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DOE OSTI2023

In Cell Thermal Creep Frames for Demonstration Project Preparations

The thrust of advanced nuclear reactor demonstrations demands the accelerated qualification of in-core materials to enable licensing processes and developing the performance data. Due to the high-operating temperatures of such reactors, long-term mechanical behavior under constant load is essential to determine the geometrical and mechanical integrity of in-core components during operation and off-normal conditions. Therefore, the thermal creep behavior of neutron-irradiated advanced reactor materials must be determined. The feasibility of using subsize specimens for the irradiation campaigns and the limited available infrastructure challenge the assessment of thermal creep behavior of advanced reactor materials. Therefore, the U.S. Department of Energy Office of Nuclear Energy (DOE-NE) National Reactor Innovation Center (NRIC) prioritizes the development of a thermal creep testing infrastructure for multiple subsize specimens to accelerate the demonstration and deployment of advanced reactor concepts. This report describes the activities for the construction of a thermal creep testing capability at Idaho National Laboratory (INL). The overall project consists of conceptual design, out-of-cell demonstration, and in-cell demonstration phases. During fiscal year (FY)-2021, the team finished the conceptual design of a thermal creep test facility that can test multiple subsize specimens. This conceptual design consisted of the determination of technical and functional requirements, the determination of the design space, and the preparation of the technical drawings. Technical and functional requirements were categorized as required and desired capabilities and the conceptual design was performed to meet all the required capabilities with the flexibility to achieve the desired capabilities. The design space identified the operational capacity of the creep frame for different advanced reactor relevant materials with the consideration of the feasible operation in the hotcell at the Fuels and Applied Science Building (FASB) at INL. Based on the requirements and design space, the multiple specimen creep frame was designed. The official INL engineering drawing process was started and the procurement of materials for construction was initiated. For FY-2022, the out-of-cell demonstration and final installation of the multiple creep frame is planned.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Development of Lightweight Material Composites to Insulate Cryogenic Tanks for 30-Day Storage in Outer Space

A conceptual design was developed for an MLI system which will meet the design constraints of an ILRV used for 7- to 30-day missions. The ten tasks are briefly described: (1) material survey and procurement, material property tests, and selection of composites to be considered; (2) definition of environmental parameters and tooling requirements, and thermal and structural design verification test definition; (3) definition of tanks and associated hardware to be used, and definition of MLI concepts to be considered; (4) thermal analyses, including purge, evacuation, and reentry repressurization analyses; (5) structural analyses (6) thermal degradation tests of composite and structural tests of fastener; (7) selection of MLI materials and system; (8) definition of a conceptual MLI system design; (9) evaluation of nondestructive inspection techniques and definition of procedures for repair of damaged areas; and (10) preparation of preliminary specifications.

Krause, D. R.↗

NASA NTRS2007

Hypervelocity Impact Evaluation of Metal Foam Core Sandwich Structures

A series of hypervelocity impact (HVI) tests were conducted by the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology Facility (HITF) [1], building 267 (Houston, Texas) between January 2003 and December 2005 to test the HVI performance of metal foams, as compared to the metal honeycomb panels currently in service. The HITF testing was conducted at the NASA JSC White Sands Testing Facility (WSTF) at Las Cruces, New Mexico. Eric L. Christiansen, Ph.D., and NASA Lead for Micro-Meteoroid Orbital Debris (MMOD) Protection requested these hypervelocity impact tests as part of shielding research conducted for the JSC Center Director Discretionary Fund (CDDF) project. The structure tested is a metal foam sandwich structure; a metal foam core between two metal facesheets. Aluminum and Titanium metals were tested for foam sandwich and honeycomb sandwich structures. Aluminum honeycomb core material is currently used in Orbiter Vehicle (OV) radiator panels and in other places in space structures. It has many desirable characteristics and performs well by many measures, especially when normalized by density. Aluminum honeycomb does not perform well in Hypervelocity Impact (HVI) Testing. This is a concern, as honeycomb panels are often exposed to space environments, and take on the role of Micrometeoroid / Orbital Debris (MMOD) shielding. Therefore, information on possible replacement core materials which perform adequately in all necessary functions of the material would be useful. In this report, HVI data is gathered for these two core materials in certain configurations and compared to gain understanding of the metal foam HVI performance.

