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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 937 records · Page 52

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

Wide-bandgap devices have pushed the operational limit of semiconductor devices in automotive power electronics packages to higher temperatures (>200 C). While a higher efficiency can be achieved through the use of wide-bandgap devices, the entire package must be re-designed with components that can withstand the higher temperature limits. Sintered silver and transient liquid phase bonds are potential candidates as bonded materials for use in higher temperatures however, the underlying mechanics of deformation under thermal loads and the resulting failure mechanisms in these materials are not well understood. Accelerated experiments conducted at NREL reveal that high-lead solder joints have better reliability than sintered silver under extreme thermal cycling conditions. Furthermore, efforts to develop a crack propagation model for the high-temperature materials are described.

ADVANCED PROPULSION SYSTEMS↗

Integrating science for water security governance

Hydrological extremes are intensifying globally, increasing the complexity of decisions required to ensure water security. Advances in hydrological science, modeling, and data systems have expanded the technical frontier of water research, yet uptake of scientific insights in policy and management decisions remains limited. This persistent science–policy gap is not primarily a failure of knowledge generation or robustness, but an institutional challenge shaped by how scientific and governance systems are organized, coordinated, and connected to support the effective use of scientific knowledge. These challenges are particularly pronounced in multi-level and transboundary water governance, where decisions span jurisdictions and require coordination across institutional and political boundaries. We synthesize research at the science–policy interface and evidence from water security initiatives to show how institutional arrangements, scientific tool development, and research practices enable or constrain the sustained use of scientific knowledge in water-security governance processes. Building on these insights, we develop ‘shared decision infrastructure’ as a framing to describe how scientific knowledge is embedded within the institutional, relational, and procedural arrangements that connect science to decision-making processes over time. We translate this framing into a practical intervention roadmap centered on institutional design, tool translation, sustained co-production, and outcome-oriented evaluation to support the integration of science into ongoing governance processes. By positioning science as shared decision infrastructure, the roadmap clarifies how researchers can design scientific efforts that support more coordinated, accountable, and adaptive water security decisions amid deepening uncertainty.

M whitney, Kristen [NASA Goddard Space Flight Cent↗

MPI Stages : A Serializable MPI Library

MPI library that supports serializing (and check-pointing) its MPI Stages is a communication library that allows nodes and programs in a computer cluster to communicate via the Message-Passing Interface (MPI). The internal data objects of the library are serializable, i.e., the user can convert the MPI state or objects, such as groups or communicators, into byte streams and save them into a checkpoint file. Later users can load the checkpoint file and de-serialize previous objects into the library. Serialization/de-serialization is useful in MPI applications to recover from node failures.

Ruefenacht, Martin↗

Impact ice stresses in rotating airfoils

Finite element analysis is used to study the tensile and shear stresses at the interface between impact ice adhering to a rotating airfoil and the metal airfoil surface. A simple rotating beam-ice structure is used to obtain basic understanding of stress distribution in the ice. Calculations show that shear stresses increase linearly with ice thickness and tensile stresses tend to zero for a fully bonded surface. When shear stresses exceed the ultimate strength, adhesive failure occurs and tensile stresses are developed in the unbonded ice, resulting in tensile failure of the impact ice. A second model is used to study the OH-58 tail rotor with a measured ice profile. Ice shedding predictions are compared to the resulting data using a statistical structural analysis.

Scavuzzo, R. J.↗

Hydrogen-assisted failure of laser melting additive manufactured IN718 superalloy

A nickel-based superalloy IN718 was fabricated by laser melting additive manufacturing process and hydrogen embrittlement (HE) behavior of this alloy was assessed via slow strain rate tensile tests. The results reveal that hydrogen-charged as-deposited samples along vertical plane exhibit the lowest susceptibility to HE, followed by as-deposited samples along horizontal plane and then heat-treated samples. Additionally, hydrogen-assisted cracking of as-deposited samples initiates from γ-matrix/Laves phase interfaces, whereas γ-matrix/δ phase interfaces along grain boundaries act as preferable damage sites for hydrogen charged heat-treated samples. These hydrogen-assisted cracking can be explained by synergistic effect of HELP mechanism and HEDE mechanism.

36 MATERIALS SCIENCE↗

U.S. Space Shuttle Solid Rocket Booster - Return to flight

The Space Shuttle Solid Rocket Booster (SRB) redesign program instituted in the wake of the Challenger accident encompassed a design requirements review, a failure modes effect analysis/critical items list determination, a hazards analysis, an operational maintenance and requirements specification study, the definition of operational maintenance instructions and launch commit criteria, and design certification and flight readiness reviews. Attention is presently given to the SRB's thrust vector control, separation, and recovery functions, as well as its electrical and instrumentation systems and its case assembly and hardware interfaces.

