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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

Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 1: Aft Skirt analysis

Using the ANSYS finite element program, a global model of the aft skirt and a detailed nonlinear model of the failure region was made. The analysis confirmed the area of failure in both STA-2B and STA-3 tests as the forging heat affected zone (HAZ) at the aft ring centerline. The highest hoop strain in the HAZ occurs in this area. However, the analysis does not predict failure as defined by ultimate elongation of the material equal to 3.5 percent total strain. The analysis correlates well with the strain gage data from both the Wyle influence test of the original design aft sjirt and the STA-3 test of the redesigned aft skirt. it is suggested that the sensitivity of the failure area material strength and stress/strain state to material properties and therefore to small manufacturing or processing variables is the most likely cause of failure below the expected material ultimate properties.

Berry, David M.↗

Computational simulation of probabilistic lifetime strength for aerospace materials subjected to high temperature, mechanical fatigue, creep, and thermal fatigue

The results of a fourth year effort of a research program conducted for NASA-LeRC by The University of Texas at San Antonio (UTSA) are presented. The research included on-going development of methodology that provides probabilistic lifetime strength of aerospace materials via computational simulation. A probabilistic material strength degradation model, in the form of a randomized multifactor interaction equation, is postulated for strength degradation of structural components of aerospace propulsion systems subjected to a number of effects or primitive variables. These primitive variables may include high temperature, fatigue, or creep. In most cases, strength is reduced as a result of the action of a variable. This multifactor interaction strength degradation equation was randomized and is included in the computer program, PROMISC. Also included in the research is the development of methodology to calibrate the above-described constitutive equation using actual experimental materials data together with regression analysis of that data, thereby predicting values for the empirical material constants for each effect or primitive variable. This regression methodology is included in the computer program, PROMISC. Actual experimental materials data were obtained from industry and the open literature for materials typically for applications in aerospace propulsion system components. Material data for Inconel 718 was analyzed using the developed methodology.

Boyce, Lola↗

Computational simulation of probabilistic lifetime strength for aerospace materials subjected to high temperature, mechanical fatigue, creep and thermal fatigue

This report presents the results of a fourth year effort of a research program, conducted for NASA-LeRC by the University of Texas at San Antonio (UTSA). The research included on-going development of methodology that provides probabilistic lifetime strength of aerospace materials via computational simulation. A probabilistic material strength degradation model, in the form of a randomized multifactor interaction equation, is postulated for strength degradation of structural components of aerospace propulsion systems subject to a number of effects or primitive variables. These primitive variables may include high temperature, fatigue or creep. In most cases, strength is reduced as a result of the action of a variable. This multifactor interaction strength degradation equation has been randomized and is included in the computer program, PROMISS. Also included in the research is the development of methodology to calibrate the above-described constitutive equation using actual experimental materials data together with regression analysis of that data, thereby predicting values for the empirical material constants for each effect or primitive variable. This regression methodology is included in the computer program, PROMISC. Actual experimental materials data were obtained from industry and the open literature for materials typically for applications in aerospace propulsion system components. Material data for Inconel 718 has been analyzed using the developed methodology.

Boyce, Lola↗

Rub tolerance evaluation of two sintered NiCrAl gas path seal materials

Two strength level variations of sintered NiCrAl (about 40 percent dense), candidate high pressure turbine seal materials, were subject to rub tolerance testing against AM 355 steel blade tips. The high strength material (17 N/sq mm tensile strength) showed frictional and radial loads that were 20 to 50 percent higher than those measured for the low strength material (15.5 N/ sq mm tensile strength). Measured wear to the AM 355 blade tips was not significantly different for the two sintered NiCrAl seal materials. Wear of the sintered NiCrAl was characterized by material removal to a depth greater than the depth to which blade tips were driven into the seal, indicating self-erosion effects.