Yasensky, John↗

NASA NTRS2011

Taurus II Stage Test Simulations: Using Large-Scale CFD Simulations to Provide Critical Insight into Plume Induced Environments During Design

This paper describes the use of targeted Loci/CHEM CFD simulations to evaluate the effects of a dual-engine first-stage hot-fire test on an evolving integrated launch pad/test article design. This effort was undertaken as a part of the NESC Independent Assessment of the Taurus II Stage Test Series. The underlying conceptual model included development of a series of computational models and simulations to analyze the plume induced environments on the pad, facility structures and test article. A pathfinder simulation was first developed, capable of providing quick-turn around evaluation of plume impingement pressures on the flame deflector. Results from this simulation were available in time to provide data for an ongoing structural assessment of the deflector. The resulting recommendation was available in a timely manner and was incorporated into construction schedule for the new launch stand under construction at Wallops Flight Facility. A series of Reynolds-Averaged Navier-Stokes (RANS) quasi-steady simulations representative of various key elements of the test profile was performed to identify potential concerns with the test configuration and test profile. As required, unsteady Hybrid-RANS/LES simulations were performed, to provide additional insight into critical aspects of the test sequence. Modifications to the test-specific hardware and facility structures thermal protection as well as modifications to the planned hot-fire test profile were implemented based on these simulation results.

Struzenberg, L. L.↗

NASA NTRS1987

A comparative overview of modal testing and system identification for control of structures

This paper presents a comparative overview of the disciplines of modal testing used in structural engineering and system identification used in control theory. A list of representative references from both areas is given and the basic methods are briefly described. Recent progress on the interaction of modal testing and control disciplines is discussed. It is concluded that combined efforts of researchers in both disciplines are required for unification of modal testing and system identification methods for control of flexible structures.

Juang, Jer-Nan↗

NASA NTRS1972

Shock and vibration tests of uranium mononitride fuel pellets for a space power nuclear reactor

Shock and vibration tests were conducted on cylindrically shaped, depleted, uranium mononitride (UN) fuel pellets. The structural capabilities of the pellets were determined under exposure to shock and vibration loading which a nuclear reactor may encounter during launching into space. Various combinations of diametral and axial clearances between the pellets and their enclosing structures were tested. The results of these tests indicate that for present fabrication of UN pellets, a diametral clearance of 0.254 millimeter and an axial clearance of 0.025 millimeter are tolerable when subjected to launch-induced loads.

Adams, D. W.↗

NASA NTRS1987

A space debris simulation facility for spacecraft materials evaluation

A facility to simulate the effects of space debris striking an orbiting spacecraft is described. This facility was purchased in 1965 to be used as a micrometeoroid simulation facility. Conversion to a Space Debris Simulation Facility began in July 1984 and it was placed in operation in February 1985. The facility consists of a light gas gun with a 12.7-mm launch tube capable of launching 2.5-12.7 mm projectiles with a mass of 4-300 mg and velocities of 2-8 km/sec, and three target tanks of 0.067 m, 0.53 a m and 28.5 a m. Projectile velocity measurements are accomplished via pulsed X-ray, laser diode detectors, and a Hall photographic station. This facility is being used to test development structural configurations and candidate materials for long duration orbital spacecraft. A summary of test results are also described.

Taylor, Roy A.↗

NASA NTRS1994

Full-scale testing and analysis of fuselage structure

This paper presents recent results from a program in the Boeing Commercial Airplane Group to study the behavior of cracks in fuselage structures. The goal of this program is to improve methods for analyzing crack growth and residual strength in pressurized fuselages, thus improving new airplane designs and optimizing the required structural inspections for current models. The program consists of full-scale experimental testing of pressurized fuselage panels in both wide-body and narrow-body fixtures and finite element analyses to predict the results. The finite element analyses are geometrically nonlinear with material and fastener nonlinearity included on a case-by-case basis. The analysis results are compared with the strain gage, crack growth, and residual strength data from the experimental program. Most of the studies reported in this paper concern the behavior of single or multiple cracks in the lap joints of narrow-body airplanes (such as 727 and 737 commercial jets). The phenomenon where the crack trajectory is curved creating a 'flap' and resulting in a controlled decompression is discussed.

