Parametric studies of the acoustic behavior of duct-lining materials
Duct lining parameters effects on engine inlet and fan discharge noise reduction during fan jet landing
Atvars, J.↗
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SS410 Process Development and Characterization
Wire-fed stainless-steel additive manufacturing provides the potential for an alternative to traditional stainless-steel tool making processes. 410 stainless steel provides the necessary hardness for long term tool use and its corrosion resistances negates the need for post processing of non-critical faces. 410 has unique characteristics that require different design and welding parameters from other materials. This paper will look at the parameters and characteristics to expect when using wire-arc deposition for 410 stainless steel. Individual weld beads and simple geometric features were printed using the mBAAM wire-arc system at ORNL to determine effective wire-arc parameters for SS410. Once parameters were chosen, additional features were printed to determine the geometric characteristics of printed SS410 as well as compare the differences between designed geometries and printed geometries. These results allow for the formulation of smarter design rules when designing parts for SS410 additive manufacturing.
Vaughan, Derek↗
Use of friction stir processing to synthesize nanocrystalline, grain boundary segregating Fe-Ti alloys
Grain boundary segregating alloys, a class of alloys designed such that nanocrystalline grain sizes are thermodynamically stabilized by the presence of high segregation energy solutes at the grain boundaries, are typically produced through geometrically limited processing techniques such as equal channel angular extrusion or thin film sputtering. Here, this study explores the use of friction stir processing (FSP) as a novel means of studying and producing these alloys using a test system of Fe-6at%Ti. Spot FSPs with a range of processing parameter sets were produced on bulk, coarse grained bars of material and optimal parameters were identified. Microscopy identified a range of processed materials which achieved nanocrystalline grains on the order of 100 nm, delineating a critical window of processing parameters which limit heat input while inducing sufficient plastic deformation for grain refinement. The finest grained nanocrystalline Fe-Ti achieved a hardness of 7.68 GPa, a significant increase in hardness over pure Fe with a similar microstructure due to increased dislocation density from FSP as well as several strengthening mechanisms produced through the presence and segregation of Ti. These results demonstrated the feasibility of using FSP to produce nanocrystalline grain boundary segregating alloys.
Fe alloys↗
Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems
A material response model is developed for the determination of erosion rates and thermal response of woven materials to enable accurate thermal protection material sizing and future missions to Venus and giant planets. The stagnation-point thermal response is further evaluated using a Monte Carlo global sensitivity analysis to determine the interactions between key parameters in the material surface energy balance, such as, convective blowing correction parameter and weave material properties including isotropic and orthotropic thermal conductivites. The time-accurate material response for the dual layer weave erosion and surface temperatures show excellent agreement with stagnation flat face arc-jet tests involving time-varying aeroheating-cooling cycles. The high-fidelity Monte Carlo sensitivity analysis technique was used to address challenges in thermal protection sizing for the Adaptive Deployable Entry and Placement Technology (ADEPT) system, a low ballistic coefficient hypersonic decelerator. The results represent new correlations for such weaves involving Carbon-air oxidation equilibrium chemistry. Through the multi-variate regression analyses and uncertainty rankings performed, only three properties were found to contribute to the transient thermal response of the gore, with emissivity contributing to nearly 95% of the total output uncertainty.
Pratibha Raghunandan↗
Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems
A material response model is developed for the determination of erosion rates and thermal response of woven materials to enable accurate thermal protection material sizing and future missions to Venus and giant planets. The stagnation-point thermal response is further evaluated using a Monte Carlo global sensitivity analysis to determine the interactions between key parameters in the material surface energy balance, such as, convective blowing correction parameter and weave material properties including isotropic and orthotropic thermal conductivites. The time-accurate material response for the dual layer weave erosion and surface temperatures show excellent agreement with stagnation flat face arc-jet tests involving time-varying aeroheating-cooling cycles. The high-fidelity Monte Carlo sensitivity analysis technique was used to address challenges in thermal protection sizing for the Adaptive Deployable Entry and Placement Technology (ADEPT) system, a low ballistic coefficient hypersonic decelerator. The results represent new correlations for such weaves involving Carbon-air oxidation equilibrium chemistry. Through the multi-variate regression analyses and uncertainty rankings performed, only three properties were found to contribute to the transient thermal response of the gore, with emissivity contributing to nearly 95% of the total output uncertainty.
