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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

Using Digital Image Correlation for Material Testing at Cryogenic Temperatures

Recent efforts were made to parametrize an aluminum alloy at cryogenic temperatures to calibrate finite element models simulating material deformation. Digital image correlation (DIC) was used to measure material properties using front/back strains of specimens during tensile tests. Data acquired from DIC was compared to physical extensometer measurements. Two camera pairs (front and back) were mounted via aluminum extrusion to the exterior of an environmental chamber of a hydraulic test stand. Images were taken through single-pane optical glass windows of the environment chamber. Positive pressure bags encased the cameras, attaching to the perimeter of the glass to keep out moisture and prevent windows from frosting. Figure 1 shows the environmental setup and the camera setup during cryogenic testing. Some of the challenges during testing at cryogenic temperatures include the gaseous flow of liquid nitrogen in the optical path of the mounted cameras, frost buildup on the windows as seen in Figure 1b, and frost on the test coupon. The temperature gradient present during the introduction of liquid nitrogen into the chamber can increase the projection error of images captured of the specimen. Figure 2 shows the estimated projection error from DIC as a function of temperature during the cool down process. This presentation addresses some of the concerns and observations when using DIC for testing at cryogenic temperatures using methods of isolated camera system and techniques for maintaining the glass panel clear from frost.

Joseph Cochran↗

Ablative material testing for low-pressure, low-cost rocket engines

The results of an experimental evaluation of ablative materials suitable for the production of light weight, low cost rocket engine combustion chambers and nozzles are presented. Ten individual specimens of four different compositions of silica cloth-reinforced phenolic resin materials were evaluated for comparative erosion in a subscale rocket engine combustion chamber. Gaseous hydrogen and gaseous oxygen were used as propellants, operating at a nominal chamber pressure of 1138 kPa (165 psi) and a nominal mixture ratio (O/F) of 3.3. These conditions were used to thermally simulate operation with RP-1 and liquid oxygen, and achieved a specimen throat gas temperature of approximately 2456 K (4420 R). Two high-density composition materials exhibited high erosion resistance, while two low-density compositions exhibited approximately 6-75 times lower average erosion resistance. The results compare favorably with previous testing by NASA and provide adequate data for selection of ablatives for low pressure, low cost rocket engines.

Richter, G. Paul↗

Mast material test program (MAMATEP)

The MAMATEP program, which is aimed at verifying the need for and evaluating the performance of various protection techniques for the solar array assembly mast of the Space Station photovoltaic power module, is discussed. Coated and uncoated mast material samples have been environmentally tested and evaluated, before and after testing, in terms of mass and bending modulus. The protective coatings include CV-1144 silicone, a Ni/Al/InSn eutectic, and an open-weave Al braid. Long-term plasma asher results from unprotected samples indicate that, even though fiberglass-epoxy samples degrade, a protection technique may not be necessary to ensure structural integrity. A protection technique, however, may be desirable to limit or contain the amount of debris generated by the degradation of the fiberglass-epoxy.

Ciancone, Michael L.↗

Playing with DIRT: Building the Framework for a Comprehensive In-Situ Soil Materials Testing Database

