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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Design solutions for the solar cell interconnect fatigue fracture problem

Mechanical fatigue of solar cell interconnects is a major failure mechanism in photovoltaic arrays. A comprehensive approach to the reliability design of interconnects, together with extensive design data for the fatigue properties of copper interconnects, has been published. This paper extends the previous work, developing failure prediction (fatigue) data for additional interconnect material choices, including aluminum and a variety of copper-Invar and copper-steel claddings. An improved global fatigue function is used to model the probability-of-failure statistics of each material as a function of level and number of cycles of applied strain. Life-cycle economic analyses are used to evaluate the relative merits of each material choce. The copper-Invar clad composites demonstrate superior performance over pure copper. Aluminum results are disappointing.

Mon, G. R.↗
NASA NTRS2000

Fatigue, Creep-Fatigue, and Thermomechanical Fatigue Life Testing of Alloys

The fatigue crack initiation resistance of an alloy is determined by conducting a series of tests over a range of values of stress amplitude or strain range. The observed number of cycles to failure is plotted against the stress amplitude or strain range to obtain a fatigue curve. The fatigue properties quoted for an alloy are typically the constants used in the equation(s) that describe the fatigue curve. Fatigue lives of interest may be as low as 10(exp 2) or higher than 10(exp 9) cycles. Because of the enormous scatter associated with fatigue, dozens of tests may be needed to confidently establish a fatigue curve, and the cost may run into several thousands of dollars. To further establish the effects on fatigue life of the test temperature, environment, alloy condition, mean stress effects, creep-fatigue effects, thermomechanical cycling, etc. requires an extraordinarily large and usually very costly test matrix. The total effort required to establish the fatigue resistance of an alloy should not be taken lightly. Fatigue crack initiation tests are conducted on relatively small and presumed to be initially crack-free, samples of an alloy that are intended to be representative of the alloy's metallurgical and physical condition. Generally, samples are smooth and have uniformly polished surfaces within the test section. Some may have intentionally machined notches of well-controlled geometry, but the surface at the root of the notch is usually not polished. The purpose of polishing is to attain a reproducible surface finish. This is to eliminate surface finish as an uncontrolled variable. Representative test specimen geometries will be discussed later. Test specimens are cyclically loaded until macroscopically observable cracks initiate and eventually grow to failure. Normally, the fatigue failure life of a specimen is defined as the number of cycles to separation of the specimen into two pieces. Alternative definitions are becoming more common, particularly for low-cycle fatigue testing, wherein some prescribed indication of impending failure due to cracking is adopted. Specific criteria will be described later. As a rule, cracks that develop during testing are not measured nor are the test parameters intentionally altered owing to the presence of cracking.

Halford, Gary R.↗
NASA NTRS1995

A study of elevated temperature testing techniques for the fatigue behavior of PMCS: Application to T650-35/AMB21

An experimental study was conducted to investigate the mechanical behavior of a T650-35/AMB21 eight-harness satin weave polymer composite system. Emphasis was placed on the development and refinement of techniques used in elevated temperature uniaxial PMC testing. Issues such as specimen design, gripping, strain measurement, and temperature control and measurement were addressed. Quasi-static tensile and fatigue properties (R(sub sigma) = 0.1) were examined at room and elevated temperatures. Stiffness degradation and strain accumulation during fatigue cycling were recorded to monitor damage progression and provide insight for future analytical modeling efforts. Accomplishments included an untabbed dog-bone specimen design which consistently failed in the gage section, accurate temperature control and assessment, and continuous in-situ strain measurement capability during fatigue loading at elevated temperatures. Finally, strain accumulation and stiffness degradation during fatigue cycling appeared to be good indicators of damage progression.

Gyekenyesi, Andrew L.↗
DOE OSTI2023

Near-Net-Shape HIP Manufacturing for sCO2 Turbomachinery Cost Reduction

sCO2 turbomachinery that operates above 650°C requires the use of γ' strengthened Ni-based superalloys, leading to high cost and barrier of market adoption. Near-net-shape (NNS) HIP manufacturing with 282® alloy powder is being developed for sCO2 turbine components, with a significant estimated cost reduction. Tensile, creep, low cycle fatigue properties of argon gas atomized and plasma atomized powders were evaluated and compared to sand cast HAYNES® 282®. While tensile strength and fatigue life outperformed sand cast material, a 10~25% debit in the creep stress capability was observed due to the fine grain size and presence of prior particle boundaries (PPBs). Finite element model calibrated by powder rheological properties accurately predicted the nonuniform shrinkage during HIP, providing HIP tooling design to achieve the target dimension. A 20 lbs. turbine nozzle ring was successfully demonstrated within 0.01 inch dimensional tolerance at the vanes. A 1700lbs. turbine casing with complex internal struts and manifolds was also demonstrated being close to the target dimension.