Bill, R. C.↗

Increased Tensile Strength of Carbon Nanotube Yarns and Sheets through Chemical Modification and Electron Beam Irradiation

The inherent strength of individual carbon nanotubes offers considerable opportunity for the development of advanced, lightweight composite structures. Recent work in the fabrication and application of carbon nanotube (CNT) forms such as yarns and sheets has addressed early nanocomposite limitations with respect to nanotube dispersion and loading; and has pushed the technology toward structural composite applications. However, the high tensile strength of an individual CNT has not directly translated to macro-scale CNT forms where bulk material strength is limited by inter-tube electrostatic attraction and slippage. The focus of this work was to assess post processing of CNT sheet and yarn to improve the macro-scale strength of these material forms. Both small molecule functionalization and e-beam irradiation was evaluated as a means to enhance tensile strength and Youngs modulus of the bulk CNT material. Mechanical testing results revealed a tensile strength increase in CNT sheets by 57 when functionalized, while an additional 48 increase in tensile strength was observed when functionalized sheets were irradiated; compared to unfunctionalized sheets. Similarly, small molecule functionalization increased yarn tensile strength up to 25, whereas irradiation of the functionalized yarns pushed the tensile strength to 88 beyond that of the baseline yarn.

composites↗

Design and Use of a Penetrating Deposition Nozzle for Z-Pinning Additive Manufacturing

Fused Filament Fabrication (FFF) involves depositing material layer-by-layer to create athree-dimensional object. This method often demonstrates high mechanical anisotropy in theprinted structure, leading to a drop in the material strength of the part when comparing structuresalong the deposition plane (X/Y-Axis) versus across layers in the build direction (Z-Axis). Initialefforts to improve anisotropy led to the development of the Z-Pinning process, where continuouspins are deposited across layers in the Z-Axis. Z-pinning has demonstrated significant gains intoughness and inter-layer strength, particularly in fiber-reinforced materials. However, thisprocess can also create flaws in the structure that increase in severity and frequency as the pinsgrow in length and diameter. To mitigate this, a penetrating nozzle has been developed thatextends a fine-tipped extrusion nozzle deep into the pin cavity and simultaneously extrudesmaterial as it retracts. This study investigates the printability of the penetrating nozzle for simplegeometries and evaluates the resulting Z-pinning mesostructure. As a result of this study, theprototype penetrating nozzle design was analyzed and built. Through a pressure driven flowanalysis it was determined that the penetrating nozzle extruder can not only flow extrudefilament. After a transient thermal simulation it was found that after a pause of 15 secondsresume printing with no drop in heat at nozzle exit.

Bales, Brenin↗

Quantitative ultrasonic evaluation of engineering properties in metals, composites, and ceramics

Ultrasonic techniques that have demonstrated potential for material characterization are reviewed. These techniques rely on physical acoustic properties of materials and the interaction of elastic stress waves with morphological factors in the ultrasonic regime. The speed of wave propagation and energy loss by interaction with material microstructure and geometrical factors underlie ultrasonic determination of material properties. Two categories of ultrasonic measurements are discussed: those related to material strengths (e.g., elastic moduli, tensile strength, and fracture toughness) and those related to morphology and material conditions that govern strength and performance (e.g., microstructure, void content, residual stress, fatigue damage). It is shown that large-scale industrial application of ultrasonic NDE will depend on advancement in such areas as theory development, instrumentation, system automation, standardization, and coordination with design.

Vary, A.↗

mystic : software for autonomous discovery and design under uncertainty

Throughout the diverse range of science and engineering applications, there is a growing desire to develop computational methods that can reliably predict the behavior of complex systems. Specifically, there is a strategic need for tools that can robustly forecast the behavior of complex physical systems, where data may be high-dimensional, noisy, or sparse, and models of the system may be time-dependent or include uncertainty. We use mystic to build tools that leverage statistical learning, physics-informed learning, and active learning in the efficient generation of reliably predictive surrogates for complex physical systems. mystic is a robust, proven, open-source optimization and uncertainty quantification toolkit with over a decade of use in the design and optimization of neutron instrumentation, solar-powered drones, and gasguns, and in iterative tuning of models for Raman spectroscopy and elastoplastic materials strength. Recent developments have focused on automated learning of statistically robust surrogates under uncertainty, with applications in materials in extreme environments, nanostructures, materials simulations and strength models, and the failure of shielding under particle radiation. In 2020, McKerns demonstrated active learning of optimally robust surrogates with respect to new simulated data for molecular dynamics simulations of materials mixing in warm dense matter, and is currently applying active learning to the automated steering of particle accelerator beams and the optimal design and control of quantum optical sensor instrumentation.