Long-term, sustainable planetary exploration will require the ability to "live off the land," relying on In-Situ Resource Utilization (ISRU) and In-Situ Construction as core capabilities. Reduction of both risk and launch mass for lunar construction will require evaluating and comparing regolith materials for use as feedstocks suitable for in-situ beneficiation and fabrication of building components. These material assessment capabilities will inform lunar infrastructure design decisions, with co-benefits for terrestrial construction using in-situ materials. Current planetary construction technology development relies on lunar mapping and orbital data, Apollo-era sample analyses, current simulant inventories, and tests conducted using analog site soils. Requirements for lunar infrastructure design decisions and construction systems will be determined based on specific environmental conditions, mission architectures, and the materials available within traverse range of lunar feedstock processing depots. Critical for success is the capability to identify, evaluate and make effective use of a wide range of materials as they are found in-situ on the lunar surface. This paper discusses the development of a digital repository for data on soil and regolith properties, beginning with their structural performance in both cementitious and non-cementitious building material formulations. The Database for In-situ Resource Testing (DIRT) compiles a catalog of raw materials, additives, and formulations, with notations pertaining to material sources and preparation techniques entered via a web-based user interface. Design of consistent data schemas for site-sourced materials evaluation will facilitate linkage with relevant terrestrial and planetary materials databases while enabling guided data input via templates for participation by broader groups of collaborators. Results of these analyses are compiled in a centralized repository to generate insights applicable for regolith resources and landing sites yet to be precisely defined. Collection of thorough records of material characteristics, applications and performance will support innovative construction solutions not only for space infrastructure but for sustainable, resilient design in the terrestrial built environment.

Sarah Joey Seitz↗

Low Activity Waste Tuning Feed Material Testing; Qualification and Transition Testing (Final Report)

The primary objective of this work was to collect data to support processing of the proposed LAW tuning feed composition at the WTP. This was achieved through assessment of the modified LAWB83 feed and glass composition by feed rheology testing and by processing selected LAW feeds through a DM100 melter to confirm that the tuning feed material can be fed to the melter with acceptable commercial or hazards risk. The testing also confirmed that transitions from the startup frit to the LAWB83 tuning feed and then to the cold commissioning simulant composition can be performed without causing any significant melter performance issues.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Ablative Material Testing at Lewis Rocket Lab

The increasing demand for a low-cost, reliable way to launch commercial payloads to low- Earth orbit has led to the need for inexpensive, expendable propulsion systems for new launch vehicles. This, in turn, has renewed interest in less complex, uncooled rocket engines that have combustion chambers and exhaust nozzles fabricated from ablative materials. A number of aerospace propulsion system manufacturers have utilized NASA Lewis Research Center's test facilities with a high degree of success to evaluate candidate materials for application to new propulsion devices.

Source record↗

Summary of Blast Shield and Material Testing for Development of Solid Debris Collection at the National Ignition Facility (NIF)

