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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Mechanical behavior of a continuous fiber reinforced aluminum matrix composite subjected to transverse and thermal loading

The transverse properties of an aluminum alloy metal matrix composite reinforced by continuous alumina fibers were investigated. The composite is subjected to both mechanical and cyclic thermal loading. The results of an experimental program indicate that the shakedown concept of structural mechanics provides a means of describing the material behavior. When the loading conditions are within the shakedown region, the material finally responds in an elastic manner after initial plastic response, and for loading conditions outside the shakedown region, the material exhibits a rapid incremental plastic strain accumulation. The failure strain varies by an order of magnitude according to the operating conditions. Hence, for high mechanical and low thermal loading, the failure strains is small; for low mechanical and high thermal loading, the failure strain is large.

Jansson, S.↗
NASA NTRS2006

Effect of Composite Substrates on the Mechanical Behavior of Brazed Joints in Metal-Composite System

Advanced composite components are being considered for a wide variety of demanding applications in aerospace, space exploration, and ground based systems. A number of these applications require robust integration technologies to join dissimilar materials (metalcomposites) into complex structural components. In this study, three types of composites (C-C, C-SiC, and SiC-SiC) were vacuum brazed to commercially pure Ti using the active metal braze alloy Cusil-ABA (63Ag-35.3Cu-1.75Ti). Composite substrates with as fabricated and polished surfaces were used for brazing. The microstructure and composition of the joint, examined using scanning electron microscopy (SEM) coupled with energy dispersive spectroscopy (EDS), showed sound metallurgical bonding in all systems. The butt strap tensile (BST) test was performed on bonded specimens at room and elevated temperatures. Effect of substrate composition, interlaminar properties, and surface roughness on the mechanical properties and failure behavior of joints will be discussed.

Singh, M.↗
NASA NTRS1989

Age hardening characteristics and mechanical behavior of Al-Cu-Li-Zr-In alloys

An investigation was conducted to determine the age-hardening response and cryogenic mechanical properties of superplastic Al-Cu-Li-Zr-In alloys. Two alloys with compositions Al-2.65Cu-2.17Li-O.13Zr (baseline) and Al-2.60Cu-2.34Li-0.16Zr-0.17In were scaled-up from 30 lb permanent mold ingots to 350 lb DC (direct chill) ingots and thermomechanically processed to 3.2 mm thick sheet. The microstructure of material which contained the indium addition was partially recrystallized compared to the baseline suggesting that indium may influence recrystallization behavior. The indium-modified alloy exhibited superior hardness and strength compared to the baseline alloy when solution-heat-treated at 555 C and aged at 160 C or 190 C. For each alloy, strength increased and toughness was unchanged or decreased when tested at - 185 C compared to ambient temperature. By using optimized heat treatments, the indium-modified alloy exhibited strength levels approaching those of the baseline alloy without deformation prior to aging. The increase in strength of these alloys in the T6 condition make them particularly attractive for superplastic forming applications where post-SPF parts cannot be cold deformed to increase strength.

Wagner, John A.↗
NASA NTRS1984

Mechanical behavior of carbon-carbon composites

A general background, test plan, and some results of preliminary examinations of a carbon-carbon composite material are presented with emphasis on mechanical testing and inspection techniques. Experience with testing and evaluation was gained through tests of a low modulus carbon-carbon material, K-Karb C. The properties examined are the density - 1.55 g/cc; four point flexure strength in the warp - 137 MPa (19,800 psi) and the fill - 95.1 MPa (13,800 psi,) directions; and the warp interlaminar shear strength - 14.5 MPa (2100 psi). Radiographic evaluation revealed thickness variations and the thinner areas of the composite were scrapped. The ultrasonic C-scan showed attenuation variations, but these did not correspond to any of the physical and mechanical properties measured. Based on these initial tests and a survey of the literature, a plan has been devised to examine the effect of stress on the oxidation behavior, and the strength degradation of coated carbon-carbon composites. This plan will focus on static fatigue tests in the four point flexure mode in an elevated temperature, oxidizing environment.

Rozak, G. A.↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted (SLM) Alloy 718

Nickel Alloy 718 has found wide use in high-temperature aerospace applications (up to 700°C), due to a combination of good mechanical properties, environmental resistance, and workability at moderate cost. These properties have led Alloy 718 to early adoption by selective laser melting (SLM) additive manufacturing. This presentation will share results from a comprehensive industry survey of 718 powder feedstock for SLM. The survey focuses on the impact of variability in powder characteristics on build quality, microstructure, tensile and high cycle fatigue in the as-fabricated and machined surface conditions. The investigation includes sixteen powder lots from eight suppliers that are produced by gas atomization or rotary atomization in argon or nitrogen. This research was previously presented and published at the 9th International Symposium on Superalloy 718 & Derivatives and was funded by NASA Space Launch System Liquid Engine Office with the Human Exploration Operations Mission Directorate.