42 ENGINEERING↗

The Enigmatic Longevity of Granular Materials on Mars: The Case for Geologically Episodic Dune Formation

Martian sand dunes are concentrated in vast sand seas in the circumpolar belt of the planet's northern hemisphere, but they are also pervasive over the whole planet. Their occurrence is to be expected on a super-arid planetary surface subjected to boundary layer drag from a continually active atmosphere. Whilst their occurrence is to be expected, their survival is enigmatic. But the enigma only arises if the martian system is considered similar to Earth's --where sand is moved highly frequently, more or less on a seasonal basis. Experimentally it is readily demonstrated that active sand will soon wear down to small grains and eventually diminish to below the critical sand size required to sustain dune formation. According to conventional wisdom, sand moves at higher speeds on Mars than on Earth, and if it were to move as frequently as it does on Earth, then the dune-forming sand population should have long since disappeared, given the great longevity of the martian aeolian system (Sagan coined the term "kamikaze" grains to express this disappearance). No supply of sand could keep pace with this depletion, especially in light of the fact that Mars does not have very active weathering, nor significant crustal differentiation. On Earth, plate tectonics, magmatic activity, and general crustal differentiation over geological time have produced great concentrations of quartz crystals in the continental crustal masses. Not only are these quartz grains chemically and mechanically resilient, they are about the right size for being transported by either wind or water. Add to this, the geologically recent contribution of glacial grinding, and it is easy to see why there are dune field on Earth. So what are the martian dunes composed of, and how does the material survive the eons of attrition? In addition to experimental demonstrations of sand comminution in laboratory aeolian simulations, the problem can be approached from first principles. Sagan showed that by simple considerations of material strength versus mechanical work applied to the material, comminution to sub-sand size would be inevitable. Another semi-analytical approach might be taken by considering that the archetypal aeolian sand surface texture is an irregularly pitted ("frosted") surface composed of chipping hollows approximately 10 microns in diameter, 5 microns deep. Their volume = about 250 cubic microns, or about 1/25000 of the volume of a 100 micron diameter dune grain. Because a saltating grain always strikes another grain, then two surfaces are impacted. Thus each grain undergoes two impacts for every one saltation leap, when the impact statistics are considered for a closed dune system (it can be calculated that a grain can never undergo <1 impact, and never >2 per saltation leap). Hence, if we conservatively assume that there is damage to a grain each time it bounces, but with the minimum damage of only 2 microscopic craters per impact, then approximately 12,500 impacts are required to completely eliminate the grain. Of course, it would require only a fraction of this amount to reduce the grain to below sand size. A grain will make only several tens of saltation leaps on the stoss side of a dune before becoming buried on the lee slope. The dune then has to move its full length before the grain is exhumed again for abrasion. Even with this hiatus in transport, it is easy to see that terrestrial dunes need resupplying with sand in order to survive. In recent theoretical work it has been shown that martian aeolian transport may be initiated with high-speed grains, but this converts to a lower energy dynamic transport equilibrium in which a reptation population dominates grain transport (on Earth, at least half of the flux is by reptation and creep). On Mars, therefore, average grain speeds may be lower than those on Earth, or at least comparable. This would permit greater longevity for martian sands, but it would not go far enough to solve the survival problem. It may, however, explain why martian dunes are about the same size as terrestrial dunes. If martian saltation leaps were significantly longer than on Earth (as usually assumed), then a dune's lee slope would have to be correspondingly longer in order to trap the sand; this would scale up the whole dune structure. But with shorter trajectories in a reptation population, larger dunes would be unnecessary. Additional information is contained in the original.