The ability to collect solid debris from the target chamber following a NIF shot has application for both capsule diagnostics, particularly for fuel-ablator mix, and measuring cross sections relevant to the Stockpile Stewardship program and nuclear astrophysics. Simulations have shown that doping the capsule with up to 10 15 atoms of an impurity not otherwise found in the capsule does not affect its performance. The dopant is an element that will undergo nuclear activations during the NIF implosion, forming radioactive species that can be collected and measured after extraction from the target chamber. For diagnostics, deuteron or alpha induced reactions can be used to probe the fuel-ablator mix. For measuring neutron cross sections, the dopant should be something that is sensitive to the 14 MeV neutrons produced through the fusion of deuterium and tritium. Developing the collector is a challenge due to the extreme environment of the NIF chamber. The collector surface is exposed to a large photon flux from x-rays and unconverted laser light before it is exposed to a debris wind that is formed from vaporized material from the target chamber center. The photons will ablate the collector surface to some extent, possibly impeding the debris from reaching the collector and sticking. In addition, the collector itself must be mechanically strong enough to withstand the large amount of energy it will be exposed to, and it should be something that will be easy to count and chemically process. In order to select the best material for the collector, a variety of different metals have been tested in the NIF chamber. They were exposed to high-energy laser shots in order to evaluate their postshot surface characterization, morphology, degree of melt, and their ability to retain debris from the chamber center. The first set of samples consisted of 1 mm thick pieces of aluminum that had been fielded in the chamber as blast shields protecting the neutron activation diagnostic. Ten of these pieces were fielded at the equator and one was fielded on the pole. The shields were analyzed using a combination of scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), x-ray fluorescence (XRF), neutron activation analysis (NAA) and chemical leaching followed by mass spectrometry. On each shield, gold debris originating from the gold hohlraum was observed, as well as large quantities of debris that were present in the center of the target chamber at the time of the shot (i.e., stainless steel, indium, copper, etc.) Debris was visible in the SEM as large blobs or splats of material that had encountered the surface of the aluminum and stuck. The aluminum itself had obviously melted and condensed, and some of the large debris splats arrived after the surface had already hardened. Melt depth was determined by cross sectioning the pieces and measuring the melted surface layers via SEM. After the SEM analysis was completed, the pieces were sent for NAA at the USGS reactor and were analyzed by U. Greife at the Colorado School of Mines. The NAA showed that the majority of gold mass present on the shields was not in the form of large blobs and splats, but was present as small particulates that had most likely formed as condensed vapor. Further analysis showed that the gold was entrained in the melted aluminum surface layers and did not extend down into the bulk of the aluminum. Once the gold mass was accounted for from the NAA, it was determined that the aluminum fielded at the equator was collecting a fraction of the total gold hohlraum mass equivalent to 120% ± 10% of the solid angle subtended by the shield. The attached presentation has more information on the results of the aluminum blast shield analysis. In addition to the information given in the presentation, the surfaces of the shields have been chemically leached and submitted for mass spectrometric analysis. The results from that analysis are expected to arrive after the due date of this report and will be written up at a later time. Based on the results of the aluminum blast shield analysis, it was determined that additional materials needed to be tested as potential collectors in the NIF chamber. 1-2 mm thick pieces of tantalum, niobium, vanadium, silver, titanium, molybdenum, and graphite foil were fielded in the Wedge Range Filter (WRF) mount at a distance of 50 cm from target chamber center during the shock timing campaign. The pieces were subsequently removed and analyzed in a similar fashion to the aluminum shields. As of this writing, the pieces are still under analysis, but initial results indicate that gold debris was collected on the various materials. Currently, the pieces are being cross-sectioned so that the melt depths of each material can be compared. In addition, NAA and/or mass spectrometry will be performed in order to determine the total gold mass that was collected on each surface.

36 MATERIALS SCIENCE↗

Thermal Systems and Materials Testing

During my internship, I was involved in Boeing Thermal System/M&P, which handles maintenance and repairs of shuttle tiles, blankets, gap fillers, etc. One project I took part in was the revision of TPS-227, a repair process to tiles that entailed drilling out tile damage and using a cylindrical insert to fill the hole. The previous specification used minimal adhesive for application and when the adhesive cured, there would be several voids in the adhered material, causing an unsatisfactory bond. The testing compared several new methods and I analyzed the number of voids produced by each method to determine which one was most effective at eliminating void space. We revised the original process to apply a light adhesive coat to the top 25% of the borehole and a heavy coat to 100% of the insert. I was also responsible for maintaining the subnominal bond database, which records all unsatisfactory SIP (Strain Isolator Pad) bonds. I then archived each SIP physically for future referral data and statistics. In addition, I performed post-flight tile inspections for damages and wrote dispositions to have these tiles repaired. This also included writing a post-flight damage report for a section of Atlantis and creating summarized repair process guidelines for orbiter technicians.

Aguirre, Nathan↗

MISSE 6-Testing Materials in Space

The objective of the Materials International Space Station Experiment (MISSE) is to study the performance of novel materials when subjected to the synergistic effects of the harsh space environment by placing them in space environment for several months. In this paper, a few materials and components from NASA Langley Research Center (LaRC) that have been flown on MISSE 6 mission will be discussed. These include laser and optical elements for photonic devices. The pre-characterized MISSE 6 materials were packed inside a ruggedized Passive Experiment Container (PEC) that resembles a suitcase. The PEC was tested for survivability due to launch conditions. Subsequently, the MISSE 6 PEC was transported by the STS-123 mission to International Space Station (ISS) on March 11, 2008. The astronauts successfully attached the PEC to external handrails and opened the PEC for long term exposure to the space environment.