Sudbrack, Chantal↗
NASA NTRS1999

Mechanical Behavior of a Hi-Nicalon(tm)/SiC Composite Having a Polycarbosilane Derived Matrix

Polymer infiltration of a rigidized preform, followed by pyrolysis to convert the polymer to a ceramic, potentially offers a lower cost alternative to CVD. It also offers more moderate temperature requirements than melt infiltration approaches, which should minimize potential fiber damage during processing. However, polymer infiltration and pyrolysis results in a more microcracked matrix. Preliminary mechanical property characterization, including elevated temperature (1204 C) tensile, 500 h stress rupture behavior and low cycle fatigue, was conducted on Hi-Nicalon (TM)/Si-C-(O) composites having a dual layer BN/SiC interface and a matrix derived by impregnation and pyrolysis of allylhydridopolycarbosilane (AHPCS). Microstructural evaluation of failure surfaces and of polished transverse and longitudinal cross sections of the failed specimens was used to identify predominant failure mechanisms. In stress rupture testing at 1093 C, the failure was interface dominated, while at 1204 C in both stress rupture and two hour hold/fatigue tests failure was matrix dominated, resulting in specimen delamination.

Hurwitz, Frances I.↗
NASA NTRS1998

Mechanical Behavior and Analytical Modeling of Melt-Infiltrated SiC/SiC Woven Composite

The desirable properties in ceramic matrix composites (CMCs), such as high temperature strength, corrosion resistance, high toughness, low density, or good creep resistance have led to increased use of CMCs in high-speed engine structural components and structures that operate in extreme temperature and hostile aero-thermo-chemical environments. Ceramic matrix composites have been chosen for turbine material in the design of 21st century civil propulsion systems to achieve high fuel economy, improved reliability, extended life, and reduced cost. Most commercial CMCs are manufactured using a chemical vapor infiltration (CVI) process. However, a lower cost fabrication known as melt-infiltration process is also providing CMCs marked for use in hot sections of high-speed civil transports. Limited samples of a SiC/SiC melt-infiltrated woven composites are being investigated at room and elevated temperature below and above matrix cracking. These samples show graceful failure and toughness at room temperature with a reduction in strength and modulus at elevated temperatures. A generic finite element model is also being developed to predict monotonic and cyclic loading behavior of the woven composite. Use of the initial test data from the woven composite is being used for the development of the analytical model. This model is the first of a iterative process leading towards the development the model's capability to predict behavior at room and elevated temperature for monotonic and cyclic loading. The purpose of this paper is to report on the material and mechanical findings of the SiC/SiC melt-infiltrated woven composite and progress on the development of the finite element model.

Lang, J.↗
DOE OSTI2025

MURR LEU structural and thermal hydraulics analyses: Part I – Preliminary irradiation thermo-mechanical behavior

The University of Missouri Research Reactor (MURR) is expected to be converted from highly enriched uranium (HEU, ≥ 20 wt% U-235) U-Al x dispersion fuel to low-enriched uranium (LEU, < 20 wt% U-235) with U-10Mo monolithic fuel. This work introduces high-fidelity irradiation thermo–mechanical (T-M) analysis of the MURR LEU focusing on changes in coolant channel gap thickness. Three-dimensional (3D) finite element (FE) models were developed to simulate the irradiation T-M behavior of the MURR LEU element with all 23 curved fuel plates, the two side plates, and the combs. It was shown that channel gap thickness changes were influenced not only by plate thickness variations due to fuel swelling and creep but also by the radial displacement of consecutive MURR LEU plates. Modeling the fuel element assembly captured side plate displacements, which were shown to reduce radial fuel plate displacements towards the convex side. The maximum local radial displacement in the element was predicted at the end of life (EOL) as 23.7 mil (602.0 µm) on the lateral centerline of plate 23 towards the convex side. The maximum stripe-averaged reduction in channel gap thickness, particularly relevant for thermal hydraulics (TH) safety analysis, was calculated as 15.9 mil (403.9 µm) in single-side heated channel 24 (the outermost channel). These results account for the thermal resistance from the oxide build-up on cladding surfaces which was shown to be up to 0.82 mil (20.8 µm) thick. It was demonstrated that accounting for oxide layer thermal resistance led to a 10 °C higher peak fuel temperature and a 4.4 mil (111.8 µm) greater maximum local radial displacement. The impact of the calculated channel gap thickness changes on the MURR LEU TH safety analysis is evaluated in Part II.