Pratibha Raghunandan↗
Study of Material Densification of In718 in the Higher Throughput Parameter Regime
Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this project is to characterize how heat treatment affects density and porosity from a microscopic point of view. This is performs using higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. Density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, and hatch spacing) and material consolidation (assessed in terms of density and porosity). The study also considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the higher energy parameter regime. Metallurgical evaluation of specimens will also be presented. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.
Cordner, Samuel↗
A robust three-parameter reference curve for condensed phase materials
Many isothermal equations of state lead to numerical problems under tension conditions due to negative bulk modulus. We summarize the properties of four existing models and devise a continuous non-piecewise reference curve to address this issue. The final functional form contains three fitting parameters that are directly related to the bulk modulus and its pressure derivative at the reference state and at infinite pressures. We also include bounds that guarantee the monotonicity of its pressure derivative in all volume space. To demonstrate the qualitative features of each isotherm, we conduct calibrations against experimental data for cyclotetramethylene tetranitramine, magnesium oxide, gold, and platinum. Furthermore, pressure residuals and root mean square deviations show that the proposed functional form is capable of adequately fitting the data compared to other three-parameter models.
36 MATERIALS SCIENCE↗
Systems and methods for generating phase diagrams for metastable material states
A system can include one or more processors configured to access at least one parameter of a material, generate a plurality of structures of the material using the at least one parameter, determine a state of each structure of the plurality of structures using the at least one parameter, determine a difference between the state of each structure of the plurality of structures and a ground state value, evaluate a convergence condition responsive to determining the difference between the state of each structure of the plurality of structures and the ground state value, and output at least one structure of the plurality of structures responsive to the convergence condition being satisfied.
Sankaranarayanan, Subramanian↗
Inadequacy of current approaches for characterizing membrane transport properties at high salinities
Cost optimal design of osmotic membrane processes requires an accurate estimate of membrane transport parameters across their full operational range. However, standard approaches for estimating these parameters rely on empirical methods, the accuracy of which remains unquantified as a function of temperature, salinity, and measurement error. Herein, we present a systematic accuracy analysis of previously developed methods for estimation of membrane transport properties in reverse osmosis, high-pressure reverse osmosis, forward osmosis, pressure retarded reverse osmosis, and osmotically assisted reverse osmosis. We use a Monte Carlo approach to sample the full range of feasible membrane water permeabilities, salt permeabilities, structural parameters, and operating conditions for these processes. These material and process parameters are then incorporated into a physical transport model for each process. Our analysis shows that the statistical uncertainty of current empirical methods for estimating membrane parameters increases by 5 times from low-salinity to high-salinity conditions. Here, the result of this work demonstrates that empirical methods are inadequate for precisely estimating membrane transport properties at high salinity and highlight a critical need for the development of statistically validated higher accuracy methods.
42 ENGINEERING↗
Phase-field model for isothermal phase transitions in binary alloys
A new phase field model is described which models isothermal phase transitions between ideal binary alloy solution phases. Equations are developed for the temporal and spatial variation of the phase field, which describes the identity of the phase, and of the composition. An asymptotic analysis, as the gradient energy coefficient of the phase field becomes small, was conducted. From the analysis, it is shown that the model recovers classical sharp interface models of this situation when the interfacial layers are thin, and they show how to relate the parameters appearing in the phase field model to material and growth parameters in real systems. Further, three stages of temporal evolution are identified: the first corresponding to interfacial genesis which occurs very rapidly; the second to interfacial motion controlled by the local energy difference across the interface and diffusion; the last taking place on a long time scale in which curvature effects are important and which correspond to Ostwald ripening. The results of the numerical calculations are presented.