Miller, M.↗

NASA NTRS2017

Advanced Deployable Shell-Based Composite Booms for Small Satellite Structural Applications Including Solar Sails

State of the art deployable structures are mainly being designed for medium to large size satellites. The lack of reliable deployable structural systems for low cost, small volume, rideshare-class spacecraft severely constrains the potential for using small satellite platforms for affordable deep space science and exploration precursor missions that could be realized with solar sails. There is thus a need for reliable, lightweight, high packaging efficiency deployable booms that can serve as the supporting structure for a wide range of small satellite systems including solar sails for propulsion. The National Air and Space Administration (NASA) is currently investing in the development of a new class of advanced deployable shell-based composite booms to support future deep space small satellite missions using solar sails. The concepts are being designed to: meet the unique requirements of small satellites, maximize ground testability, permit the use of low-cost manufacturing processes that will benefit scalability, be scalable for use as elements of hierarchical structures (e.g. trusses), allow long duration storage, have high deployment reliability, and have controlled deployment behavior and predictable deployed dynamics. This paper will present the various rollable boom concepts that are being developed for 5-20 m class size deployable structures that include solar sails with the so-called High Strain Composites (HSC) materials. The deployable composite booms to be presented are being developed to expand the portfolio of available rollable booms for small satellites and maximize their length for a given packaged volume. Given that solar sails are a great example of volume and mass optimization, the booms were designed to comply with nominal solar sail system requirements for 6U CubeSats, which are a good compromise between those of smaller form factors (1U, 2U and 3U CubeSats) and larger ones (12 U and 27 U future CubeSats, and ESPA-class microsatellites). Solar sail missions for such composite boom systems are already under consideration and development at NASA, as well as mission studies that will benefit from planned scaled-up versions of the composite boom technologies to be introduced. The paper presents ongoing research and development of thin-shell rollable composite booms designed under the particular stringent and challenging system requirements of relatively large solar sails housed on small satellites. These requirements will be derived and listed. Several new boom concepts are proposed and other existing ones are improved upon using thin-ply composite materials to yield unprecedented compact deployable structures. Some of these booms are shown in Fig. 1. For every boom to be introduced the scalable fabrication process developed to keep the overall boom system cost down will be shown. Finally, the initial results of purposely designed boom structural characterization test methods with gravity off-loading will be presented to compare their structural performance under expected and general load cases.

Fernandez, Juan M.↗

NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

Acoustics↗

NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

Acoustics↗

NASA NTRS1991

Two Point Exponential Approximation Method for structural optimization of problems with frequency constraints

The point exponential approximation method was introduced by Fadel et al. (Fadel, 1990), and tested on structural optimization problems with stress and displacement constraints. The reports in earlier papers were promising, and the method, which consists of correcting Taylor series approximations using previous design history, is tested in this paper on optimization problems with frequency constraints. The aim of the research is to verify the robustness and speed of convergence of the two point exponential approximation method when highly non-linear constraints are used.

Fadel, G. M.↗

NASA NTRS1991

YBa2Cu3O(7-x)/Au/Nb device structures

Fabrication and testing of planar and edge geometry YBaCuO/Au/Nb superconductor/normal-metal/superconductor (SNS) device structures is described. Weak-link devices of this type serve as sensitive probes of the electrical quality of the YBaCuO/Au interface. The devices are fabricated using laser-ablated, in situ, c-axis-oriented YBaCuO thin films, with both annealed and unannealed YBaCuO/Au interfaces. The planar SNS structures are formed by sequential, in situ deposition of YBaCuO, Au, and Nb, followed by etching, planarization, and wiring electrode definition to produce junctions ranging from 5 to 20 micron on a side. Resulting RnA products are 1-10 x 10 to the -8th ohm-sq cm with critical current densities up to 5 kA/sq cm. For the edge geometry devices, the YBaCuO film edges are patterned using Ar ion milling, followed by a low energy ion cleaning step and in situ deposition of Au and Nb. Devices with areas in the 10 to the -7th to 10 to the -8th sq cm range have been fabricated with RnA products lower than 10 to the -8th ohm-sq cm and critical current densities up to 3kA/sq cm. Both types of devices show ac Josephson steps under microwave irradiation. The best results have been obtained with annealed YBaCuO/Au interfaces.

