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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles

The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads at a high altitude, with an anchored computational methodology. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests, and deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four different degrees of ovalization: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation-line-jump is the peak side load physics for the round, slightly our-of-round, and more out-of-round cases, and the peak side load increases as the degree of out-of-roundness increases. For the significantly out-of-round nozzle, however, the peak side load reduces to comparable to that of the round nozzle and the separation line jump is not the peak side load physics. The counter-intuitive result of the significantly out-of-round case is found to be related to a side force reduction mechanism that splits the effect of the separation-line-jump into two parts, not only in the circumferential direction and most importantly in time.

Wang, Ten-See↗
NASA NTRS2011

Effect of Water on the Thermo-Mechanical Behavior of Carbon Cloth Phenolic

The results of thermo-mechanical experiments, which were conducted previously by one of the authors, are reviewed. The strain in the direction normal to the fabric plane was measured as a function of temperature for a variety of initial moisture contents and heating rates. In this paper, the general features of the thermo-mechanical response are discussed and the effect of heating rate and initial moisture content are highlighted. The mechanical interaction between the phenolic polymer and water trapped within its free volumes as the polymer is heated to high temperatures is discussed. An equation for the internal stresses which are generated within the polymer due to trapped water is obtained from the total stress expression for a binary mixture of polymer and water. Numerical solutions for moisture diffusion in the thermo-mechanical experiments were performed and the results of these solutions are presented. The results of the moisture diffusion solutions help to explain the effects of heating rate and moisture content on the strain behavior normal to the fabric plane.

Sullivan, Roy M.↗
NASA NTRS2012

Transient Side Load Analysis of Out-of-Round Film-Cooled Nozzle Extensions

There was interest in understanding the impact of out-of-round nozzle extension on the nozzle side load during transient startup operations. The out-of-round nozzle extension could be the result of asymmetric internal stresses, deformation induced by previous tests, and asymmetric loads induced by hardware attached to the nozzle. The objective of this study was therefore to computationally investigate the effect of out-of-round nozzle extension on the nozzle side loads during an engine startup transient. The rocket engine studied encompasses a regeneratively cooled chamber and nozzle, along with a film cooled nozzle extension. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and transient inlet boundary flow properties derived from an engine system simulation. Six three-dimensional cases were performed with the out-of-roundness achieved by three different degrees of ovalization, elongated on lateral y and z axes: one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation line jump was the primary source of the peak side loads. Comparing to the peak side load of the perfectly round nozzle, the peak side loads increased for the slightly and more ovalized nozzle extensions, and either increased or decreased for the two significantly ovalized nozzle extensions. A theory based on the counteraction of the flow destabilizing effect of an exacerbated asymmetrical flow caused by a lower degree of ovalization, and the flow stabilizing effect of a more symmetrical flow, created also by ovalization, is presented to explain the observations obtained in this effort.

Wang, Ten-See↗
NASA NTRS2013

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗
NASA NTRS2016

Overview of the CHarring Ablator Response (CHAR) Code

An overview of the capabilities of the CHarring Ablator Response (CHAR) code is presented. CHAR is a one-, two-, and three-dimensional unstructured continuous Galerkin finite-element heat conduction and ablation solver with both direct and inverse modes. Additionally, CHAR includes a coupled linear thermoelastic solver for determination of internal stresses induced from the temperature field and surface loading. Background on the development process, governing equations, material models, discretization techniques, and numerical methods is provided. Special focus is put on the available boundary conditions including thermochemical ablation, surface-to-surface radiation exchange, and flowfield coupling. Finally, a discussion of ongoing development efforts is presented.

Amar, Adam J.↗
NASA NTRS2015

NEO Test Stand Analysis

A project within SwampWorks is building a test stand to hold regolith to study how dust is ejected when exposed to the hot exhaust plume of a rocket engine. The test stand needs to be analyzed, finalized, and fabrication drawings generated to move forward. Modifications of the test stand assembly were made with Creo 2 modeling software. Structural analysis calculations were developed by hand to confirm if the structure will hold the expected loads while optimizing support positions. These calculations when iterated through MatLab demonstrated the optimized position of the vertical support to be 98'' from the far end of the stand. All remaining deflections were shown to be under the 0.6'' requirement and internal stresses to meet NASA Ground Support Equipment (GSE) Safety Standards. Though at the time of writing, fabrication drawings have yet to be generated, but are expected shortly after.

Internship↗
NASA NTRS2016

Overview of the CHarring Ablator Response (CHAR) Code

An overview of the capabilities of the CHarring Ablator Response (CHAR) code is presented. CHAR is a one-, two-, and three-dimensional unstructured continuous Galerkin finite-element heat conduction and ablation solver with both direct and inverse modes. Additionally, CHAR includes a coupled linear thermoelastic solver for determination of internal stresses induced from the temperature field and surface loading. Background on the development process, governing equations, material models, discretization techniques, and numerical methods is provided. Special focus is put on the available boundary conditions including thermochemical ablation and contact interfaces, and example simulations are included. Finally, a discussion of ongoing development efforts is presented.