Wheeler, A. A.↗
On-line, continuous monitoring in solar cell and fuel cell manufacturing using spectral reflectance imaging
A monitoring system 100 comprising a material transport system 104 providing for the transportation of a substantially planar material 102, 107 through the monitoring zone 103 of the monitoring system 100. The system 100 also includes a line camera 106 positioned to obtain multiple line images across a width of the material 102, 107 as it is transported through the monitoring zone 103. The system 100 further includes an illumination source 108 providing for the illumination of the material 102, 107 transported through the monitoring zone 103 such that light reflected in a direction normal to the substantially planar surface of the material 102, 107 is detected by the line camera 106. A data processing system 110 is also provided in digital communication with the line camera 106. The data processing system 110 is configured to receive data output from the line camera 106 and further configured to calculate and provide substantially contemporaneous information relating to a quality parameter of the material 102, 107. Also disclosed are methods of monitoring a quality parameter of a material.
14 SOLAR ENERGY↗
DMA Modulus as a Screening Parameter for Compatibility of Polymeric Containment Materials with Various Solutions for use in Space Shuttle Microgravity Protein Crystal Growth (PCG) Experiments
Protein crystals are grown in microgravity experiments inside the Space Shuttle during orbit. Such crystals are basically grown in a five-component system containing a salt, buffer, polymer, organic and water. During these experiments, a number of different polymeric containment materials must be compatible with up to hundreds of different PCG solutions in various concentrations for durations up to 180 days. When such compatibility experiments are performed at NASA/MSFC (Marshall Space Flight Center) simultaneously on containment material samples immersed in various solutions in vials, the samples are rather small out of necessity. DMA4 modulus was often used as the primary screening parameter for such small samples as a pass/fail criterion for incompatibility issues. In particular, the TA Instruments DMA 2980 film tension clamp was used to test rubber O-rings as small in I.D. as 0.091 in. by cutting through the cross-section at one place, then clamping the stretched linear cord stock at each end. The film tension clamp was also used to successfully test short length samples of medical/surgical grade tubing with an O.D. of 0.125 in.
Wingard, Charles Doug↗
Process Parameter Evaluation and Optimization for Advanced Material Development Final Report CRADA No. TC-1234-96
This project was established as a three-year collaboration to produce and characterize · silica aerogels prepared by a Rapid Supercritical Extraction (RSCE) process to meet . BNA, Inc. application requirements. The objectives of this project were to study the parameters necessary to produce optimized aerogel parts with narrowly specified properties and establish the range and limits of the process for producing such aerogels. The project also included development of new aerogel materials useful for high temperature applications. The results of the project were expected to set the conditions necessary to produce quantities of aerogels having particular specifications such as size, shape, density, and mechanical strength. BNA, Inc. terminated the project on April 7, 1999, 10-months prior to the anticipated completion date, due to termination of corporate funding for the project. The technical accomplishments achieved are outlined in Paragraph C below.
36 MATERIALS SCIENCE↗
Metal-ceramic materials. Study and prediction of effective mechanical properties
Mechanical behavior of stochastic metal-ceramic composite materials was numerically simulated on mesoscopic scale level. Deformation of mesoscopic volumes of composites, whose structure consists of a metal matrix and randomly distributed ceramic inclusions, was numerically simulated. The results of the numerical simulation were used for evaluation of the effective elastic and strength properties of metal-ceramic materials with different parameters of the structure. The values of the effective mechanical properties of investigated materials were obtained, and the character of the dependence of the effective elastic and strength properties on the structure parameters of composites was determined.