Irradiation thermo-mechanical analysis↗
NASA NTRSDate not supplied

Multiscale Analysis of Thermo-Mechanical Behavior of Boron Nitride-Reinforced Epoxy Nanocomposites

The effect of size, shape, morphology, and arrangement of micro constituents of Boron Nitrite (BN) nanoplatelet/epoxy composites on their properties were investigated using a multi scale approach that includes Molecular Dynamics (MD) and micromechanics. The thermo-mechanical properties of the composites were evaluated using molecular theory and the analysis showed that the elastic constants of BN/epoxy composites were not severely affected by temperature. Also, the micromechanical analysis of Generalized Method of Cells (GMC) was utilized at higher length scale to evaluate elastic properties of the composites, for different geometries and arrangements of micro constituents. The predicted results of the analysis showed that the size, aspect ratios, morphology, and the arrangements of inclusions in BN/epoxy nanocomposites all have remarkable effect on the mechanical performances of the material systems.

nanocomposites↗
DOE OSTI2024

High Temperature Mechanical Behavior of Refractory Alloys with Digital Image Correlation

Gas turbine efficiency is typically limited by the maximum allowable temperature for components at the inlet side and in the hot gas flow. Refractory alloys and SiC/SiC ceramic-matrix composites (CMCs) are promising candidates for advancing operating temperatures beyond those of Ni-based alloys (>1200 °C). Refractory alloys are more suitable than SiC/SiC CMCs for dynamic components, due to the latter's low toughness and ductility. However, it is well known that refractory alloys suffer from poor oxidation behavior under service lifetimes and conditions, leading to embrittlement concerns. The ARPA-E ULTIMATE program has set out to combine new alloys with advanced coatings to mitigate oxidation/embrittlement effects, while increasing the mechanical performance benefits of refractory materials. Low oxygen (inert gas) or vacuum systems are needed to assess high temperature mechanical performance of developed alloys. To investigate the environmental sensitivity of candidate alloys and develop high temperature testing capabilities, four argon tensile frames were upgraded as well as a single vacuum system at Oak Ridge National Laboratory. Digital image correlation was incorporated into the vacuum frame allowing for surface strain determination and refined insight into thermomechanical response. Creep testing was performed at 1300 °C on two alloys, C-103 and MHC in vacuum and high purity argon environments. The Mo-based alloy showed less sensitivity to oxygen, indicating that testing in well-controlled argon environments may be suitable. The C-103 alloy demonstrated a stronger sensitivity to oxygen in the well-controlled argon environment, illustrating the need for the developed vacuum testing capabilities. “Small” 25 mm and “large” 76 mm MHC specimens showed comparable results in terms of strain rate during creep testing and ultimate tensile strength during tensile testing, suggesting the viability of smaller geometries that use less material of advanced developmental alloys.

Bell, Sam↗
NASA NTRS1984

Mechanical behavior of thermal barrier coatings for gas turbine blades

Plasma-sprayed thermal barrier coatings (TBCs) will enable turbine components to operate at higher temperatures and lower cooling gas flow rates; thereby improving their efficiency. Future developments are limited by precise knowledge of the material properties and failure mechanisms of the coating system. Details of this nature are needed for realistic modeling of the coating system which will, in turn, promote advancements in coating technology. Complementary experiments and analytical modeling which were undertaken in order to define and measure the important failure processes for plasma-sprayed coatings are presented. The experimental portion includes two different tests which were developed to measure coating properties. These are termed tensile adhesion and acoustic emission tests. The analytical modeling section details a finite element method which was used to calculate the stress distribution in the coating system. Some preliminary results are presented.

Berndt, C. C.↗
NASA NTRS1986

Space radiation effects on the thermo-mechanical behavior of graphite-epoxy composites

This investigation of composite material properties utilized T300/934 graphite-epoxy that was subjected to 1.0 MeV electron radiation for a total dose of 1.0 x 10 to the 10th rads at a rate of 5.0 x 10 to the 7th rads/hour, simulating a worst-case exposure equivalent to 30 years in space. Mechanical testing was performed on 4-ply unidirectional laminates over the temperature range of -250 F (116 K) to +250 F (394 K). In-plane elastic tensile and shear properties as well as strength were obtained. The results show that electron radiation degrades the epoxy matrix and produces products that volatilize at the temperatures considered. These degradation products plasticize the epoxy at elevated temperatures and embrittle it at low temperatures, thereby altering the mechanical properties of the composite.