Coates, K. D.↗

Utilizing Testing Frameworks for Launch Control Systems Continuous Integration

Command and control software is an integral part of the launch procedure. The most important part of this type of software is its ability to communicate well with the user and relay information in a correctly formatted way such that the user can understand the data. There is a tool that aides the communication between the different parts of the system, and effectively, the user. This instrument is capable of taking several complex values and ensuring that they are correctly sorted into their distinctive message values and distributed properly among the different facets of the system. This tool will easily translate and publish the data inside of messages in the system to something that is readable and understandable. The tool also allows for transmission of the recorded data to the user, effectively ensuring the communication between different components of the system. As well as keeping track of messages and ensuring that the information contained within each of them reaches the correct location, this tool has the ability to keep track of its own statistics and determine how many messages passed in were erroneous and how many were successfully transmitted. It is able to check and see what the total message failure count is when an invalid message is given, as well as the number of different messages and their respective types passed into the tool. This tool is of great value to the new Space Launch System (SLS). As such, the tool must be thoroughly tested with test cases that, although improbable, are possible, where the tool may not function properly. Testing an interface this complex is necessary to ensure mission safety and create unlikely scenarios where the tool would work as intended, and stretch its limits to test that even under the most uncommon conditions it would still continue to function. This software will be an important part of the control system for the newest spacecraft which will fly deeper into space than humans have ever travelled. It will fly beyond the moon, into deep space to Mars and perhaps set the groundwork for a manned mission even further to create more opportunities for interplanetary and even interstellar travel by humans. This mission relies heavily on software and hardware to ensure the safety of the humans that will be on board and therefore must be checked, exhausting each and every different situation, such that there is not a doubt surrounding the well-being of the humans aboard the rocket. That is why testing is such an important part of the mission. It provides evidence that the systems aboard the rocket and on the launch pad are safe.

Unit Testing↗

Strong Local-Nonlocal Coupling for Integrated Fracture Modeling

Peridynamics, a nonlocal extension of continuum mechanics, is unique in its ability to capture pervasive material failure. Its use in the majority of system-level analyses carried out at Sandia, however, is severely limited, due in large part to computational expense and the challenge posed by the imposition of nonlocal boundary conditions. Combined analyses in which peridynamics is employed only in regions susceptible to material failure are therefore highly desirable, yet available coupling strategies have remained severely limited. This report is a summary of the Laboratory Directed Research and Development (LDRD) project “Strong Local-Nonlocal Coupling for Integrated Fracture Modeling,” completed within the Computing and Information Sciences (CIS) Investment Area at Sandia National Laboratories. A number of challenges inherent to coupling local and nonlocal models are addressed. A primary result is the extension of peridynamics to facilitate a variable nonlocal length scale. This approach, termed the peridynamic partial stress, can greatly reduce the mathematical incompatibility between local and nonlocal equations through reduction of the peridynamic horizon in the vicinity of a model interface. A second result is the formulation of a blending-based coupling approach that may be applied either as the primary coupling strategy, or in combination with the peridynamic partial stress. This blending-based approach is distinct from general blending methods, such as the Arlequin approach, in that it is specific to the coupling of peridynamics and classical continuum mechanics. Facilitating the coupling of peridynamics and classical continuum mechanics has also required innovations aimed directly at peridynamic models. Specifically, the properties of peridynamic constitutive models near domain boundaries and shortcomings in available discretization strategies have been addressed. The results are a class of position-aware peridynamic constitutive laws for dramatically improved consistency at domain boundaries, and an enhancement to the meshfree discretization applied to peridynamic models that removes irregularities at the limit of the nonlocal length scale and dramatically improves convergence behavior. Finally, a novel approach for modeling ductile failure has been developed, motivated by the desire to apply coupled local-nonlocal models to a wide variety of materials, including ductile metals, which have received minimal attention in the peridynamic literature. Software implementation of the partial-stress coupling strategy, the position-aware peridynamic constitutive models, and the strategies for improving the convergence behavior of peridynamic models was completed within the Peridigm and Albany codes, developed at Sandia National Laboratories and made publicly available under the open-source 3-clause BSD license.