Amar, Adam J.↗
NASA NTRS2016

Progress on the Fabrication of High Resolution and Lightweight Monocrystalline Silicon X-ray Mirrors

Monocrystalline silicon is an excellent X-ray mirror substrate material due to its high stiffness, low density, high thermal conductivity, zero internal stress, and commercial availability. Our work at NASA Goddard Space Flight Center focuses on identifying and developing a manufacturing process to produce high resolution and lightweight X-ray mirror segments in a cost and time effective manner. Previous efforts focused on demonstrating the feasibility of cylindrical silicon mirror polishing and lightweighting. Present efforts are aimed towards producing true paraboloidal and hyperboloidal mirror surfaces on the lightweight silicon segments. This paper presents results from these recent investigations, including a mirror which features a surface quality sufficient for a 3 arcsecond telescope.

X-ray optics↗
NASA NTRS2018

Through Thickness Thermal Gradients in Thick Laminates During Cure, Influence on Tg and Modulus

Carbon fiber composites are materials of great interest to the aerospace industry because of their light weight and high strength properties. Composite use in high load bearing applications such as roto-craft gearing requires manufacturing parts that are 1.5 inches thick and beyond. Very thick composite parts (laminates) produce thermal gradients and temperature spikes due to the heat released by resin polymerization and cross-linking during composite cure. It is believed that these thermal gradients will cause internal stresses to build-up inside these ultra-thick laminates during the cure-cycle, yielding parts with non-uniform mechanical properties throughout the thickness of the laminate. The goal of this study is to identify these thermal gradients and determine the magnitude of difference in mechanical properties generated by them.

Mechanical Properties↗
NASA NTRSDate not supplied

Fabrication of monocrystalline silicon x-ray mirrors

Progress within the fi eld of x-ray astronomy depends on astronomical x-ray observations of ever-increasing quality and speed. Fast and high-resolution x-ray observations over a broad spectral range promise amazing new discoveries. These observations, however, require a spaceborne x-ray telescope of unprecedented imaging power. Of the numerous technological concerns associated with the design and construction of such a telescope, the x-ray focusing optics present a particularly complex and arduous set of challenges. An x-ray optical assembly comprises many thousands of x-ray mirrors, a most critical element. Our group at NASA Goddard Space Flight Center (GSFC) pursues the development of an x-ray mirror manufacturing process capable of meeting the stringent quality, production time, and cost requirements of the next-generation of x-ray telescopes. The manufacturing process employs monocrystalline silicon: a lightweight, stiff, thermally conductive, and readily available material which is free of internal stress; it is a nearly ideal material for a thin mirror substrate. The process involves various traditional optical fabrication techniques adapted to x-ray mirror geometry. Presently, our process is capable of fabricating sub-arcsecond half-power diameter (HPD) resolution mirror pairs (primary and secondary) at a mirror thickness of 0.5 mm and of virtually any x-ray optical design (e.g. Wolter-I, Wolter-Schwarzschild, etc.). The mirror substrate surface quality is comparable to, and sometimes exceeding, that of the mirrors on the Chandra X-ray Observatory. This paper describes the various manufacturing steps involved in the production of x-ray mirror substrates and a present status report.

Raul E. Riveros↗
NASA NTRSDate not supplied

Laser Forming of Sheet Metal for In-Space Manufacturing Applications

As the in-space economy matures, the migration of typically Earth-bound manufacturing methods, such as metal forming and joining, up to space will be required to meet the increasing demand for refueling and supply depots, habitats, laboratories, lunar surface structures, and sites for deep-space exploration shipbuilding. Only in this way can the magnitude of individual structures begin to exceed what can be launched, deployed, docked, or inflated and allow true economies of scale to be unlocked in space. However, typical terrestrial methods of forming and shaping sheet metal require massive machinery with the ability to deflect reaction forces to a large mass in a fixed reference frame (Earth). To both limit up-mass required for manufacture and to mitigate the issues of reaction forces in the relative reference frames of space, a non-contact, laser-based method of forming metal sheet is proposed. NASA Marshall Space Flight Center (MSFC), in cooperation with DARPA and the University of Florida (UF), have begun investigation of non-contact methods of laser forming sheet metal in thermal vacuum (TVAC) conditions to great success. To date, several grades of aluminum, stainless steel, and titanium coupons have been formed via laser-induced internal stresses in these metals at both ambient atmosphere and vacuum conditions. Temperatures in these tests ranged from -120 to 60 C, and though the total energy required to induce strain does vary with workpiece temperature and environmental pressure, the method remains predictable and controllable for the materials investigated. It is believed that this method will revolutionize manufacturing in-space as it not only continues to build upon the capabilities of the laser (sensing, marking, cutting, drilling, joining, and now forming) as an all-in-one tool, but also reduces the need to counteract forming forces as would be required in mechanical bending. In theory, all required stress to induce bending is generated through thermal gradient and strain within the workpiece, meaning that the need for reaction control and fuel expense on-orbit will be limited. Archimedes once stated, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world”. With a laser as our lever and our workpiece its own fulcrum, we can move the world’s manufacturing into space.