Hunt, B. D.↗

NASA NTRS1994

Fabrication and Testing of a Large Primary Reflector Structure

This paper discusses the fabrication considerations and proposed testing concepts related to a large twelve meter, graphite-epoxy space truss that is being developed to provide support of the primary mirror system for the Beam Transmission Optical System (BTOS).

space truss primary reflector free electron laser ↗

NASA NTRS1989

Remote Attitude Measurement Sensor (RAMS)

Remote attitude measurement sensor (RAMS) offers a low-cost, low-risk, proven design concept that is based on mature, demonstrated space sensor technology. The electronic design concepts and interpolation algorithms were tested and proven in space hardware like th Retroreflector Field Tracker and various star trackers. The RAMS concept is versatile and has broad applicability to both ground testing and spacecraft needs. It is ideal for use as a precision laboratory sensor for structural dynamics testing. It requires very little set-up or preparation time and the output data is immediately usable without integration or extensive analysis efforts. For on-orbit use, RAMS rivals any other type of dynamic structural sensor (accelerometer, lidar, photogrammetric techniques, etc.) for overall performance, reliability, suitability, and cost. Widespread acceptance and extensive usage of RAMS will occur only after some interested agency, such as OAST, adopts the RAMS concept and provides the funding support necessary for further development and implementation of RAMS for a specific program.

Davis, H. W.↗

DOE OSTI2017

Multiscale Persistent Functions for Biomolecular Structure Characterization

Here in this paper, we introduce multiscale persistent functions for biomolecular structure characterization. The essential idea is to combine our multiscale rigidity functions (MRFs) with persistent homology analysis, so as to construct a series of multiscale persistent functions, particularly multiscale persistent entropies, for structure characterization. To clarify the fundamental idea of our method, the multiscale persistent entropy (MPE) model is discussed in great detail. Mathematically, unlike the previous persistent entropy (Chintakunta et al. in Pattern Recognit 48(2):391–401, 2015; Merelli et al. in Entropy 17(10):6872–6892, 2015; Rucco et al. in: Proceedings of ECCS 2014, Springer, pp 117–128, 2016), a special resolution parameter is incorporated into our model. Various scales can be achieved by tuning its value. Physically, our MPE can be used in conformational entropy evaluation. More specifically, it is found that our method incorporates in it a natural classification scheme. This is achieved through a density filtration of an MRF built from angular distributions. To further validate our model, a systematical comparison with the traditional entropy evaluation model is done. Additionally, it is found that our model is able to preserve the intrinsic topological features of biomolecular data much better than traditional approaches, particularly for resolutions in the intermediate range. Moreover, by comparing with traditional entropies from various grid sizes, bond angle-based methods and a persistent homology-based support vector machine method (Cang et al. in Mol Based Math Biol 3:140–162, 2015), we find that our MPE method gives the best results in terms of average true positive rate in a classic protein structure classification test. More interestingly, all-alpha and all-beta protein classes can be clearly separated from each other with zero error only in our model. Finally, a special protein structure index (PSI) is proposed, for the first time, to describe the “regularity” of protein structures. Basically, a protein structure is deemed as regular if it has a consistent and orderly configuration. Our PSI model is tested on a database of 110 proteins; we find that structures with larger portions of loops and intrinsically disorder regions are always associated with larger PSI, meaning an irregular configuration, while proteins with larger portions of secondary structures, i.e., alpha-helix or beta-sheet, have smaller PSI. Essentially, PSI can be used to describe the “regularity” information in any systems.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1991

Using adaptive structures to enable future missions by relaxing ground test requirements

Future NASA missions will require large space structures that must maintain accurate surface tolerances for up to 20 years; most flight programs require a ground test verification of the hardware. Because of the influence of gravity, the current state-of-the-art ground test technology cannot accurately determine whether the hardware complies with the requirements. The incorporation of adaptive structures into the spacecraft will enable a relaxation of the ground test requirements necessary to validate the hardware for flight. This paper describes the challenges in testing large precision structures, adaptive structures, the data establishing the current state of the art in ground testing, and the utilization of adaptive structures to alleviate the ground test requirements.

Wada, Ben K.↗

DOE OSTI2019

Failure of Steel Grinding Balls

Abstract—The structure of grinding balls with an atypical central zone is studied after failure in tests. The structure of the corresponding blanks is also analyzed. The appearance of martensitic sections in the central zone is explained. Recommendations are made for eliminating this problem.

42 ENGINEERING↗