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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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NASA NTRS1974

Long Life Technology Work at Rockwell International Space Division

This paper presents highlights of long-life technology oriented work performed at the Space Division of Rockwell International Corporation under contract to NASA. This effort included evaluation of Saturn V launch vehicle mechanical and electromechanical components for potential extended life capabilities, endurance tests, and accelerated aging experiments. A major aspect was evaluation of the components at the subassembly level (i.e., at the interface between moving surfaces) through in-depth wear analyses and assessments. Although some of this work is still in progress, preliminary conclusions are drawn and presented, together with the rationale for each. The paper concludes with a summary of the effort still remaining.

D K Huzel↗

NASA NTRS2007

Development of a HTSMA-Actuated Surge Control Rod for High-Temperature Turbomachinery Applications

In recent years, a demand for compact, lightweight, solid-state actuation systems has emerged, driven in part by the needs of the aeronautics industry. However, most actuation systems used in turbomachinery require not only elevated temperature but high-force capability. As a result, shape memory alloy (SMA) based systems have worked their way to the forefront of a short list of viable options to meet such a technological challenge. Most of the effort centered on shape memory systems to date has involved binary NiTi alloys but the working temperatures required in many aeronautics applications dictate significantly higher transformation temperatures than the binary systems can provide. Hence, a high temperature shape memory alloy (HTSMA) based on NiTiPdPt, having a transformation temperature near 300 C, was developed. Various thermo-mechanical processing schemes were utilized to further improve the dimensional stability of the alloy and it was later extruded/drawn into wire form to be more compatible with envisioned applications. Mechanical testing on the finished wire form showed reasonable work output capability with excellent dimensional stability. Subsequently, the wire form of the alloy was incorporated into a benchtop system, which was shown to provide the necessary stroke requirements of approx.0.125 inches for the targeted surge-control application. Cycle times for the actuator were limited to ~4 seconds due to control and cooling constraints but this cycle time was determined to be adequate for the surge control application targeted as the primary requirement was initial actuation of a surge control rod, which could be completed in approximately one second.

Padula, Santo, II↗

NASA NTRS1998

Waveform Analysis of AE in Composites

Advanced, waveform based acoustic emission (AE) techniques have been developed to evaluate damage mechanisms in the testing of composite materials. This approach, more recently referred to as Modal AE, provides an enhanced capability to discriminate and eliminate noise signals from those generated by damage mechanisms. Much more precise source location can also be obtained in comparison to conventional, threshold crossing arrival time determination techniques. Two successful examples of the application of Modal AE are presented in this work. In the first, the initiation of transverse matrix cracking in cross-ply, tensile coupons was monitored. In these tests, it was documented that the same source mechanism, matrix cracking, can produce widely different AE signal amplitudes dependent on laminate stacking sequence and thickness. These results, taken together with well known propagation effects of attenuation and dispersion of AE signals in composite laminates, cast further doubt on the validity of simple amplitude or amplitude distribution analysis for AE source determination. For the second example, delamination propagation in composite ring specimens was monitored. Pressurization of these composite rings is used to simulate the stresses in a composite rocket motor case. AE signals from delamination propagation were characterized by large amplitude flexural plate mode components which have long signal durations because of the large dispersion of this mode.

Prosser, William H.↗

NASA NTRS1989

Initial operating capability for the hypercluster parallel-processing test bed

The NASA Lewis Research Center is investigating the benefits of parallel processing to applications in computational fluid and structural mechanics. To aid this investigation, NASA Lewis is developing the Hypercluster, a multi-architecture, parallel-processing test bed. The initial operating capability (IOC) being developed for the Hypercluster is described. The IOC will provide a user with a programming/operating environment that is interactive, responsive, and easy to use. The IOC effort includes the development of the Hypercluster Operating System (HYCLOPS). HYCLOPS runs in conjunction with a vendor-supplied disk operating system on a Front-End Processor (FEP) to provide interactive, run-time operations such as program loading, execution, memory editing, and data retrieval. Run-time libraries, that augment the FEP FORTRAN libraries, are being developed to support parallel and vector processing on the Hypercluster. Special utilities are being provided to enable passage of information about application programs and their mapping to the operating system. Communications between the FEP and the Hypercluster are being handled by dedicated processors, each running a Message-Passing Kernel, (MPK). A shared-memory interface allows rapid data exchange between HYCLOPS and the communications processors. Input/output handlers are built into the HYCLOPS-MPK interface, eliminating the need for the user to supply separate I/O support programs on the FEP.