Marshall, J.↗

Comparison of impact results for several polymeric composites over a wide range of low impact velocities

Static indentation, falling weight, and ballistic impact tests were conducted in clamped plates made of AS4/3501-6 and IM7/8551-7 prepreg tape. The transversely isotropic plates were nominally 7-mm thick. Pendulum and ballistic tests were also conducted on simply supported plates braided with Celion 12000 fibers and 3501-6 epoxy. The 20 degree braided plates were about 5-mm thick. The impactors had spherical or hemispherical shapes with a 12.7 mm diameter. Residual compression strength and damage size were measured. For a given kinetic energy, damage size was least for IM7/8551-7 and greatest for the braided material. Strengths varied inversely with damage size. For a given damage size, strength loss as a fraction of original strength was least for the braided material and greatest for AS4/3501-6 and IM7/8551-7. Strength loss for IM7/8551-7 and AS4/3501-6 was nearly equal. No significant differences were noticed between damage sizes and residual compression strengths for the static indentation, falling weight, and ballistic tests of AS4/3501-6 and IM7/8551-7. For the braided material, sizes of damage were significantly less and compression strengths were significantly more for the falling weight tests than for the ballistic tests.

Poe, C. C., Jr.↗

Solvent-Mediated Control of Nanocellulose Dispersion: An Integrated Computational and Experimental Investigation

Fibrillated cellulose derived from forestry feedstocks represents a renewable and high-strength materials platform for circular bioeconomies. However, its practical implementation is hindered by the irreversible aggregation of nanocellulose architectures, including cellulose nanofibers (CNFs). Solvent-based dispersion offers a simple and practical route to prevent CNF aggregation. Here, in this work, we integrate classical and enhanced sampling molecular dynamics (MD) simulations with experimental suspension rheology and atomic force microscopy (AFM) to elucidate how solvent environments tune CNF–CNF interactions and dispersion stability. CNF–CNF contact free energies computed from MD simulations reveal reduced aggregation in acetone/water, γ-valerolactone (GVL)/water, and tetrahydrofuran (THF)/water and pure acetone compared with pure water, reflecting stronger CNF-solvent relative to inter-CNF interactions. Correspondingly, CNF-solvent suspensions in these solvent systems exhibit stronger inter-fibril network structures and enhanced recovery compared to water, indicating improved CNF-solvent affinity. Liquid cell AFM imaging in acetone–water mixtures and in pure acetone further confirm the presence of well-dispersed CNFs. By combining multiscale computation with targeted experiments, this study establishes a rational framework for solvent design to achieve stable nanocellulose dispersions for high-strength biobased materials and efficient bioenergy conversion.

cellulose↗

Measuring the Tensile Strength of B/AL Composites

Proposed nondestructive technique correlates damping measurements with material strength. Increasing axial damping and decreasing axial tensile strength are observed after 1-hour treatment of B/AL composites containing about 50 percent fiber. Damping was measured in vacuum at frequencies near 2,000 Hz, and tensile strength was normalized by maximum strength observed before thermally induced degradation.

Dicarlo, J. A.↗

Elucidating size effects on the yield strength of single-crystal Cu via the Richtmyer–Meshkov instability

Capturing the dynamic response of a material under high strain-rate deformation often demands challenging and time consuming experimental effort. While shock hydrodynamic simulation methods can aid in this area, a priori characterizations of the material strength under shock loading and spall failure are needed in order to parameterize constitutive models needed for these computational tools. Moreover, parameterizations of strain-rate-dependent strength models are needed to capture the full suite of Richtmyer–Meshkov instability (RMI) behavior of shock compressed metals, creating an unrealistic demand for these training data solely on experiments. Herein, we sweep a large range of geometric, crystallographic, and shock conditions within molecular dynamics (MD) simulations and demonstrate the breadth of RMI in Cu that can be captured from the atomic scale. In this work, yield strength measurements from jetted and arrested material from a sinusoidal surface perturbation were quantified as Y RMI = 0.787 ± 0.374 GPa, higher than strain-rate-independent models used in experimentally matched hydrodynamic simulations. Defect-free, single-crystal Cu samples used in MD will overestimate Y RMI , but the drastic scale difference between experiment and MD is highlighted by high confidence neighborhood clustering predictions of RMI characterizations, yielding incorrect classifications.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