14 SOLAR ENERGY↗
DOE OSTI2024

Key results from examinations of seven high burnup pressurized water reactor spent nuclear fuel rods

At present, spent nuclear fuel (SNF) assemblies discharged from US commercial power plants are placed into dry storage following a short cooling time (<10 years) in the plant’s spent fuel pool. The process of packaging the spent fuel into dry-storage canisters includes a drying step to remove residual water from the canister. During the drying process, the fuel rod cladding may reach temperatures as high as 400°C. Oak Ridge National Laboratory (ORNL) is performing destructive examinations of high burnup (HBU) (>45 GWd/MTU) SNF rods to address knowledge and data gaps related to extended interim storage and eventual transportation for disposal. The rods examined include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. Three rods were subjected to a thermal transient to assess the effects of decay-heat-driven high temperatures expected during vacuum drying of the fuel as it is prepared for interim dry storage. The examinations focus on the composite fuel rod performance, as compared with the performance of defueled rod cladding, and establish the baseline mechanical properties of a fuel rod before interim dry storage. The key results of these examinations are presented, including the measured mechanical and fatigue properties, observations of cladding hydrogen pickup and hydride reorientation effects on rod performance, effects of the simulated drying temperatures on rod performance, and general conclusions of SNF performance in extended interim dry storage and transport. The rods were found to be strong and durable in the expected loading conditions, even considering the formation of radial hydrides associated with vacuum drying. The combined testing provides a broad body of data supporting extended interim storage and transportation performance of HBU spent fuel.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1992

Physical aging and solvent effects on the fracture of LaRC-TPI adhesives

When amorphous materials are quenched below their glass transition temperature, excess enthalpy is trapped in the glassy material because the viscosity is too great to allow the material to remain in volumetric equilibrium. Over time, this excess free volume is reduced as the material slowly approaches its equilibrium configuration. This process, known as physical aging, leads to substantial changes in the constitutive behavior of polymers, as has been widely discussed in the literature. Less is known about the effects of this physical aging process on fracture and fatigue properties of aged materials. The original goal of the summer was to investigate the effects of physical aging on the fracture and fatigue behavior of LaRC-TPI, a thermoplastic polyimide developed at NASA-Langley. Preliminary results are reported, although a lack of equipment availability prevented completion of this task. In the process of making specimens, the current LaRC-TPI was observed to be extremely susceptible to environmental stress cracking. A study of the unique failure patterns resulting from this degradation process in bonded joints was conducted and is also reported herein.

Dillard, David A.↗
DOE OSTI2022

A cycle-jump acceleration method for the crystal plasticity simulation of high cycle fatigue of the metallic microstructure

For metallic materials, high-cycle fatigue life is sensitive to underlying microstructure features including secondary phases, textures, grains morphology, etc. The traditional, data-based safe-life approaches for modeling fatigue don’t explicitly consider the microstructure and can’t guide study in microstructure modification for improved fatigue property. Crystal plasticity-based simulation provides increased model fidelity at the expense of immense computation time, making it inapplicable for high cycle fatigue. In this work, an acceleration method based on cycle-jump approach (Lesne and Savalle, 1989) was developed for microstructure-based high-cycle FE simulation using crystal plasticity constitutive-model. We report this method demonstrated high efficiency in benchmark tests of various conditions.

36 MATERIALS SCIENCE↗
NASA NTRS1983

The construction of life prediction models for the design of Stirling engine heater components

The service life of Stirling-engine heater structures of Fe-based high-temperature alloys is predicted using a numerical model based on a linear-damage approach and published test data (engine test data for a Co-based alloy and tensile-test results for both the Co-based and the Fe-based alloys). The operating principle of the automotive Stirling engine is reviewed; the economic and technical factors affecting the choice of heater material are surveyed; the test results are summarized in tables and graphs; the engine environment and automotive duty cycle are characterized; and the modeling procedure is explained. It is found that the statistical scatter of the fatigue properties of the heater components needs to be reduced (by decreasing the porosity of the cast material or employing wrought material in fatigue-prone locations) before the accuracy of life predictions can be improved.

Petrovich, A.↗
NASA NTRS1994

A Note of Appreciation for the MUS

This note has been written to acknowledge the pervasive impact the Method of Universal Slopes (MUS) has had on the design and development of the Space Shuttle Main Engine (SSME) through its use in material fatigue properties definition for component analysis. Included is a brief historical perspective describing propulsion system development leading up to the SSME, the need for fatigue analysis capability in the SSME design, the role that MUS played in meeting that need as a material modeling tool and the engine's subsequent successful operating history.