Cole, Gary L.↗

DOE OSTI2022

Li-Ion Battery Electrode Contact Resistance Estimation by Mechanical Peel Test

Li-ion battery electrode electronic properties, including bulk conductivity and contact resistance, are critical parameters affecting cell performance and fast-charge capability. Contact resistance between the coating and current collector is often the largest electronic resistance in an electrode and is affected by chemical, microstructural, and interfacial variations. Direct measurements of contact resistance and bulk conductivity have proven to be challenging. In their absence, a mechanical electrode peel test is often used to compare adhesion and electrical contact resistance. However, using a micro-flexible-surface probe, contact resistance can be directly determined. Here, this work compares contact resistance and mechanical peel strength of multiple commercial-grade HE5050 and NCM523 cathodes and graphite and silicon anodes. It was found that peel strength correlates well with contact resistance in a carefully curated data set (p < 0.05) and in some situations may be a good metric to estimate electrical properties. However, there were distinct outliers in the data set, indicating that peel strength may not accurately reflect electrical properties when there is significant variation in electrode composition. These results illustrate the value of the micro-flexible-surface probe in quantifying contact resistance and bulk conductivity to better understand how battery composition and processing steps affect microstructure and resulting cell performance.

25 ENERGY STORAGE↗

DOE OSTI2020

Mechanical Modeling and Testing of Pouch Cells under Various Loading Conditions

Understanding the mechanical behaviors of batteries is critical to improve battery safety since mechanical failure may directly lead to short-circuits. Nevertheless, mechanical modeling of batteries is challenging since a cell usually contains multiple thin layers with drastically different material properties, and they exhibit different responses under different loading conditions. In this work, we developed a mechanical model for a large-format pouch cell, where the cell is represented by thick shell elements that are not only computationally efficient but also account for different thickness and material properties of individual components. Moreover, the mechanical properties of active materials in electrodes are described by a continuous surface cap model that can capture both compaction and shear deformation modes and can include strain rate effect and damage. Furthermore, to evaluate the model capabilities, we conducted abuse tests under various loading conditions (quasi-static compression, shear and impact). It is shown that the model prediction of load-displacement relationship and failure condition agree with experimental results, which demonstrates that the developed model can capture the mechanical behaviors of a cell in different abuse events. Details of element formulation, material parameters evaluation and test setup are presented. Capabilities, limitations and future directions of model development are also discussed.

25 ENERGY STORAGE↗

NASA NTRS2020

Pterodactyl: Control System Demonstrator Development for Integrated Control Design of a Mechanically Deployed Entry Vehicle

The NASA-funded Pterodactyl project is a design, test, and build capability to (i) advance the current state of the art for Deployable Entry Vehicle (DEV) guidance and control (G&C), and (ii) determine the feasibility of control system integration for various entry vehicle types including those without aeroshells. This capability is currently being used to develop control systems for one such unconventional entry vehicle, the Lifting Nano-ADEPT (LNA) vehicle. ADEPT offers the possibility of integrating control systems directly onto the mechanically deployed structure and building hardware demonstrators will help assess integration and design challenges. Control systems based on aerodynamic control surfaces, mass movement, and reaction control systems (RCS) are currently being investigated for a down-select to the most suitable control architecture for the LNA.To that effect, in this submission, we detail the efforts of the Pterodactyl project to develop a series of hardware demonstrators for the different LNA control systems. Rapid prototypes, for a set of quarter- model or eighth-model vehicle segments, will be developed for all three architectures to validate mechanical design assumptions, and hardware-in-the-loop (HIWL) control approaches. A ground test control system demonstrator will be designed and built after the trade study is complete. The industrial-grade demonstrator will be designed so that it can be incorporated into a HWIL simulation to further validate the findings of the initial trade study. The HWIL simulation will leverage the iPAS environment developed at NASA's Johnson Space Center which facilitates integration testing to support technology maturation and risk reduction, necessary elements for the hardware demonstration development detailed in this paper.

