electric aircraft. The transport of electric power between the points of generation and use requires power cables. These cables must be smaller, lighter and provide a more predictable life than power cables used in stationary applications. Consequently, this investigation provided heretofore unavailable information supporting the safety and reliability of smaller lighter power cables for electrified aircraft. In addition, the research identified key additional engineering data needed to support quantitative reliability assessments. Important advances included: • Demonstrated that at least one manufacturer can make a novel, smaller, lighter power cable that is free from serious defects. • Developed and published an appropriate analytical construct to describe the life of this novel cable. This is a necessary step for use in aviation where the understanding of remaining life is critical. • Demonstrated thermal-mechanical aging that suggested 1000+ flights before the thermal-mechanical processes produced defects large enough that the defect growth was accelerated electrically. • Showed that electrical aging took place at two rates. The first possibly lasting weeks to months and the second possibly days to weeks. If robust, this provides a good diagnostic for cable replacement. • Demonstrated that the traditional electrical testing of cable materials using manufactured voids can be misleading due to the size of the voids. Emerging laser drilling technology permitted demonstration that the physics of failure in realistically small voids is different from that in the unrealistically large voids used in earlier research, which is very important for high-quality, high-performance, small aircraft cables. Although this project represents a significant contribution to the specifics of cable aging in the aircraft environment, important additional research remains to be completed, including: • Non-uniform thermal cycling by applying the heat from the center conductor to maximize thermal stress next to the core area where the electric gradient is the strongest. This builds on the uniform thermal cycling that has been completed. • The augmentation of the thermal-mechanical failure rate by electrical processes. Better understanding of these time constants strongly affects the ability to predict life. • Termination design: Terminations provide not only electrical reflection potential, but a location for a series arc fault and an area where ozone can diffuse into the center conductor and negatively affect cable insulation. • The abrasion and ozone resistance of the cable jacket. • Pressure cycling as an accelerant of thermal, mechanical, and/or electrical aging. • Possible methods for online PD detection and offline PD localization

model↗

NASA NTRS1999

Ultrasonic Nondestructive Characterization of Adhesive Bonds

Adhesives and adhesive joints are widely used in various industrial applications to reduce weight and costs, and to increase reliability. For example, advances in aerospace technology have been made possible, in part, through the use of lightweight materials and weight-saving structural designs. Joints, in particular, have been and continue to be areas in which weight can be trimmed from an airframe through the use of novel attachment techniques. In order to save weight over traditional riveted designs, to avoid the introduction of stress concentrations associated with rivet holes, and to take full advantage of advanced composite materials, engineers and designers have been specifying an ever-increasing number of adhesively bonded joints for use on airframes. Nondestructive characterization for quality control and remaining life prediction has been a key enabling technology for the effective use of adhesive joints. Conventional linear ultrasonic techniques generally can only detect flaws (delamination, cracks, voids, etc) in the joint assembly. However, more important to structural reliability is the bond strength. Although strength, in principle, cannot be measured nondestructively, a slight change in material nonlinearity may indicate the onset of failure. Furthermore, microstructural variations due to aging or under-curing may also cause changes in the third order elastic constants, which are related to the ultrasonic nonlinear parameter of the polymer adhesive. It is therefore reasonable to anticipate a correlation between changes in the ultrasonic nonlinear acoustic parameter and the remaining bond strength. It has been observed that higher harmonics of the fundamental frequency are generated when an ultrasonic wave passes through a nonlinear material. It seems that such nonlinearity can be effectively used to characterize bond strength. Several theories have been developed to model this nonlinear effect. Based on a microscopic description of the nonlinear interface binding force, a quantitative method was presented. Recently, a comparison between the experimental and simulated results based on a similar theoretical model was presented. A through-transmission setup for water immersion mode-converted shear waves was used to analyze the ultrasonic nonlinear parameter of an adhesive bond. In addition, ultrasonic guided waves have been used to analyze adhesive or diffusion bonded joints. In this paper, the ultrasonic nonlinear parameter is used to characterize the curing state of a polymer/aluminum adhesive joint. Ultrasonic through-transmission tests were conducted on samples cured under various conditions. The magnitude of the second order harmonic was measured and the corresponding ultrasonic nonlinear parameter was evaluated. A fairly good correlation between the curing condition and the nonlinear parameter is observed. The results show that the nonlinear parameter might be used as a good indicator of the cure state for adhesive joints.