Newell, J. F.↗
NASA NTRS1987

Rapidly solidified metal coatings by peen plating

Specimens of 7075-T6 aluminum alloy were peen plated with rapidly solidified tin-lead and aluminum powders, and the cross-sections of the coated specimens were examined by light and electron microscopy. The properties of the peen plated specimens were also compared with those of shot peened specimens without any coating. It is found that peen plating with rapidly solidified metals improves the fatigue properties of the coated samples to a greater extent than shot peening alone. Specimens of 7075-T6 alloy peen plated with rapidly solidified tin-lead and aluminum exhibited better fatigue resistance than shot peened specimens in both air and salt water.

Chu, H. P.↗
DOE OSTI2021

A review of technologies for welding magnesium alloys to steels

Here we review various state-of-the-art methods for welding magnesium alloys and steels using different joint configurations. Microstructural characterizations indicate that four microstructures may form at the Mg/steel interface after welding: unwelded gap, metal oxides, solid solutions, or intermetallic compounds. Reaction products at the Mg/steel interface vary with different welding methods, alloying elements in base materials, interlayers or coatings applied, and preparations of base material before welding. Regarding mechanical property characterization, (a) lap tensile shear testing for lap-welded and spot-welded joints, (b) tensile testing for butt-welded joints and (c) fatigue properties of lap-welded and spot-welded joints are summarized and compared, separately. Reaction products at the Mg/steel interface are correlated with mechanical properties. Finally, ways to enhance Mg/steel joint strength, such as introducing interlocking features during friction stir lap and butt welding, are discussed.

Wang, Tianhao↗
NASA NTRS1987

Application of single crystal superalloys for Earth-to-orbit propulsion systems

Single crystal superalloys were first identified as potentially useful engineering materials for aircraft gas turbine engines in the mid-1960's. Although they were not introduced into service as turbine blades in commercial aircraft engines until the early 1980's, they have subsequently accumulated tens of millions of flight hours in revenue producing service. The space shuttle main engine (SSME) and potential advanced earth-to-orbit propulsion systems impose severe conditions on turbopump turbine blades which for some potential failure modes are more severe than in aircraft gas turbines. Research activities which are directed at evaluating the potential for single crystal superalloys for application as turbopump turbine blades in the SSME and advanced rocket engines are discussed. The mechanical properties of these alloys are summarized and the effects of hydrogen are noted. The use of high gradient directional solidification and hot isostatic pressing to improve fatigue properties is also addressed.

Dreshfield, R. L.↗
NASA NTRS1987

Application of single crystal superalloys for earth-to-orbit propulsion systems

Single crystal superalloys were first identified as potentially useful engineering materials for aircraft gas turbine engines in the mid-1960s. Although they were not introduced into service as turbine blades in commercial aircraft engines until the early 1980's, they have subsequently accumulated tens of millions of flight hours in revenue producing service. The Space Shuttle main engine (SSME) and potential advanced earth-to-orbit propulsion systems impose severe conditions on turbopump turbine blades which for some potential failure modes are more severe than in aircraft gas turbines. Research activities which are directed at evaluating the potential for single crystal superalloys for application as turbopump turbine blades in the SSME and advanced rocket engines are discussed. The mechanical properties of these alloys are summarized and the effects of hydrogen are noted. The use of high gradient directional solidification and hot isostatic pressing to improve fatigue properties is also addressed.

Dreshfield, R. L.↗
NASA NTRS2004

Third-Generation TiAl Alloy Tested: Exhibits Promising Properties for Rotating Components

The Revolutionary Turbine Accelerator/Turbine-Based Combined Cycle (RTA/TBCC) Program for the next-generation launch vehicle has targeted gamma titanium aluminide as a potential compressor and structural material. Because of the high compressor inlet and exit temperatures, the TBCC engine requires higher temperature materials than conventional Ti alloys, and because of its stringent thrust-to-weight requirements, the engine requires low-density material to be utilized wherever possible. Third-generation gamma alloys offer higher temperature capability along with low density and high stiffness. A high-temperature, high-strength *-TiAl alloy with a high Nb-content (Gamma MET PX1) was selected for evaluation. The microstructure and mechanical properties of Gamma Met PX (GMPX) in both the as-extruded and a lamellar heat-treated condition and the influence of the microstructure on the tensile, creep, and fatigue properties were investigated in-house.

Draper, Susan L.↗
NASA NTRS1975

Effect of service usage on tensile, fatigue, and fracture properties of 7075-T6 and 7178-T6 aluminum alloys

A study has been made to determine the effects of extensive service usage on some basic material properties of 7075-T6 and 7178-T6 aluminum alloy materials. The effects of service usage were determined by comparing material properties for new material (generally obtained from the literature) with those for material cut from the center wing box of a C-130B transport airplane with 6385 flight-hours of service. The properties investigated were notched and unnotched fatigue strengths, fatigue-crack-growth rate, fracture toughness, and tensile properties. For the properties investigated and the parameter ranges considered (crack length, stress ratio, etc.), the results obtained showed no significant difference between service and new materials.

Everett, R. A., Jr.↗