Margolis, Benjamin W.↗

NASA NTRS1987

DACS II - A distributed thermal/mechanical loads data acquisition and control system

A distributed data acquisition and control system has been developed for the NASA Flight Loads Research Facility. The DACS II system is composed of seven computer systems and four array processors configured as a main computer system, three satellite computer systems, and 13 analog input/output systems interconnected through three independent data networks. Up to three independent heating and loading tests can be run concurrently on different test articles or the entire system can be used on a single large test such as a full scale hypersonic aircraft. Thermal tests can include up to 512 independent adaptive closed loop control channels. The control system can apply up to 20 MW of heating to a test specimen while simultaneously applying independent mechanical loads. Each thermal control loop is capable of heating a structure at rates of up to 150 F per second over a temperature range of -300 to +2500 F. Up to 64 independent mechanical load profiles can be commanded along with thermal control. Up to 1280 analog inputs monitor temperature, load, displacement and strain on the test specimens with real time data displayed on up to 15 terminals as color plots and tabular data displays. System setup and operation is accomplished with interactive menu-driver displays with extensive facilities to assist the users in all phases of system operation.

Zamanzadeh, Behzad↗

NASA NTRS1977

Analysis of shock pulses for environmental tests

Specifications for shock testing of components that will be used on the Space Shuttle vehicles require very high acceleration levels. A special shock machine was built for testing of rocket components to determine if they can meet the specified accelerations. Calibrations of transducers and methods to monitor the shock tests raised several signature-analysis questions. In this report, calibration capabilities of shock accelerometers are found to be limited to 10,000g. Equivalency of the mechanical shock test and the rocket pyrotechnic shock are examined, and two simple relationships for equivalency are proposed. Five different pulse signature-analysis techniques are tested on analytical and experimental pulse data and recommendations are made for the signature technique which most clearly identifies the magnitude of the impulse applied to the test specimen.

Houghton, J. R.↗

DOE OSTI2020

Development of a Fast Spectrum Test Loop at the Advanced Test Reactor

The United States currently has no infrastructure to provide a fast neutron flux for research purposes. With the increased interest in Sodium Fast Reactor (SFR) technology, this type of infrastructure is necessary for further development of key components such as Versatile Test Reactor. The purpose of this research is to characterize the thermal hydraulics of a test loop capable of providing SFR like operating conditions. This includes showcasing feasibility in mechanical design, reaching a high fast to thermal neutron flux ratio ideally near 15, an inlet temperature of 600 K, a temperature increase of 50 K from inlet to outlet, and test chamber radial temperature profiles similar to SFR fuel rods. Existing infrastructure must be used to provide the neutron flux for the test loop, and it was decided that the Advanced Test Reactor (ATR) was the optimal choice due to its availability and previous work conducted similar to this project. To achieve the goals of this project, several mechanical designs were put forward with the most feasible design being chosen. The neutronics and thermal hydraulics analysis were conducted in tandem, with an iterative process used to maximize efficiency of both systems. Analysis of the neutronics system was done using Attila and MCNP while the thermal hydraulic analysis was done using RELAP5. This document outlines the thermal hydraulic analysis, though it includes the results from the mechanical design and neutronics analysis. The loop design includes a primary system with molten sodium, a set of “booster fuel plates” to increase the fast flux within the test section, a water system to cool the booster fuel plates, a helium system to separate the sodium and water systems, and a thermal neutron shield to decrease the thermal flux. Each of these systems is modeled in the neutronics and thermal hydraulic analyses. The RELAP5 model showcased the feasibility of the design proposed by this report. For all designs tested, the desired 50 K temperature increase from inlet to outlet was reached. The fuel rod radial temperature profile was lower than was expected, likely due to a lower rod thermal power than expected. A parametric study was also conducted to characterize the system with three fuel pins. This study showed the effect of thermal power, fluid pressure, fluid velocity, and inlet temperature on the system. ©Copyright by Anton Higgins December 11, 2019 All Rights Reserved

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2021

Simulants for Testing the Blend Can Loading System

Eleven simulants have been provided to the Savannah River National Laboratory (SRNL) Mechanical Systems & Custom Equipment Development (MSCED) organization to further test the capabilities of the Blend Can Loading System (BCLS). The basis for the materials used in these simulants are based on SRNL-STI-2020-00503, “Simulant Recommendation for the Blend Can Loading System” (Ref. i). The 11 different simulants provided to MSCED are summarized in Table ES-1. This table provides a basis of why they were selected and what properties were specifically targeted, given the composition of the procured materials.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Exploitation of Defects in High Entropy Ceramic Barrier Materials

A critical mission need exists to develop new materials that can withstand extreme environments and multiple sequential threats. High entropy materials, those containing 5 or more metals, exhibit many exciting properties which would potentially be useful in such situations. However, a particularly hard challenge in developing new high entropy materials is determining a priori which compositions will form the desired single phase material. The project outlined here combined several modeling and experimental techniques to explore several structure-property-relationships of high entropy ceramics in an effort to better understand the connection between their compositional components, their observed properties, and stability. We have developed novel machine learning algorithms which rapidly predict stable high entropy ceramic compositions, identified the stability interplay between configurational entropy and cation defects, and tested the mechanical stability of high entropy oxides using the unique capabilities at the Dynamic Compression Sector facility and the Saturn accelerator.

