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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Interlaminar tension strength of graphite/epoxy composite laminates

An L-shaped curved beam specimen and a tension loading fixture were proposed to measure the interlaminar tension strength of laminated and textile composites. The specimen size was 2 X 2 in. (51 X 51 mm). The use of a standard tension test machine and the introduction of load nearly at the specimen midthickness were the advantages of the proposed specimen. Modified Lekhnitskii and beam theory equations for calculating interlaminar stresses of an L-beam were verified by finite element analysis. The beam theory equation is simple and accurate for mean radius to thickness ratios greater than 1.5. The modified Lekhnitskii equations can be used for detailed stress field calculation. AS4/3501-6 graphite/epoxy unidirectional specimens with thicknesses of 16, 24, and 32 piles were fabricated and tested. The delamination initiation site agreed with the calculated maximum interlaminar tension stress location for all three thicknesses. Average interlaminar tension strengths of 16-, 24-, and 32-ply laminates were 47.6, 40.9, and 23.4 MPa, respectively.

Shivakumar, Kunigal N.↗
NASA NTRS1984

A study of environmental characterization of conventional and advanced aluminum alloys for selection and design. Phase 2: The breaking load test method

A technique is demonstrated for accelerated stress corrosion testing of high strength aluminum alloys. The method offers better precision and shorter exposure times than traditional pass fail procedures. The approach uses data from tension tests performed on replicate groups of smooth specimens after various lengths of exposure to static stress. The breaking strength measures degradation in the test specimen load carrying ability due to the environmental attack. Analysis of breaking load data by extreme value statistics enables the calculation of survival probabilities and a statistically defined threshold stress applicable to the specific test conditions. A fracture mechanics model is given which quantifies depth of attack in the stress corroded specimen by an effective flaw size calculated from the breaking stress and the material strength and fracture toughness properties. Comparisons are made with experimental results from three tempers of 7075 alloy plate tested by the breaking load method and by traditional tests of statistically loaded smooth tension bars and conventional precracked specimens.

Sprowls, D. O.↗
NASA NTRS1993

The effects of aircraft fuel and fluids on the strength properties of Resin Transfer Molded (RTM) composites

The resin transfer molding (RTM) process offers important advantages for cost-effective composites manufacturing, and consequently has become the subject of intense research and development efforts. Several new matrix resins have been formulated specifically for RTM applications in aircraft and aerospace vehicles. For successful use on aircraft, composite materials must withstand exposure to the fluids in common use. The present study was conducted to obtain comparative screening data on several state-ofthe-art RTM resins after environmental exposures were performed on RTM composite specimens. Four graphite/epoxy composites and one graphite/bismaleimide composite were tested; testing of two additional graphite epoxy composites is in progress. Zero-deg tension tests were conducted on specimens machined from eight-ply (+45-deg, -45-deg) laminates, and interlaminar shear tests were conducted on 32-ply 0-deg laminate specimens. In these tests, the various RTM resins demonstrated widely different strengths, with 3501-6 epoxy being the strongest. As expected, all of the matrix resins suffered severe strength degradation from exposure to methylene chloride (paint stripper). The 3501-6 epoxy composites exhibited about a 30 percent drop in tensile strength in hot, wet tests. The E905-L epoxy exhibited little loss of tensile strength (less than 8 percent) after exposure to water. The CET-2 and 862 epoxies as well as the bismaleimide exhibited reduced strengths at elevated temperature after exposure to oils and fuel. In terms of the percentage strength reductions, all of the RTM matrix resins compared favorably with 3501-6 epoxy.

Falcone, Anthony↗
NASA NTRSDate not supplied

Process Development and Testing for Lunar Habitats

Non-metallic composites are appealing for Lunar habitats due to their low specific weight and contribution to passive radiation shielding. This application of composite materials presents notable challenges, however: flammability risks are higher due to elevated oxygen levels expected in habitat structures and absorbed radiation can cause damage long-term. The Materials and Processes Laboratory at Marshall Space Flight Center awarded funding for an internal research and development study which included fabrication and testing of composite materials for Lunar habitats. Composite layups used carbon fiber or ultra-high molecular weight polyethylene reinforcement and a variety of polymer matrices. Pre-impregnated fabric was autoclave cured; however, novel coatings were incorporated during select layups. Samples from each panel were used for screening-level flammability testing (ASTM D 2863) and combined vacuum ultraviolet and electron irradiation followed by tension testing (ASTM D5766). Two of the tested composite materials exceeded a 37% limiting oxygen index. Material property degradation for a 10 year simulated radiation dose was minimal in most cases.