36 MATERIALS SCIENCE↗

Differential lipid binding of vinculin isoforms promotes quasi-equivalent dimerization

The main cause of death globally remains debilitating heart conditions, such as dilated cardiomyopathy (DCM) and hypertrophic cardiomyopathy (HCM), which are often due to mutations of specific components of adhesion complexes. Vinculin regulates these complexes and plays essential roles in intercalated discs that are necessary for muscle cell function and coordinated movement and in the development and function of the heart. Humans bearing familial or sporadic mutations in vinculin suffer from chronic, progressively debilitating DCM that ultimately leads to cardiac failure and death, whereas autosomal dominant mutations in vinculin can also provoke HCM, causing acute cardiac failure. The DCM/HCM-associated mutants of vinculin occur in the 68-residue insert unique to the muscle-specific, alternatively spliced isoform of vinculin, termed metavinculin (MV). Contrary to studies that suggested that phosphoinositol-4,5-bisphosphate (PIP 2 ) only induces vinculin homodimers, which are asymmetric, we show that phospholipid binding results in a domain-swapped symmetric MV dimer via a quasi-equivalent interface compared with vinculin involving R975. Although one of the two PIP 2 binding sites is preserved, the symmetric MV dimer that bridges two PIP 2 molecules differs from the asymmetric vinculin dimer that bridges only one PIP 2 . Unlike vinculin, wild-type MV and the DCM/HCM-associated R975W mutant bind PIP 2 in their inactive conformations, and R975W MV fails to dimerize. Here, mutating selective vinculin residues to their corresponding MV residues, or vice versa, switches the isoform’s dimeric constellation and lipid binding site. Collectively, our data suggest that MV homodimerization modulates microfilament attachment at muscular adhesion sites and furthers our understanding of MV-mediated cardiac remodeling.

59 BASIC BIOLOGICAL SCIENCES↗

Effects of Water Contamination on Micropitting and Rolling Contact Fatigue of Bearing Steels

Abstract In this research, the effects of water contamination in oil were investigated on two kinds of failures that occur in bearing steel: micropitting and rolling contact fatigue. Whereas the presence of water in the oil had little effect on the generation of surface wear in these experiments, increases in the occurrences of micropitting and rolling contact fatigue were observed due to the presence of either dissolved or free water in lubricants. Additionally, the presence of white etching matter at crack interfaces was observed and evaluated. The experimental results showed that water content can be considered as a significant factor that accelerates the formation of micropitting and fatigue cracks in rolling bearings.

Engineering↗

Effect of 0.1 at. pct Zirconium on the cyclic oxidation resistance of beta-NiAl

The effect of 0.1 at. pct Zr on the cyclic oxidation of hipped beta-NiAl was studied. Oxidation testing was performed in static air at 1100-1200 C, using 1-hr exposure cycles for test times up to 3000 hr. The weight change versus time data were modeled with the COSP computer program to analyze and predict cyclic-oxidation behavior. Zr additions significantly change the nature of the scale-spalling process during cooling, so that the oxide spalls near the oxide-air interface at a relatively low depth within the scale. Without Zr, the predominantly alpha-Al2O3 scale tends to spall randomly to bare metal at relatively high effective-scale-loss rates, particularly at 1150 C and 1200 C. This leads to higher rates of Al consumption for the Zr-free aluminide and much earlier depletion of Al, leading to eventual breakaway (i.e., failure).

Barrett, Charles A.↗

Characterization and Damping Control of Mechanical Connections to Improve Performance of Horn Stripline

Magnetic focusing horns are critical components for creating a stable beam of neutrinos for neutrino facilities, such as the Long Baseline Neutrino Facility (LBNF) and the Neutrinos and Main Injector (NuMI) beam lines at Fermilab. The pulsed magnetic horns are powered by high current electricity through long striplines. In addition to requirements for low inductance and voltage standoff, the striplines must survive in a harsh radiation environment for the operational life of the component, specified as the 100 million pulses requirement for LBNF. Each stripline assembly consists of four (eight layers that splits off to 2 pairs of four layers at the horn interface) layers of Al 6101-T6. As an electromechanical system, the stripline layers are bolted together with ceramic isolators for electrical insulation and connections must facilitate passive cooling and mechanical stability. The striplines experience vibrational force in addition to clamping force, repetitive thermal and electro-magnetic loading. The holes of stripline plates for ceramic joints represent one of the weak links for potential failure [1,2]. By characterizing the contact behavior of these joints and optimizing their damping properties through finite element analysis and experimental modal analysis, stripline performance and longevity can be improved. This study not only helps predict the behavior of the striplines but also improves their performance to meet the required operational lifetime.