Qu, Jianmin↗

NASA NTRS2005

Life Modeling and Design Analysis for Ceramic Matrix Composite Materials

The primary research efforts focused on characterizing and modeling static failure, environmental durability, and creep-rupture behavior of two classes of ceramic matrix composites (CMC), silicon carbide fibers in a silicon carbide matrix (SiC/SiC) and carbon fibers in a silicon carbide matrix (C/SiC). An engineering life prediction model (Probabilistic Residual Strength model) has been developed specifically for CMCs. The model uses residual strength as the damage metric for evaluating remaining life and is posed probabilistically in order to account for the stochastic nature of the material s response. In support of the modeling effort, extensive testing of C/SiC in partial pressures of oxygen has been performed. This includes creep testing, tensile testing, half life and residual tensile strength testing. C/SiC is proposed for airframe and propulsion applications in advanced reusable launch vehicles. Figures 1 and 2 illustrate the models predictive capabilities as well as the manner in which experimental tests are being selected in such a manner as to ensure sufficient data is available to aid in model validation.

Source record↗

NASA NTRS2016

Stewardship of NASA's Earth Science Data and Ensuring Long-Term Active Archives

Program, NASA has followed an open data policy, with non-discriminatory access to data with no period of exclusive access. NASA has well-established processes for assigning and or accepting datasets into one of 12 Distributed Active Archive Centers (DAACs) that are parts of EOSDIS. EOSDIS has been evolving through several information technology cycles, adapting to hardware and software changes in the commercial sector. NASA is responsible for maintaining Earth science data as long as users are interested in using them for research and applications, which is well beyond the life of the data gathering missions. For science data to remain useful over long periods of time, steps must be taken to preserve: (1) Data bits with no corruption, (2) Discoverability and access, (3) Readability, (4) Understandability, (5) Usability' and (6). Reproducibility of results. NASAs Earth Science data and Information System (ESDIS) Project, along with the 12 EOSDIS Distributed Active Archive Centers (DAACs), has made significant progress in each of these areas over the last decade, and continues to evolve its active archive capabilities. Particular attention is being paid in recent years to ensure that the datasets are published in an easily accessible and citable manner through a unified metadata model, a common metadata repository (CMR), a coherent view through the earthdata.gov website, and assignment of Digital Object Identifiers (DOI) with well-designed landing product information pages.

Data Management↗

NASA NTRS2002

Land Use and Land Cover Change in Forest Frontiers: The Role of Household Life Cycles

Tropical deforestation remains a critical issue given its present rate and a widespread consensus regarding its implications for the global carbon cycle and biodiversity. Nowhere is the problem more pronounced than in the Amazon basin, home to the world's largest intact, tropical forest. This article addresses land cover change processes at household level in the Amazon basin, and to this end adapts a concept of domestic life cycle to the current institutional environment of tropical frontiers. In particular, it poses a risk minimization model that integrates demography with market-based factors such as transportation costs and accessibility. In essence, the article merges the theory of Chayanov with the household economy framework, in which markets exist for inputs (including labor), outputs, and capital. The risk model is specified and estimated, using survey data for 261 small producers along the Transamazon Highway in the eastern sector of the Brazilian Amazon.

Walker, Robert↗

NASA NTRS1997

Retirement for Cause as an Alternate Means of Managing Component Lives

In the current budgetary environment, fielded equipment is often used beyond its design life. To avoid the large cost of replacing critical rotating parts as they reach their "safelife" limits, a Retirement For Cause (RFC) program may prove to be a cost-effective, yet safe, alternative. Studies indicate that a full 80 percent of parts replaced at low-cycle fatigue calculated "safe life" limits have at least a full order of magnitude of remaining fatigue life. The Air Force has embraced RFC and currently uses it successfully to manage parts life for several of their gas turbine engines.