A statistical, micromechanical theory of the compressive strength of brittle materials

A general theory of the compressive strength of brittle materials is presented. This theory proposes that failure is brought about by structural weakening from accumulated crack damage which increases with the stress level. The statistics of the flaw distribution and the mechanism of crack initiation and extension are important. A sample calculation using the theory is given to demonstrate its application

Adams, M.↗

Statistical distribution of mechanical properties for three graphite-epoxy material systems

Graphite-epoxy composites are playing an increasing role as viable alternative materials in structural applications necessitating thorough investigation into the predictability and reproducibility of their material strength properties. This investigation was concerned with tension, compression, and short beam shear coupon testing of large samples from three different material suppliers to determine their statistical strength behavior. Statistical results indicate that a two Parameter Weibull distribution model provides better overall characterization of material behavior for the graphite-epoxy systems tested than does the standard Normal distribution model that is employed for most design work. While either a Weibull or Normal distribution model provides adequate predictions for average strength values, the Weibull model provides better characterization in the lower tail region where the predictions are of maximum design interest. The two sets of the same material were found to have essentially the same material properties, and indicate that repeatability can be achieved.

Reese, C.↗

Probabilistic and Possibilistic Analyses of the Strength of a Bonded Joint

The effects of uncertainties on the strength of a single lap shear joint are explained. Probabilistic and possibilistic methods are used to account for uncertainties. Linear and geometrically nonlinear finite element analyses are used in the studies. To evaluate the strength of the joint, fracture in the adhesive and material strength failure in the strap are considered. The study shows that linear analyses yield conservative predictions for failure loads. The possibilistic approach for treating uncertainties appears to be viable for preliminary design, but with several qualifications.

Stroud, W. Jefferson↗

Design application and development of spacecraft in LEO utilizing LDEF results

In general, the results from the Long Duration Exposure Facility (LDEF) have provided much useful information on material sensitivity in the low-Earth orbit (LEO) environment. This is particularly true for selected materials such as thermal control coatings, composites, polymers, fasteners and solar cells. However, LDEF material sensitivity data for other materials like glasses, glass coatings, lubricants, adhesives and seal materials were limited. Some of this important LDEF material sensitivity data has not yet been addressed in detail at the LDEF meetings. The type of material information needed in the design and development of a new spacecraft in LEO depends to a large extent on program phase. In early program phases it is only necessary to have material sensitivity data to determine what materials may or may not work. Later program phases require details on the material strength, optical properties, and/or other long term survivability requirements for materials in LEO. Unfortunately, documentation of exposure results for many materials sensitivity experiments that flew on LDEF has not yet been summarized in a convenient form for use by multiple users. Documentation of this data in a form convenient for scientists, engineers as well as technicians remains a significant area of concern for the aerospace industry. Many of the material experiments that flew on LDEF were only designed to measure material sensitivity for one year in an LEO environment. However, some materials expected to survive one year simply did not survive the 5.8 years that LDEF eventually remained in orbit. Therefore the survivability of several materials in an LEO environment was determined by default. Most of the LDEF materials experiments were not designed to establish long term material survivability data. This long term material survivability data is particularly useful in later program phases of spacecraft development. The lack of more controlled materials experiments to determine long term material survivability was one of the major limitations of many LDEF experiments. The identified need for this critical information on the long term survivability offers a challenge to possible future LDEF type experiments.

Rauch, George B., Jr.↗