36 MATERIALS SCIENCE↗

NASA NTRS1985

Appendange deployment mechanism for the Hubble Space Telescope program

The key requirements, a design overview, development testing (qualification levels), and two problems and their solutions resolved during the mechanism development testing phase are presented. The mechanism described herein has demonstrated its capability to deploy/restow two large Hubble Space Telescope deployable appendages in a varying but controlled manner.

Greenfield, H. T.↗

NASA NTRS2019

Cracking Problems in Low-Voltage Chip Ceramic Capacitors

Cracking remains the major reason of failures in multilayer ceramic capacitors (MLCCs) used in in space electronics. Due to a tight quality control of space-grade components, the probability that as manufactured capacitors have cracks is relatively low, and cracking is often occurs during assembly, handling and the following testing of the systems. Majority of capacitors with cracks are revealed during the integration and testing period, but although extremely rarely, defective parts remain undetected and result in failures during the mission. This situation is aggravated by manual soldering and rework that are often used during low volume production of circuit boards for space. Although failures of MLCCs are often attributed to the post-manufacturing stresses, in many cases they are due to a combination of certain deviations in the manufacturing processes that result in hidden defects in the parts and excessive stresses during assembly and use. This report gives an overview of design, manufacturing and testing processes of MLCCs focusing on elements related to cracking problems. The existing and new screening and qualification procedures and techniques are briefly described and assessed by their effectiveness in revealing cracks. The capability of different test methods to simulate stresses resulting in cracking, mechanisms of failures in capacitors with cracks, and possible methods of selecting the most robust to manual soldering stresses capacitors are discussed.

testing↗

NASA NTRS2019

Evaluation of an Alternate Method for Determining Yield Strength Offset Values for Selective Laser Sintered Polymeric Materials

Due to the unique characteristics of Additively Manufactured (AM) polymeric materials, typical mechanical strength characterization methods such as those commonly used for traditionally-processed polymers or composite materials can produce results that do not accurately represent material capabilities. In order to characterize mechanical properties of these materials, new test and analysis methods are required. As part of the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP), Boeing has evaluated true yield testing as an alternative or complimentary test to 0.2% offset yield testing for determining appropriate yield strength values of polymer materials. Previous testing has shown high strain, low modulus polymer materials such as selective laser sintered (SLS) Nylon 11 at elevated temperatures produce large variations in yield strength. The true yield test method was successful in finding the applied strain level when yield commences and appears to offer an increase in data robustness.

Henry, Chelsey↗

DOE OSTI2026

Coupling Microstructural Evolution Simulations to Material Property Degradation Predictions for Plasma-Facing Materials

Reliable material performance is required for plasma-facing material (PFM) candidates. Previous research has shown that plasma and neutron radiation exposure induces microstructural changes in PFMs; changes in thermal and electrical conductivities and in material hardening and embrittlement were also observed after neutron irradiation. These material property changes will negatively impact the performance of the PFMs in a fusion reactor. Despite the well-known connection between material microstructure, properties, and performance, there is a need for validated modeling capabilities connecting PFM property degradation with microstructural evolution under fusion-relevant conditions. We are developing a simulation capability to couple plasma-induced microstructural evolution to material property degradation. Our approach relies on deliberate mapping between individual simulation models and experimental characterization for validation. The open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) software was used for this simulation capability development. A MOOSE phase-field model was coupled with the cluster dynamics code, Xolotl, to predict microstructural evolution. Microstructure characterization techniques, including scanning electron microscopy (SEM), transmission electron microscopy (TEM), and laser scanning confocal microscopy (LSCM) are used to validate these microstructural evolution simulations. Calculation of thermal and electrical conductivities with first principles simulations was performed for bulk material and for grain boundaries; these results are used within MOOSE models to calculate effective thermal and electrical conductivities as a function of grain characteristics. Thermoreflectance and four-probe techniques were employed to measure the thermal and electrical conductivities, respectively. A MOOSE crystal plasticity model was adapted to predict microstructure-sensitive deformation behavior, and X-ray diffraction (XRD) was used to collect bulk dislocation density data for validation. After individual simulation validation, these models are coupled to predict material property changes resulting from plasma exposure. We focused here on an experimental design to emphasize the separate effects of moderate thermal loads and plasma exposure using tungsten. Annealing of tungsten was performed under a protective environment for temperatures ranging from 500 C to 1500 C. The plasma exposure was completed in the Tritium Plasma Experiment at Idaho National Laboratory under a deuterium flux of 1e22 D/m^2-s. This incremental approach is employed to build confidence in the modeling capability: separate-effects tests ensure that the models capture key mechanisms from single environmental conditions before predicting PFM property degradation under combined loads. We will show our early results from coupling these simulation models to predict PFM property changes from microstructural evolution. Comparisons of the simulation results with preliminary validation data will be discussed.