Prasad, Narasimha S↗

Stress-Dependent Voltage Offsets From Polymer Insulators Used in Rock Mechanics and Material Testing

Dielectric insulators are used in a variety of laboratory settings when performing experiments in rock mechanics, petrology, and electromagnetic studies of rocks in the fields of geophysics,material science, and civil engineering. These components may be used to electrically isolate geological samples from the experimental equipment, to perform a mechanical compliance function between brittle samples and the loading equipment, to match ultrasonic transducers, or perform other functions. In manyexperimental configurations the insulators bear the full brunt of force applied to the sample but do not need to withstand high voltages, therefore the insulators are often thin sheets of mechanically tough polymers. From an instrument perspective, transduction from various types of mechanical perturbation has beenqualitatively compared for a number of polymers [1, 2] and these error sources are readily apparent duringhigh-impedance measurements if not mitigated. However even when following best practices, a force dependent voltage signal still remains and its behavior is explored in this presentation. In this experimenttwo thin sheets (0.25 mm) of high-density polyethylene (HDPE) were set up in a stack, held alternatelybetween three aluminum bars; this stack was placed on the platen of a 60T capacity hydraulic testingmachine. The surface area, A, over which the force is applied to the PE sheets in this sandwich is roughly 40 square cm, each sheet forming a parallel-plate capacitor having roughly 320 pF [3], assuming therelative dielectric permittivity of PE is approximately 2.3. The outer two aluminum bars were connected to the LO input ofthe electrometer and the central aluminum bar was connected to the HI input of a Keithley model 617 electrometer. Once the stack is mechanically well-seated with no air gaps, the voltage offset is observed tobe a linear function of the baseline voltage for a given change in applied force. For a periodically appliedforce of 66.7 kN the voltage offsets were measured as a function of initial voltage, and these data were fitwith a linear function that was constrained to pass through the origin. The best fit solution had a correlation coefficient of R=0.85 and a slope of approximately -0.0228 volts/volt. The voltage offset when normalizedis demonstrated to be constant -2.28% for both positive and negative polarities over nearly 3 orders ofbaseline voltage magnitude. From this, the voltage-force coefficient is derived to be -0.34 ppm/N. Thiscorrelates well to a first-order parallel plate capacitor model that assumes constant area, and smalldeformation such that the polymer may be mechanically modeled by a spring that obeys Hookes law. Thissimple model predicts that the coefficient of proportionality is a function of Youngs modulus E= 0.8 GPaand surface area of the insulator, theoretically -1EA= -0.31 ppm/N. The outcome of this work is animproved insulator made from ultra-high molecular weight (UHMW) polyethylene and other approachestoward the minimization of and compensation for these experimental artifacts.

Electromagnetic Studies of Rocks↗

Polymethylmethacrylate (PMMA) Material Test Results for the Capillary Flow Experiments (CFE)

In support of the Capillary Flow Experiments (CFE) program, several polymethylmethacrylate (PMMA) flight vessels were constructed. Some vessels used a multipiece design, which was chemically welded together. Due to questions regarding the effects of the experiment fluid (silicone oil) on the weld integrity, a series of tests were conducted to provide evidence of the adequacy of the current vessel design. Tensile tests were conducted on PMMA samples that were both in the as-received condition, and also aged in air or oil for up to 8 weeks. Both welded and unwelded samples were examined. Fracture of the joints was studied using notched tensile specimens and Brazilian disk tests. Results showed that aging had no effect on tensile properties. While the welded samples were weaker than the base parent material, the weld strength was found to be further degraded by bubbles in the weld zone. Finally a fracture analysis using the worst-case fracture conditions of the vessel was performed, and the vessel design was found to have a factor of three safety margin.