36 MATERIALS SCIENCE↗
Comparison of steady and transient flow boiling critical heat flux for FeCrAl accident tolerant fuel cladding alloy, Zircaloy, and Inconel
Steady and transient (with a heating rate of 685?/s) internal-flow CHF (Critical Heat Flux) experiments were conducted under atmospheric pressure at a fixed inlet temperature (40? or 60?) and mass flow (300kg/m 2 s) on Fe-13Cr-6Al alloy, Inconel 600 and Zircaloy-4 tube samples. Multiple experiments were repeated on the same specimen to investigate the effect of surface characteristic changes (i.e., roughness, wettability, and oxide scale morphology) on the occurrence of CHF. Despite notable changes of wettability, roughness, and oxide layer characteristics on samples that had already been subjected to CHF, measured flow CHF remained unchanged throughout repeated experiments for tested materials. This demonstrates that the surface effects on flow CHF are limited in the test conditions. In the steady-state flow boiling condition, Fe-13Cr-6Al alloy demonstrated a 22% and 14% increase in CHF compared to Zircaloy-4 and Inconel 600, respectively. Compared to the 2006 Groeneveld CHF lookup table, Fe-13Cr-6Al alloy gives a 13% increase in the tested flow boiling condition. Material properties are considered primarily responsible for the observed CHF differences among the tested materials. The surface thermal economy parameter $\frac{(pc_p)^{3/2}}{\sqrt{k}}$ is proposed as an explanation for the observed CHF differences; this parameter is related to material’s ability to avoid an irreversible dry spot formation. The apparent disagreement of Zircaloy-4 CHF with both the look up table predictions and Inconel 600 shows the limitation of departure of nuclate boiling (DNB) evaluations that do not consider cladding materials. The transient Fe-13Cr-6Al CHF is 39% and 23% higher than the lookup table prediction and the steady-state condition experimental result, respectively.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Multiplication and Presence of Shielding Material from Time-Correlated Pulse-Height Measurements of Subcritical Plutonium Assemblies
Here, we present the results from the first measurements of the Time-Correlated Pulse-Height (TCPH) distributions from 4.5 kg sphere of α-phase weapons-grade plutonium metal in five configurations: bare, reflected by 1.27 cm and 2.54 cm of tungsten, and 2.54 cm and 7.62 cm of polyethylene. A new method for characterizing source multiplication and shielding configuration is also demonstrated. The method relies on solving for the underlying fission chain timing distribution that drives the spreading of the measured TCPH distribution. We found that a gamma distribution fits the fission chain timing distribution well and that the fit parameters correlate with both multiplication (rate parameter) and shielding material types (shape parameter). The source-to-detector distance was another free parameter that we were able to optimize, and proved to be the most well constrained parameter. MCNPX-PoliMi simulations were used to complement the measurements and help illustrate trends in these parameters and their relation to multiplication and the amount and type of material coupled to the subcritical assembly.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Determining The Degree Of Graphitization In Carbon Composites
Method for determining degree of graphitization of carbon/carbon composite material combines infrared spectral experimental technique with thermodynamical theoretical model of solubility. By interrupting manufacturing process at almost any time and applying method, one can judge quality of composite and monitor chemical transformations taking place during process. Also computes effective solubility parameter for composite considered as unitary material. Parameter significant for subsequent fabrication steps involving chemical treatments; e.g., coating or joining with adhesives.
Lawson, Daniel D.↗
Nasa Hytec CMC Turbine Blade Durability
The objective of the CMC turbine blade durability program is to identify critical material and design parameters that affect durability of ceramic matrix composite (CMC) turbine blades. A baseline architecture for a cooled high-pressure turbine (HPT) CMC blade and accompanying sub-component test articles were developed with the intent to demonstrate through analysis and subcomponent testing how material and design parameters impact key failure modes. As part of this program, a notional architecture for a cooled CMC blade was matured through a design review rhythm to produce a blade test article containing the necessary features required for operation in an engine like environment. Further validation of the durability of these features were achieved through coupon and sub-component testing to demonstrate the durability of cooling hole configurations and blade attachment designs. Analytical methods were also used to evaluate the acceptability of the baseline blade test article architecture against relevant design requirements and identify abatement and recommended changes to key design drivers to improve component durability for future design iterations.
CMC, Blade↗