Liu, Zunping [Fermilab]↗

Nondissipative Martensitic Phase Transformation after Multimillion Superelastic Cycles

Superelastic alloys used for stents, biomedical implants, and solid-state cooling devices rely on their reversible stress-induced martensitic transformations. These applications require the alloy to sustain high deformability over millions of cycles without failure. Here, we report an alloy capable of enduring 10 × 10 7 tensile stress-induced phase transformations while still exhibiting over 2% recoverable elastic strains. After millions of cycles, the alloy is highly reversible with zero stress hysteresis. We show that the major martensite variant is reversible even after multimillions of cycles under tensile loadings with a highly coherent $(1\bar{1}0)_A$ interface. Finally, this discovery provides new insights into martensitic transformation, and may guide the development of superelastic alloys for multimillion cycling applications.

36 MATERIALS SCIENCE↗

Chemical bonding technology for terrestrial photovoltaic modules

Encapsulated photovoltaic modules must hold together for 20 years, reliably resisting delamination and separation of any of the component materials. Delamination of encapsulation materials from each other, or from solar cells and interconnects, can create voids for accumulation of water, promoting corrosive failure. Delamination of silicone elastomers from unprimed surfaces was a common occurrence with early modules, but the incidences of silicone delamination with later modules decreased when adhesion promoters recommended by silicone manufacturers were used. An investigation of silicone delamination from unprimed surfaces successfully identified the mechanism, which was related to atmospheric oxygen and moisture. This early finding indicated that reliance on physical bonding of encapsulation interfaces for long life in an outdoor environment would be risky. For long outdoor life, the material components of a module must therefore be held together by weather-stable adhesion promoters that desirably form strong, interfacial chemical bonds.

Coulter, D. R.↗

GENOA-PFA: Progressive Fracture in Composites Simulated Computationally

GENOA-PFA is a commercial version of the Composite Durability Structural Analysis (CODSTRAN) computer program that simulates the progression of damage ultimately leading to fracture in polymer-matrix-composite (PMC) material structures under various loading and environmental conditions. GENOA-PFA offers several capabilities not available in other programs developed for this purpose, making it preferable for use in analyzing the durability and damage tolerance of complex PMC structures in which the fiber reinforcements occur in two- and three-dimensional weaves and braids. GENOA-PFA implements a progressive-fracture methodology based on the idea that a structure fails when flaws that may initially be small (even microscopic) grow and/or coalesce to a critical dimension where the structure no longer has an adequate safety margin to avoid catastrophic global fracture. Damage is considered to progress through five stages: (1) initiation, (2) growth, (3) accumulation (coalescence of propagating flaws), (4) stable propagation (up to the critical dimension), and (5) unstable or very rapid propagation (beyond the critical dimension) to catastrophic failure. The computational simulation of progressive failure involves formal procedures for identifying the five different stages of damage and for relating the amount of damage at each stage to the overall behavior of the deteriorating structure. In GENOA-PFA, mathematical modeling of the composite physical behavior involves an integration of simulations at multiple, hierarchical scales ranging from the macroscopic (lamina, laminate, and structure) to the microscopic (fiber, matrix, and fiber/matrix interface), as shown in the figure. The code includes algorithms to simulate the progression of damage from various source defects, including (1) through-the-thickness cracks and (2) voids with edge, pocket, internal, or mixed-mode delaminations.

Murthy, Pappu L. N.↗

The X-15 3-65 Accident: An Aircraft Systems and Flight Control Perspective

Despite the NASA X-15 program's outstanding success in developing and operating the first manned hypersonic research platform, the program suffered a fatal accident on November 15, 1967, when X-15-3, the only aircraft outfitted with advanced pilot displays and an adaptive flight control system, was lost after entering uncontrolled flight at an altitude of 230,000 feet and a velocity near Mach 5. The pilot, Major Michael J. Adams, was incapacitated by the aircraft accelerations and was killed either during the ensuing breakup or upon ground impact. In light of mitigating risk to current and emerging manned aerospace vehicles, a comprehensive systems level analysis of the accident is presented with a focus on the electrical power, flight control, and instrumentation failures that affected not only the vehicle dynamics but substantially impacted the pilot decisions that led to an inevitable loss of control. Insights based on reconstructed flight data as well as analysis and simulation of the X-15's unique adaptive control system, yield new conclusions about the reasons for the control systems anomalous behavior and the system-level interactions and human-machine interface design oversights that led to the accident.

Accident Investigation↗

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties).To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