Laser↗
NASA NTRS1989

Micromechanical stresses in SiC-reinforced Al2O3 composites

Applying an Eshelby (1957) approach, the internal micromechanical stresses within an SiC-inclusion-reinforced (platelet to whisker geometries) polycrystalline alumina matrix composite were calculated. The results are compared to the experimental residual stress measurements of a SiC-whisker-reinforced Al2O3 by Predecki, et al. (in press) and found to be in excellent agreement. The calculations are then extended to SiC-reinforced composites with polycrystalline mullite, silicon nitride, and cordierite matrices. It is concluded that the internal stresses are significantly influenced by the inclusion geometry as well as the thermoelastic differences between the inclusion and the matrix and also the volume fraction.

Li, Zhuang↗
NASA NTRS1979

Stress-intensity factors for internal surface cracks in cylindrical pressure vessels

The stress intensity factors were calculated by a three dimensional finite element method. The finite element models employed singularity elements along the crack front and linear strain elements elsewhere. The models had about 6500 degrees of freedom. The stress intensity factors were evaluated from a nodal force method. An equation for the stress intensity factors was obtained form the results of the present analysis. The equation applies over a wide range of configuration parameters and was within about 5 percent of the present results. A comparison was made between the present results and other analyses of internal surface cracks in cylinders. The results from a boundary integral equation method were in agreement (+ or - 2 percent) and those from another finite element were in fair agreement (+ or - 8 percent) with the present results.

Newman, J. C., Jr.↗
NASA NTRS1998

Mechanical Characterization of Thermomechanical Matrix Residual Stresses Incurred During MMC Processing

In recent years, much effort has been spent examining the residual stress-strain states of advanced composites. Such examinations are motivated by a number of significant concerns that affect composite development, processing, and analysis. The room-temperature residual stress states incurred in many advanced composite systems are often quite large and can introduce damage even prior to the first external mechanical loading of the material. These stresses, which are induced during the cooldown following high-temperature consolidation, result from the coefficient of thermal expansion mismatch between the fiber and matrix. Experimental techniques commonly used to evaluate composite internal residual stress states are non-mechanical in nature and generally include forms of x-ray and neutron diffraction. Such approaches are usually complex, involving a number of assumptions and limitations associated with a wide range of issues, including the depth of penetration, the volume of material being assessed, and erroneous effects associated with oriented grains. Furthermore, and more important to the present research, these techniques can assess only "single time" stress in the composite. That is, little, if any, information is obtained that addresses the time-dependent point at which internal stresses begin to accumulate, the manner in which the accumulation occurs, and the presiding relationships between thermoelastic, thermoplastic, and thermoviscous behaviors. To address these critical issues, researchers at the NASA Lewis Research Center developed and implemented an innovative mechanical test technique to examine in real time, the time-dependent thermomechanical stress behavior of a matrix alloy as it went through a consolidation cycle.

Castelli, Michael G.↗
NASA NTRS1979

A simplified method of evaluating the stress wave environment of internal equipment

A simplified method called the transfer function technique (TFT) was devised for evaluating the stress wave environment in a structure containing internal equipment. The TFT consists of following the initial in-plane stress wave that propagates through a structure subjected to a dynamic load and characterizing how the wave is altered as it is transmitted through intersections of structural members. As a basis for evaluating the TFT, impact experiments and detailed stress wave analyses were performed for structures with two or three, or more members. Transfer functions that relate the wave transmitted through an intersection to the incident wave were deduced from the predicted wave response. By sequentially applying these transfer functions to a structure with several intersections, it was found that the environment produced by the initial stress wave propagating through the structure can be approximated well. The TFT can be used as a design tool or as an analytical tool to determine whether a more detailed wave analysis is warranted.

Colton, J. D.↗
NASA NTRS1980

Stress-intensity factors for internal surface cracks in cylindrical pressure vessels

The paper presents stress-intensity factors for a wide range of semi-elliptical surface cracks on the inside of pressurized cylinders. The ratio of crack depth to crack length ranged from 0.2 to 1; the ratio of crack depth to wall thickness ranged from 0.2 to 0.8; and the ratio of wall thickness to vessel radius was 0.1 to to 0.25. The stress-intensity factors were calculated by a three-dimensional finite-element method using singularity elements along the crack front and linear-strain elements elsewhere. An equation for the stress-intensity factors was obtained which applies over a wide range of configuration parameters and was within about 5 percent of the present results. A comparison was also made between the results and other analyses of internal surface cracks in cylinders. The results from a boundary-integral equation method were in agreement and those from another finite-element method were in fair agreement (+ or - 8 percent) with the results.

Newman, J. C., Jr.↗