Lerch, Bradley A.↗

Results of a FRSI material test under Space Shuttle ascent conditions in the Ames Research Center 9x7 foot supersonic wind tunnel (OS13). Space Shuttle aerothermodynamic data report

A test was conducted in the NASA/ARC 9 x 7 foot supersonic wind tunnel to verify the integrity of Felt Reusable Surface Insulation (FRSI) material in a panel flutter environment. A FRSI sample panel was subjected to the shocks, pressure gradients, and turbulence characteristics encountered at dynamic pressure 1.5 times the 3(sigma) dispersed trajectory flight conditions of the Space Shuttle. Static and fluctuating pressure data were obtained for Mach numbers ranging from 1.55 to 2.5 with dynamic pressures of 625 to 1250 psf. The FRSI panel suffered no appreciable damage as a result of the test.

Lemoine, P. L.↗

Low Activity Waste Tuning Feed Material Testing VSL-18R4350-1 (Final Report)

High level waste (HLW) from the Hanford tank farms will be retrieved and transferred to the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The waste will be pretreated to separate the soluble chemical salts (mostly sodium nitrate/nitrite and sodium hydroxide) from the bulk of the radioactive materials. This decontaminated salt solution is the low activity waste (LAW) stream which constitutes most of the total waste volume. The remaining HLW contains most of the radioactive materials but a fraction of the volume. Each of these waste streams is directed to an independent processing facility where the waste is mixed with glass forming chemicals (mostly silica and borax or boric acid) and fed into the melters for stabilization by conversion into glass. The molten glass is poured into stainless steel containers to produce packages for disposal: local shallow burial for the LAW containers and a future geologic repository for the HLW containers. The LAW facility melters produce significant quantities of NOx-laden off-gas that require abatement in accordance with 10 CFR 830 and air emission requirements. The NOx emissions also pose a safety risk. The LAW facility commissioning sequence requires that the melters be operated and process control loops tuned prior to introducing waste or waste feed materials that produce NOx. Therefore, a temporary or permanent system architecture is needed that provides a feed supply to the melters for the purpose of melter testing and off-gas tuning that does not result in the production of significantly hazardous off-gas products.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Nd and Sm isotopic composition of spent nuclear fuels from three material test reactors

Rare earth elements such as neodymium and samarium are ideal for probing the neutron environment that spent nuclear fuels are exposed to in nuclear reactors. The large number of stable isotopes can provide distinct isotopic signatures for differentiating the source material for nuclear forensic investigations. The rare-earth elements were isolated from the high activity fuel matrix via ion exchange chromatography in a shielded cell. The individual elements were then separated using cation exchange chromatography. In conclusion, the neodymium and samarium aliquots were analyzed via MC–ICP–MS, resulting in isotopic compositions with a precision of 0.01–0.3%.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Material Testing for Shear-Dominated Ductile Failure

An initial foray into the design of specimens that can be used to provide data about the quasistatic ductile failure of metals when subjected to shear-dominated (low triaxiality) states of stress was undertaken. Four specimen geometries made from two materials with different ductility (Al 7075, lower ductility and steel A286, higher ductility) were considered as candidates. Based on results from analysis and experimentation, it seems that two show promise for further consideration. Whereas preliminary results indicate that the Johnson-Cook model fit the failure data for Al 7075 well, it did not fit the data for steel A286. Further work is needed to consolidate the results and evaluate other failure models that may fit the steel data better, as well as to extend the results of this work to the dynamic loading regime.

36 MATERIALS SCIENCE↗

Enhancing activated-peroxide formulations for porous materials: Test methods and results

During an urban wide-area incident involving the release of a biological warfare agent, the recovery/restoration effort will require extensive resources and will tax the current capabilities of the government and private contractors. In fact, resources may be so limited that decontamination by facility owners/occupants may become necessary and a simple decontamination process and material should be available for this use. One potential process for use by facility owners/occupants would be a liquid sporicidal decontaminant, such as pHamended bleach or activated-peroxide, and simple application devices. While pH-amended bleach is currently the recommended low-tech decontamination solution, a less corrosive and toxic decontaminant is desirable. The objective of this project is to provide an operational assessment of an alternative to chlorine bleach for low-tech decontamination applications activated hydrogen peroxide. This report provides the methods and results for activatedperoxide evaluation experiments. The results suggest that the efficacy of an activated-peroxide decontaminant is similar to pH-amended bleach on many common materials.