manufacturing↗
DOE OSTI2021

Assessing tension metrics with dark energy survey and Planck data

ABSTRACT Quantifying tensions – inconsistencies amongst measurements of cosmological parameters by different experiments – has emerged as a crucial part of modern cosmological data analysis. Statistically significant tensions between two experiments or cosmological probes may indicate new physics extending beyond the standard cosmological model and need to be promptly identified. We apply several tension estimators proposed in the literature to the dark energy survey (DES) large-scale structure measurement and Planck cosmic microwave background data. We first evaluate the responsiveness of these metrics to an input tension artificially introduced between the two, using synthetic DES data. We then apply the metrics to the comparison of Planck and actual DES Year 1 data. We find that the parameter differences, Eigentension, and Suspiciousness metrics all yield similar results on both simulated and real data, while the Bayes ratio is inconsistent with the rest due to its dependence on the prior volume. Using these metrics, we calculate the tension between DES Year 1 3 × 2pt and Planck, finding the surveys to be in ∼2.3σ tension under the ΛCDM paradigm. This suite of metrics provides a toolset for robustly testing tensions in the DES Year 3 data and beyond.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Summary of LWRS Research in Addressing RPV Research Gaps in NRC EMDA Report

Reactor Pressure Vessels (RPVs) are critical components in nuclear reactors, housing the reactor core and coolant under extreme conditions of temperature, pressure, and radiation. These harsh environments contribute to the degradation of RPV materials over time, presenting challenges for extending reactor operations beyond their original design lifespans. The NRC Expanded Materials Degradation Assessment (EMDA) report volume 3 have been instrumental in guiding research to support extending the operational life of light water reactors (LWRs) up to 80 years. It provides a comprehensive framework to address technical challenges related to aging and degradation mechanisms in RPVs. The LWRS program has played a key role in advancing this research, supporting projects such as the UCSB ATR-2 Experiment, material testing from Zion and Palisades reactors, and the development of advanced mini-compact tension testing techniques. These efforts have been crucial in identifying and addressing gaps in our understanding of RPV aging, contributing to the successful subsequent license renewals of eight LWR units in the U.S. The EMDA report volume 3, built on the Phenomena Identification and Ranking Table (PIRT) analysis from earlier versions of the EPRI Materials Degradation Matrix (MDM) and Issue Management Tables (IMTs), provides a detailed assessment of RPV degradation mechanisms. However, as EPRI has updated the MDM and IMT, it is important to revisit research priorities and methodologies to reflect these changes. The revised MDM and IMT may introduce new factors affecting long-term RPV performance and safety, highlighting the need for continued research and updated guidance to ensure the reliable and safe operation of reactors beyond 80 years.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1972

Required critical aspect ratio of fibers intended for stress rupture applications.

The observed critical aspect ratio for pullout specimens of tungsten wire in a copper matrix tested in stress rupture at 649 and 816 C was slightly greater than for tension tests at the same temperature. Time for failure of the stress rupture specimens was controlled by the properties of the fiber (tungsten) at aspect ratios greater than the critical aspect ratio and by the properties of the matrix (copper) at aspect ratios less than the critical ratio.

Jech, R. W.↗
NASA NTRS1998

Damage Tolerance of Sandwich Plates with Debonded Face Sheets

Axial compression tests were performed on debonded sandwich composites made of graphite/epoxy face-sheets and aramid fiber honeycomb core. The sandwich beams were manufactured using a vacuum baccrin2 process. The face-sheet and the sandwich beam were co-cured. Delamination between one of the face sheets and the core was introduced by using a Teflon layer during the curing process. Axial compression tests were performed to determine the ultimate load carrying capacity of the debonded beams. Flatwise tension tests and Double Cantilever Beam tests were performed to determine. respectively, the strength and fracture toughness of the face-sheet/core interface. From the test results semi-empirical formulas were derived for the fracture toughness and ultimate compressive load carrying capacity in terms of the core density. core thickness. face-sheet thickness and debond length. Four different failure modes and their relation to the structural properties were identified. Linear buckling analysis was found to be inadequate in predicting the compressive load carrying capacity of the debonded sandwich composites.