Milkovich, Scott M.↗
DOE OSTI2025

Chemo-Mechanical Behavior and Stability of High-Loading Cathodes in Solid-State Batteries

Solid-state batteries can offer higher energy density and improved safety compared to lithium ion batteries, which use flammable liquid electrolytes. Increasing the ratio of cathode active materials in composite cathodes enhances the energy density and reduces manufacturing costs. Changes in the ratio of cathode active materials alter the microstructure and chemo-mechanical response of a cathode during operation. Understanding the relationship between composition, microstructure, and chemo-mechanical interactions is critical for optimizing solid-state cathodes. Here, in this study, we engineered composite cathodes with varying ratios of LiNi 0.8 Co 0.1 Mn 0.1 O 2 and Li 6 PS 5 Cl to systematically investigate the role of microstructural evolution in long-term chemo-mechanical transformations. Chemo-mechanical stresses resulting from the volume changes of the cathode active materials led to degradation mechanisms, such as fracture and interfacial delamination. Active material fracture and delamination led to underutilization of active material and significant capacity decay during cycling. Coatings that suppress active material-active material interactions during cycling may aid in suppressing the generation of local stress hotspots.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Mechanical Behavior of Advanced Materials for Aerospace Applications

The purpose of this study was to determine whether High Cycle Fatigue (HCF) loading has any deleterious synergistic effect on life when combined with the typical Low Cycle Fatigue (LCF) loading present in engine disks. This interaction is particularly important in the rim region of blisk applications, where fatigue initiations from vibratory stresses (HCF) may be propagated to the disk by LCF. The primary effort in this study was focused on determining and documenting initiation sites and damage mechanisms. Under LCF loading conditions the failures were predominantly surface initiated, while HCF loading favored internal initiations. Deleterious HCF/LCF interactions would always result in a transition from internal to surface initiations. The results indicated that under the relative stress conditions evaluated there was no interaction between HCF and LCF. In FY99 this effort was extended to investigate several other loading conditions (R-ratio effects) as well as interactions between LCF and two-hour tensile dwells. The results will be published as a NASA Technical Memorandum.

Telesman, Ignancy↗
NASA NTRSDate not supplied

Understanding Variability in Mechanical Behavior of Adhesively Bonded Sandwich Joints due to Stochastic Material Damage

A mesoscale progressive damage analysis was applied to the analysis of recently tested adhesively bonded sandwich panels, in which ten nominally identical tension loaded panels failed in three different failure modes, with peakloads ranging from 13.0 –16.1 kips. A parametric finite element model for progressive damage analysis of an adhesively bonded joint (ABJ) considering matrix and fiber damage, and delamination cracks in unidirectional and fabric composite sections of the joint, as well as core crushing, and adhesive fracture was developed. The model was developed using Abaqus/Explicit and utilized continuum damage mechanics material models for intralaminar damage in the facesheet and doubler plies, cohesive elements for delamination and adhesive debonding, and discretized cells considering plasticity to model crushing of the aluminum honeycomb core. Analysis predictions obtained with a pristine model agreed well with the average experimental peak load, strain in the joint, and post-test damage states. Then, various methods to incorporate stochastic material variability into ABJ model were evaluated. These methods included simulation of pre-existing matrix damage, pre-existing adhesive porosity, and uniform modification of adhesive properties. These material and manufacturing defects changed the damage mode predictions in some cases. The analysis of stochastic strength due to the considered defects revealed unintuitive damage mode interaction in the ABJ, explaining some structure-property relationships observed experimentally.

Richard Larson↗
DOE OSTI2024

Image-based modeling of coupled electro-chemo-mechanical behavior of Li-ion battery cathode using an interface-modified reproducing kernel particle method

Abstract An interface-modified reproducing kernel particle method (IM-RKPM) is introduced in this work to allow for a direct model construction from image pixels of heterogeneous polycrystalline Li-ion battery microstructures. The interface-modified reproducing kernel (IM-RK) approximation is constructed through scaling of a kernel function by a regularized distance function in conjunction with strategic placement of interface node locations. This leads to RK shape functions with either weak or strong discontinuities across material interfaces, suitable for modeling various interface mechanics. With the placement of a triple junction node and distance-based scaling of kernel functions, the resulting IM-RK shape function also possesses proper discontinuities at the triple junctions. This IM-RK approximation effectively remedies the well-known Gibb’s oscillation in the smooth approximation of discontinuities. Different from the conventional meshfree approaches for interface discontinuities, this IM-RK approach is done without additional degrees of freedom associated with the enrichment functions, and it is formulated with the standard procedures in the RK shape function construction. This work focuses on identifying the accuracy and convergence properties of IM-RKPM for modeling the coupled electro-chemo-mechanical system. A linear patch test is formulated and numerically tested for the electro-chemo-mechanical coupled problem with a Butler–Volmer boundary condition representing the physical conditions in Li-ion battery microstructures. This is followed by verification of the optimal rates of convergence of IM-RKPM for solving the coupled problem with higher order solutions. The image-based modeling of Li-ion battery microstructures in the numerical examples demonstrates the applicability of the proposed method to realistic Li-ion battery materials modeling.

25 ENERGY STORAGE↗