36 - MATERIALS SCIENCE↗

DOE OSTI2026

Connect microstructure evolution to property degradation with validated simulation

Reliable material performance is required for plasma-facing material (PFM) candidates. Previous research has shown that plasma and neutron radiation exposure induces microstructural changes in PFMs; changes in thermal and electrical conductivities and in material hardening and embrittlement were also observed after neutron irradiation. These material property changes will negatively impact the performance of the PFMs in a fusion reactor. Despite the well-known connection between material microstructure, properties, and performance, there is a need for validated modeling capabilities connecting PFM property degradation with microstructural evolution under fusion-relevant conditions. We are developing a simulation capability to couple plasma-induced microstructural evolution to material property degradation. Our approach relies on deliberate mapping between individual simulation models and experimental characterization for validation. The open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) software was used for this simulation capability development. A MOOSE phase-field model was coupled with the cluster dynamics code, Xolotl, to predict microstructural evolution. Microstructure characterization techniques, including scanning electron microscopy (SEM), transmission electron microscopy (TEM), and laser scanning confocal microscopy (LSCM) are used to validate these microstructural evolution simulations. Calculation of thermal and electrical conductivities with first principles simulations was performed for bulk material and for grain boundaries; these results are used within MOOSE models to calculate effective thermal and electrical conductivities as a function of grain characteristics. Thermoreflectance and four-probe techniques were employed to measure the thermal and electrical conductivities, respectively. A MOOSE crystal plasticity model was adapted to predict microstructure-sensitive deformation behavior, and X-ray diffraction (XRD) was used to collect bulk dislocation density data for validation. After individual simulation validation, these models are coupled to predict material property changes resulting from plasma exposure. We focused here on an experimental design to emphasize the separate effects of moderate thermal loads and plasma exposure using tungsten. Annealing of tungsten was performed under a protective environment for temperatures ranging from 500$^o$C to 1500$^o$C. The plasma exposure was completed in the Tritium Plasma Experiment at Idaho National Laboratory under a deuterium flux of 1e22 $\frac{D}{m^2s}$. This incremental approach is employed to build confidence in the modeling capability: separate-effects tests ensure that the models capture key mechanisms from single environmental conditions before predicting PFM property degradation under combined loads. We will show our early results from coupling these simulation models to predict PFM property changes from microstructural evolution. Comparisons of the simulation results with preliminary validation data will be discussed.

36 - MATERIALS SCIENCE↗

NASA NTRS2016

System Level Aerothermal Testing for the Adaptive Deployable Entry and Placement Technology (ADEPT)

The Adaptive Deployable Entry and Placement Technology (ADEPT), a mechanically deployable entry vehicle technology, has been under development at NASA since 2011. As part of the technical maturation of ADEPT, designs capable of delivering small payloads (10 kg) are being considered to rapidly mature sub 1 m deployed diameter designs. The unique capability of ADEPT for small payloads comes from its ability to stow within a slender volume and deploy to achieve a mass efficient drag surface with a high heat rate capability. The low ballistic coefficient results in entry heating and mechanical loads that can be met by a revolutionary three-dimensionally woven carbon fabric supported by a deployable skeleton structure. This carbon fabric has test proven capability as both primary structure and payload thermal protection system. In order to rapidly advance ADEPTs technical maturation, the project is developing test methods that enable thermostructural design requirement verification of ADEPT designs at the system level using ground test facilities. Results from these tests are also relevant to larger class missions and help us define areas of focused component level testing in order to mature material and thermal response design codes. The ability to ground test sub 1 m diameter ADEPT configurations at or near full-scale provides significant value to the rapid maturation of this class of deployable entry vehicles. This paper will summarize arc jet test results, highlight design challenges, provide a summary of lessons learned and discuss future test approaches based upon this methodology.

Hypersonic↗