Avery, John L., III↗
DOE OSTI2022

High-temperature superelasticity in NiTiPt and NiTiPd shape memory alloys

Alloying NiTi shape memory alloys with sufficient Pt and Pd at the expense of Ni has been shown to increase transformation temperatures well above those possible with the binary composition, enabling consideration of a new class of high-temperature mechanical sensors and actuators. To achieve shape memory behavior at temperatures greater than 200 °C, previous studies of NiTiPt and NiTiPd compositions have focused primarily on alloys with greater than 16 at.% Pt and 25 at.% Pd. While generally not the focus, none of these previous studies demonstrated superelastic behavior at high temperatures. In an effort to identify alloys that transform to austenite at approximately 200 °C and exhibit superelastic behavior with recoverable strains greater than 2%, a series of Ti-rich NiTiPt ternary alloys with 15.5–16.5 at.% Pt, and Ti-rich NiTiPd ternary alloys with 25–26 at.% Pd have been targeted. The polycrystalline alloys were processed via arc melting followed by homogenization heat treatment. Thermomechanical properties were measured using electro-discharge machined tension test coupons and a miniature load frame equipped with a clamshell furnace. Ultimately, superelasticity in uniaxial tension with clear plateau regions was demonstrated and characterized in these alloys at temperatures between 219 °C and 270 °C.

Massad, Jordan E.↗
NASA NTRS2022

Design Optimization of Energized Composite Using Simulation and Experimental Methods

As electric vehicles (EVs) are evolving, innovative technologies like “energized composite” that can store energy in the car's body helps extend its range per charge. The composite's unique ability to function as both structural body panel and charge storage medium stems from its unique pattern design between “electrochemical areas (EcA)” and “epoxy area (EpA)”. Herein, a design optimization study is presented to obtain a balanced ratio between EcA versus EpA to maximize the charge storage ability of the composite while maintaining a decent tensile and bending strength. Simulations using ANSYS software and experimental confirmation using universal testing machines and electrochemical analyzers are used to derive optimum ratios between EcA and EpA. Uniaxial tension test and 3-point bend test have been performed to optimize the tensile and bend strengths, whereas cyclic voltammetry, galvanic charge–discharge, and electrochemical impedance spectroscopy are used to determine the electrochemical performance of various design configurations by modulating the ratios of EcA versus EpA. Overall, the highest achieved energy storage per lamina is 2531 mWh m−2 for a maximum of 81.6% EcA with a tensile strength of 417.73 MPa and bending strength of 263.13 MPa. This study is highly beneficial for EVs and aerospace applications.

energy storage↗
NASA NTRS1989

Fabrication and evaluation of enhanced diffusion bonded titanium honeycomb core sandwich panels with titanium aluminide face sheets

A joining process was developed for fabricating lightweight, high temperature sandwich panels for aerospace applications using Ti-14Al-21Nb face sheets and Ti-3Al-2.5V honeycomb core. The process, termed Enhanced Diffusion Bonding (EDB), relies on the formation of a eutectic liquid through solid-state diffusion at elevated temperatures and isothermal solidification to produce joints in thin-gage titanium and titanium aluminide structural components. A technique employing a maskant on the honeycomb core was developed which permitted electroplating a controlled amount of EDB material only on the edges of the honeycomb core in order to minimize the structural weight and metallurgical interaction effects. Metallurgical analyses were conducted to determine the interaction effects between the EDB materials and the constituents of the sandwich structure following EDB processing. The initial mechanical evaluation was conducted with butt joint specimens tested at temperatures from 1400 - 1700 F. Further mechanical evaluation was conducted with EDB sandwich specimens using flatwise tension tests at temperatures from 70 - 1100 F and edgewise compression tests at ambient temperature.

Hoffmann, E. K.↗
NASA NTRS1972

Effect of metallurgical structure and properties on adhesion and friction behavior of cobalt alloys

The metallurgical structure and some of the mechanical properties of two cobalt alloys, cobalt-50% iron and cobalt-25% molybdenum-10% chromium, were determined under various heat treated conditions. The mechanical properties of the bcc disordered Co-50Fe alloy, which was found to be very brittle, indicated an exceedingly low fracture strength, low hardness, and very weak grain boundary strength. Ordering by suitable heat treatment only produced a more brittle material with a lower fracture strength and a slightly higher hardness value. Work hardening was found to produce a finer grain structure and a greater grain boundary strength. Tensile properties were examined. It was found that the Co-25Mo-10Cr alloy was difficult to place in the alpha Co solid solution condition, which limited the ability to use precipitation as a hardening reaction. Over two hundred adhesion cycles from zero contact load, to maximum load, to fracture were conducted between couples for each of the above alloys in an ultrahigh vacuum system which would permit the sample surfaces to be cleaned of all contaminant layers. In the Co-50Fe case, the calculated fracture stress from the adhesion tests showed values in the range of 80 to 150 k.s.i., which is about ten times greater than the values from tension tests.