36 MATERIALS SCIENCE↗

Material Testing of PH13-8MO H950 Steel for Xue-Wierzbicki Fracture Criterion Determination

Four tensile coupon designs of PH13-8Mo H950 steel were tested to failure using quasi-static rates to obtain data to calibrate the Xue-Wierzbicki failure model for ductile fracture. The tests recorded the force-displacement, location of the first crack, displacement to fracture, area reduction, and crack propagation path. The test method and coupon designs were adopted from Tomasz Wierzbicki’s “Calibration and evaluation of seven fracture models” report. The XueWierzbicki model predicts fracture based on accumulated equivalent plastic strain, stress triaxiality, and deviatoric state parameter. Calibrating the Xue-Wierzbicki failure model required testing four coupon designs to calculate the four free parameters in the model. The coupon designs tested a range of stress triaxialities with two axisymmetric tests, one shear test, and one plane stress test. The data obtained and presented in this report can be used to develop a Xue-Wierzbicki fracture model for PH13-8Mo H950 steel.

36 MATERIALS SCIENCE↗

Laser High-Cycle Thermal Fatigue of Pulse Detonation Engine Combustor Materials Tested

Pulse detonation engines (PDE's) have received increasing attention for future aerospace propulsion applications. Because the PDE is designed for a high-frequency, intermittent detonation combustion process, extremely high gas temperatures and pressures can be realized under the nearly constant-volume combustion environment. The PDE's can potentially achieve higher thermodynamic cycle efficiency and thrust density in comparison to traditional constant-pressure combustion gas turbine engines (ref. 1). However, the development of these engines requires robust design of the engine components that must endure harsh detonation environments. In particular, the detonation combustor chamber, which is designed to sustain and confine the detonation combustion process, will experience high pressure and temperature pulses with very short durations (refs. 2 and 3). Therefore, it is of great importance to evaluate PDE combustor materials and components under simulated engine temperatures and stress conditions in the laboratory. In this study, a high-cycle thermal fatigue test rig was established at the NASA Glenn Research Center using a 1.5-kW CO2 laser. The high-power laser, operating in the pulsed mode, can be controlled at various pulse energy levels and waveform distributions. The enhanced laser pulses can be used to mimic the time-dependent temperature and pressure waves encountered in a pulsed detonation engine. Under the enhanced laser pulse condition, a maximum 7.5-kW peak power with a duration of approximately 0.1 to 0.2 msec (a spike) can be achieved, followed by a plateau region that has about one-fifth of the maximum power level with several milliseconds duration. The laser thermal fatigue rig has also been developed to adopt flat and rotating tubular specimen configurations for the simulated engine tests. More sophisticated laser optic systems can be used to simulate the spatial distributions of the temperature and shock waves in the engine. Pulse laser high-cycle thermal fatigue behavior has been investigated on a flat Haynes 188 alloy specimen, under the test condition of 30-Hz cycle frequency (33-msec pulse period and 10-msec pulse width including a 0.2-msec pulse spike; ref. 4). Temperature distributions were calculated with one-dimensional finite difference models. The calculations show that that the 0.2-msec pulse spike can cause an additional 40 C temperature fluctuation with an interaction depth of 0.08 mm near the specimen surface region. This temperature swing will be superimposed onto the temperature swing of 80 C that is induced by the 10-msec laser pulse near the 0.53-mm-deep surface interaction region.

Zhu, Dong-Ming↗