Bonacuse, Peter J.↗

NASA NTRS2001

Transgene expression patterns indicate that spaceflight affects stress signal perception and transduction in arabidopsis

The use of plants as integral components of life support systems remains a cornerstone of strategies for long-term human habitation of space and extraterrestrial colonization. Spaceflight experiments over the past few decades have refined the hardware required to grow plants in low-earth orbit and have illuminated fundamental issues regarding spaceflight effects on plant growth and development. Potential incipient hypoxia, resulting from the lack of convection-driven gas movement, has emerged as a possible major impact of microgravity. We developed transgenic Arabidopsis containing the alcohol dehydrogenase (Adh) gene promoter linked to the beta-glucuronidase (GUS) reporter gene to address specifically the possibility that spaceflight induces the plant hypoxia response and to assess whether any spaceflight response was similar to control terrestrial hypoxia-induced gene expression patterns. The staining patterns resulting from a 5-d mission on the orbiter Columbia during mission STS-93 indicate that the Adh/GUS reporter gene was activated in roots during the flight. However, the patterns of expression were not identical to terrestrial control inductions. Moreover, although terrestrial hypoxia induces Adh/GUS expression in the shoot apex, no apex staining was observed in the spaceflight plants. This indicates that either the normal hypoxia response signaling is impaired in spaceflight or that spaceflight inappropriately induces Adh/GUS activity for reasons other than hypoxia.

manned↗

NASA NTRS2010

Optical Structural Health Monitoring Device

This non-destructive, optical fatigue detection and monitoring system relies on a small and unobtrusive light-scattering sensor that is installed on a component at the beginning of its life in order to periodically scan the component in situ. The method involves using a laser beam to scan the surface of the monitored component. The device scans a laser spot over a metal surface to which it is attached. As the laser beam scans the surface, disruptions in the surface cause increases in scattered light intensity. As the disruptions in the surface grow, they will cause the light to scatter more. Over time, the scattering intensities over the scanned line can be compared to detect changes in the metal surface to find cracks, crack precursors, or corrosion. This periodic monitoring of the surface can be used to indicate the degree of fatigue damage on a component and allow one to predict the remaining life and/or incipient mechanical failure of the monitored component. This wireless, compact device can operate for long periods under its own battery power and could one day use harvested power. The prototype device uses the popular open-source TinyOS operating system on an off-the-shelf Mica2 sensor mote, which allows wireless command and control through dynamically reconfigurable multi-node sensor networks. The small size and long life of this device could make it possible for the nodes to be installed and left in place over the course of years, and with wireless communication, data can be extracted from the nodes by operators without physical access to the devices. While a prototype has been demonstrated at the time of this reporting, further work is required in the system s development to take this technology into the field, especially to improve its power management and ruggedness. It should be possible to reduce the size and sensitivity as well. Establishment of better prognostic methods based on these data is also needed. The increase of surface roughness with fatigue is closely connected to the microstructure of the metal, and ongoing research is seeking to connect this observed evidence of the fatigue state with microstructural theories of fatigue evolution to allow more accurate prognosis of remaining component life. Plans are also being discussed for flight testing, perhaps on NASA s SOFIA platform.

Buckner, Benjamin D.↗

NASA NTRS1985

Response of thick, notched laminates subjected to tension-compression cyclic loads

The fatigue response of a (0/24/90/-45)s4 T300-5208 graphite-epoxy laminate with a drilled centerhole subjected to fully reversed tension-compression (R=-1, T-C) constant amplitude loading was investigated. Damage evaluation techniques such as stiffness monitoring, penetrant-enchanced X-ray radiography, C-scan, laminate deeply and residual strength were used to establish the mechanisms of damage development as well as the relations between this damage and the stiffness, strength and life of the laminate. Damage initiated at the hole as matrix cracking parallel to the fibers in all plies. Matrix cracks had a significant effect on delamination initiation and growth. Delaminations initiated near the surface in the densely cracked region at the hole and grew along major matrix cracks. Compressive properties degraded more rapidly than tensile properties. At the stress levels used, residual tensile strength increased early in the fatigue life and remained approximately constant to near the end of life, when failure was precipitated by excessive laminate instability during the compressive portion of the loading.