Keller, D. V., Jr.↗
NASA NTRS1991

Post flight system analysis of FRECOPA (AO 138)

The unexpected duration for the flight of the Long Duration Exposure Facility (LDEF) conducted CNES to create a special investigation group in order to analyze all the materials and systems which compose the French Cooperative Payload (FRECOPA) except the experiments especially prepared for the flight. The FRECOPA tray was on the trailing face (V-) of the LDEF and protected from the atomic oxygen flux during all the flight. However, the solar irradiation was very important with solar flux quite perpendicular to the experiment once an orbit. There was also a good vacuum environment. The objectives are to test the effects of the combined space environment on materials and components like: structure, thermal control coatings and blankets, electronic unit, motors, and mechanical fixtures. When the LDEF returned to Kennedy Space Center, a visual inspection showed the very good behavior of the materials used and it was noted that the three mechanisms to open and close the experiment canisters worked completely. Many impacts of micrometeoroids or space debris on the structure and on the thermal protections were observed. After FRECOPA was brought back to Toulouse, many tests were performed and include: working order tests, mechanical tests (tension), optical and electronic microscopy (SEM), surface analysis (ESCA, SIMS, RBS, AUGER, etc.), thermal analysis, pressure measurements, and gas analysis (outgassing tests). The results of these experiments are discussed.

Durin, Christian↗
NASA NTRS1984

Investigation of Toughened Neat Resins and Their Relations to Advanced Composite Mechanical Properties

Four epoxies (Hercules 3502, Hercules 2220-1 and 2220-3, and Ciba-Geigy Fibredux 914 epoxy) were evaluated to judge their merits within the ACEE program and also to provide material property input for a micromechanics finite element program. A casting procedure was developed for the four matrix systems mentioned and mechanical properties were studied at three test temperatures and two moisture contents. A scanning electron microscope study was performed to catalogue fracture surfaces for the unreinforced (neat) epoxies. In addition, tension testing, shear testing, a limited amount of fracture toughness testing, and thermal expansion coefficient and moisture expansion coefficient testing were carried out. Mechanical material properties were generated for input into a micromechanics program and to characterize these four matrix systems.

R. S. Zimmerman↗
DOE OSTI2021

AFRL Additive Manufacturing Modeling Series: Challenge 4, In Situ Mechanical Test of an IN625 Sample with Concurrent High-Energy Diffraction Microscopy Characterization

In this work, we describe 3D characterization of an additively manufactured Inconel 625 nickel-base superalloy specimen conducted during a uniaxial tension test using a suite of nondestructive x-ray techniques. High-energy diffraction microscopy in both near- and far-field modalities are employed in situ to track evolution of the material orientation and stress–strain fields at six points during the mechanical test, and these data streams are registered with micro-computed tomography reconstructions which probe the material density. This data volume was matched to a multi-modal serial sectioning characterization of the specimen taken after loading, described in this article’s companion. Twenty-eight grains which were monitored throughout the experiment were selected to form the basis for AFRL AM Modeling Series Challenge 4, Microscale Structure-to-Properties.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Experimental evaluation of outer planets probe thermal insulation concepts

An experimental program was conducted to evaluate various thermal insulation concepts for use in the Outer Planets Probe (OPP) during entry and descent into the atmospheres of Jupiter, Saturn, and Uranus. Phenolic fiberglass honeycomb specimens representative of the OPP structure were packed and tested with various fillers: Thermal conductivity measurements were made over a temperature range of 300 K to 483 K and pressures from vacuum up to 10 atmospheres in helium and nitrogen gas environments. The conductivity results could not be fully explained so new test specimens were designed with improved venting characteristics, and tested to determine the validity of the original data. All of the conductivity data showed results that were substantially higher than expected. The original test data in helium were lower than the data from the redesigned specimens, probably due to inadequate venting of nitrogen gas from the original specimens. The thermal conductivity test results show only a marginal improvement in probe thermal protection performance for a filled honeycomb core compared to an unfilled core. In addition, flatwise tension tests showed a severe bond strength degradation due to the inclusion of either the powder or foam fillers. In view of these results, it is recommended that the baseline OPP design utilize an unfilled core.

Grote, M. G.↗
NASA NTRS2005

Preparation Torque Limit for Composites Joined with Mechanical Fasteners

Current design guidelines for determining torque ranges for composites are based on tests and analysis from isotropic materials. Properties of composites are not taken into account. No design criteria based upon a systematic analytical and test analyses is available. This paper is to study the maximum torque load a composite component could carry prior to any failure. Specifically, the torque-tension tests are conducted. NDT techniques including acoustic emission, thermography and photomicroscopy are also utilized to characterize the damage modes.

Thomas, Frank P.↗