Bakis, C. E.↗

NASA NTRS1986

Response of thick, notched laminates subjected to tension-compression cyclic loads

The fatigue response of a (0/24/90/-45)s4 T300-5208 graphite-epoxy laminate with a drilled centerhole subjected to fully reversed tension-compression (R=-1, T-C) constant amplitude loading was investigated. Damage evaluation techniques such as stiffness monitoring, penetrant-enhanced X-ray radiography, C-scan, laminate deply and residual strength were used to establish the mechanisms of damage development as well as the relations between this damage and the stiffness, strength and life of the laminate. Damage initiated at the hole as matrix cracking parallel to the fibers in all plies. Matrix cracks had a significant effect on delamination initiation and growth. Delaminations initiated near the surface in the densely cracked region at the hole and grew along major matrix cracks. Compressive properties degraded more rapidly than tensile properties. At the stress levels used, residual tensile strength increased early in the fatigue life and remained approximately constant to near the end of life, when failure was precipitated by excessive laminate instability during the compressive portion of the loading.

Bakis, C. E.↗

NASA NTRS2010

Detection of Natural Oil Seeps in the Atlantic Ocean Using MODIS

Natural oil seepage is the release of crude oil into the ocean from fissures in the seabed. Oil seepage is a major contributor to the total amount of oil entering the world s oceans. According to a 2003 study by the National Academy of Sciences (NAS), 47 percent of oil entering the world s oceans is from natural seeps, and 53 percent is from human sources (extraction, transportation, and consumption). Oil seeps cause smooth oil slicks to form on the water s surface. Oil seeps can indicate the location of stores of fossil fuel beneath the ocean floor. Knowledge of the effect of oil seepage on marine life and marine ecosystems remains limited. In the past, remote sensing has been used to detect oil seeps in the Gulf of Mexico and off of the coast of southern California. This project utilized sun glint MODIS imagery to locate oil slicks off of the Atlantic coast, an area that had not previously been surveyed for natural oil seeps using remote sensing. Since 1982, the Atlantic Ocean has been closed to any oil and gas drilling. Recently, however, the U.S. Minerals Management Services (MMS) has proposed a lease for oil and gas drilling off the coasts of Virginia and North Carolina. Determining the location of seepage sites in the Atlantic Ocean will help MMS locate potential deposits of oil and natural gas, thereby reducing the risk of leasing areas for petroleum extraction that do not contain these natural resources.

Reahard, Ross↗

NASA NTRS1992

Fracture mechanics expert system

Attention is given to fracture mechanics, an analytical method used extensively in the National Space Transportation System to conservatively predict the remaining service life of an article when a flaw or a material defect is detected. These analyses are performed on hardware containing material defects that have been detected by various nondestructive inspection techniques. An expert system being developed to streamline the process so that hardware dispositions may be obtained in a timely and consistent manner is discussed. The expert system reduces the potential for errors due to the manual transcription between the various software programs involved in completing a fracture mechanics analysis. NEXPERT Object, the expert system development shell selected for this purpose, allows the various software programs used in fracture mechanics analyses to be accessed and manipulated from the same platform.

Powers, E.↗

NASA NTRS1991

Alkali metal pool boiler life tests for a 25 kWe advanced Stirling conversion system

The overall operating temperature and efficiency of solar-powered Stirling engines can be improved by adding an alkali metal pool boiler heat transport system to supply heat more uniformly to the heater head tubes. One issue with liquid metal pool boilers is unstable boiling. Stable boiling is obtained with an enhanced boiling surface containing nucleation sites that promote continuous boiling. Over longer time periods, it is possible that the boiling behavior of the system will change. An 800-h life test was conducted to verify that pool boiling with the chosen fluid/surface combination remains stable as the system ages. The apparatus uses NaK boiling on a - 100 + 140 stainless steel sintered porous layer, with the addition of a small amount of xenon. Pool boiling remained stable to the end of life test. The pool boiler life test included a total of 82 cold starts, to simulate startup each morning, and 60 warm restarts, to simulate cloud cover transients. The behavior of the cold and warm starts showed no significant changes during the life test. In the experiments, the fluid/surface combination provided stable, high-performance boiling at the operating temperature of 700 C. Based on these experiments, a pool boiler was designed for a full-scale 25-kWe Stirling system.

Anderson, W. G.↗

NASA NTRS1981

Sputtered protective coatings for die casting dies

Three experimental research designs investigating candidate materials and processes involved in protective die surface coating procedures by sputter deposition, using ion beam technologies, are discussed. Various pre-test results show that none of the coatings remained completely intact for 15,000 test cycles. The longest lifetime was observed for coatings such as tungsten, platinum, and molybdenum which reduced thermal fatigue, but exhibited oxidation and suppressed crack initiation only as long as the coating did not fracture. Final test results confirmed earlier findings and coatings with Pt and W proved to be the candidate materials to be used on a die surface to increase die life. In the W-coated specimens, which remained intact on the surface after thermal fatigue testing, no oxidation was found under the coating, although a few cracks formed on the surface where the coating broke down. Further research is planned.

Mirtich, M. J.↗

NASA NTRS2006

Material Issues in Space Shuttle Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPV) store gases used in four subsystems for NASA's Space Shuttle Fleet. While there are 24 COPV on each Orbiter ranging in size from 19-40", stress rupture failure of a pressurized Orbiter COPV on the ground or in flight is a catastrophic hazard and would likely lead to significant damage/loss of vehicle and/or life and is categorized as a Crit 1 failure. These vessels were manufactured during the late 1970's and into the early 1980's using Titanium liners, Kevlar 49 fiber, epoxy matrix resin, and polyurethane coating. The COPVs are pressurized periodically to 3-5ksi and therefore experience significant strain in the composite overwrap. Similar composite vessels were developed in a variety of DOE Programs (primarily at Lawrence Livermore National Laboratories or LLNL), as well as for NASA Space Shuttle Fleet Leader COPV program. The NASA Engineering Safety Center (NESC) formed an Independent Technical Assessment (ITA) team whose primary focus was to investigate whether or not enough composite life remained in the Shuttle COPV in order to provide a strategic rationale for continued COPV use aboard the Space Shuttle Fleet with the existing 25-year-old vessels. Several material science issues were examined and will be discussed in this presentation including morphological changes to Kevlar 49 fiber under stress, manufacturing changes in Kevlar 49 and their effect on morphology and tensile strength, epoxy resin strain, composite creep, degradation of polyurethane coatings, and Titanium yield characteristics.

Sutter, James K.↗

NASA NTRS2014

NASA GeneLab Concept of Operations

NASA's GeneLab aims to greatly increase the number of scientists that are using data from space biology investigations on board ISS, emphasizing a systems biology approach to the science. When completed, GeneLab will provide the integrated software and hardware infrastructure, analytical tools and reference datasets for an assortment of model organisms. GeneLab will also provide an environment for scientists to collaborate thereby increasing the possibility for data to be reused for future experimentation. To maximize the value of data from life science experiments performed in space and to make the most advantageous use of the remaining ISS research window, GeneLab will apply an open access approach to conducting spaceflight experiments by generating, and sharing the datasets derived from these biological studies in space.Onboard the ISS, a wide variety of model organisms will be studied and returned to Earth for analysis. Laboratories on the ground will analyze these samples and provide genomic, transcriptomic, metabolomic and proteomic data. Upon receipt, NASA will conduct data quality control tasks and format raw data returned from the omics centers into standardized, annotated information sets that can be readily searched and linked to spaceflight metadata. Once prepared, the biological datasets, as well as any analysis completed, will be made public through the GeneLab Space Bioinformatics System webb as edportal. These efforts will support a collaborative research environment for spaceflight studies that will closely resemble environments created by the Department of Energy (DOE), National Center for Biotechnology Information (NCBI), and other institutions in additional areas of study, such as cancer and environmental biology. The results will allow for comparative analyses that will help scientists around the world take a major leap forward in understanding the effect of microgravity, radiation, and other aspects of the space environment on model organisms. These efforts will speed the process of scientific sharing, iteration, and discovery.

Space Life Science↗

NASA NTRS1973

U.S. view of human problems to be addressed for long duration space flights

The Russian and American space programs have consisted of several thousands of hours of exposure of man to the space environment. In spite of numerous biological phenomena of adaptation observed, the space travellers have displayed, after their return, no enduring pathological effect. Although the usable data remain too limited to reflect fully the effects of space flight, it is possible to sketch the biological responses in the absence of gravity and to define the work bases for the future. Beyond its basic physiological effects, weightlessness has operational consequences in the daily life of the astronauts. These consequences will be still more evident during missions of long duration. The conclusions drawn in flight as well as on the ground are reviewed, and future requirements concerning prolonged flights are outlined. The gaps in actual knowledge are discussed and solutions are suggested. The problems of habitability are considered, particularly those which remain at present without satisfactory solutions: psychological responses to a confined life, cleaning, hygiene, and used material.

Berry, C. A.↗