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At least 145 records · Page 8

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NASA NTRS1994

Inlet Flow Test Calibration for a Small Axial Compressor Facility. Part 1: Design and Experimental Results

An axial compressor test rig has been designed for the operation of small turbomachines. The inlet region consisted of a long flowpath region with two series of support struts and a flapped inlet guide vane. A flow test was run to calibrate and determine the source and magnitudes of the loss mechanisms in the inlet for a highly loaded two-stage axial compressor test. Several flow conditions and IGV angle settings were established in which detailed surveys were completed. Boundary layer bleed was also provided along the casing of the inlet behind the support struts and ahead of the IGV. A detailed discussion of the flowpath design along with a summary of the experimental results are provided in Part 1.

Miller, D. P.↗

NASA NTRS2018

Preload Loss in a Spacecraft Fastener via Vibration-Induced Unwinding

Sound engineering practice requires that fasteners and bolted joints maintain preload in service. NASA recently concluded a series of vibration tests of a multicomponent structure intended to simulate an upper stage section of a launch vehicle. The stacked components were joined through six circumferentially placed bolted cup-cone-style pyrotechnic joint mechanisms designed to share spacecraft structural loads and then enable separation during ascent. Over the course of the vibration test campaign, all six bolted cup-cone mechanisms experienced some degree of preload loss with two mechanisms losing half of their original bolt preload. A subsequent forensic anomaly investigation concluded that vibration-induced unwinding of the preload nut-and-bolt assemblies occurred despite the use of safety wire and high levels of thread friction. A series of experiments were done to better understand how large, heavily preloaded fasteners could unwind. Additionally, thread friction torque was measured and the fastener locking capability of safety wire was evaluated. The friction coefficient between the clamped cup-cone components was characterized and finally a highly instrumented mechanism-level vibration test was done to reproduce the unwinding phenomenon to better understand the mechanism's behavior. The conclusion drawn was that vibration and structural forces led to relative motion (sliding) of the clamped components, resulting in self-loosening and unwinding effects on the nut-and-bolt assembly. To counter this phenomenon, more effective fastener locking methodologies were recommended and a follow-on effort was initiated to quantify the relationship between preload, component motion, and resulting unwinding forces. It is hoped that elucidation of these effects can be used to design more effective fastener locking features.

fasteners↗

NASA NTRS1992

Composite fuselage shell structures research at NASA Langley Research Center

Fuselage structures for transport aircraft represent a significant percentage of both the weight and the cost of these aircraft primary structures. Composite materials offer the potential for reducing both the weight and the cost of transport fuselage structures, but only limited studies of the response and failure of composite fuselage structures have been conducted for transport aircraft. The behavior of these important primary structures must be understood, and the structural mechanics methodology for analyzing and designing these complex stiffened shell structures must be validated in the laboratory. The effects of local gradients and discontinuities on fuselage shell behavior and the effects of local damage on pressure containment must be thoroughly understood before composite fuselage structures can be used for commercial aircraft. This paper describes the research being conducted and planned at NASA LaRC to help understand the critical behavior or composite fuselage structures and to validate the structural mechanics methodology being developed for stiffened composite fuselage shell structure subjected to combined internal pressure and mechanical loads. Stiffened shell and curved stiffened panel designs are currently being developed and analyzed, and these designs will be fabricated and then tested at Langley to study critical fuselage shell behavior and to validate structural analysis and design methodology. The research includes studies of the effects of combined internal pressure and mechanical loads on nonlinear stiffened panel and shell behavior, the effects of cutouts and other gradient-producing discontinuities on composite shell response, and the effects of local damage on pressure containment and residual strength. Scaling laws are being developed that relate full-scale and subscale behavior of composite fuselage shells. Failure mechanisms are being identified and advanced designs will be developed based on what is learned from early results from the LaRC research activities. Results from combined load tests will be used to validate analytical models of critical nonlinear response mechanisms as well as shell scaling laws.

Starnes, James H., Jr.↗

NASA NTRS1995

Detecting gear tooth fracture in a high contact ratio face gear mesh

This paper summarized the results of a study in which three different vibration diagnostic methods were used to detect gear tooth fracture in a high contact ratio face gear mesh. The NASA spiral bevel gear fatigue test rig was used to produce unseeded fault, natural failures of four face gear specimens. During the fatigue tests, which were run to determine load capacity and primary failure mechanisms for face gears, vibration signals were monitored and recorded for gear diagnostic purposes. Gear tooth bending fatigue and surface pitting were the primary failure modes found in the tests. The damage ranged from partial tooth fracture on a single tooth in one test to heavy wear, severe pitting, and complete tooth fracture of several teeth on another test. Three gear fault detection techniques, FM4, NA4*, and NB4, were applied to the experimental data. These methods use the signal average in both the time and frequency domain. Method NA4* was able to conclusively detect the gear tooth fractures in three out of the four fatigue tests, along with gear tooth surface pitting and heavy wear. For multiple tooth fractures, all of the methods gave a clear indication of the damage. It was also found that due to the high contact ratio of the face gear mesh, single tooth fractures did not significantly affect the vibration signal, making this type of failure difficult to detect.

Zakrajsek, James J.↗

NASA NTRS2002

NiH2 Cycle Life Study

Cycle life studies have been performed at Eagle Picher Technologies (EPT), on HST Mantech design cells with various pedigrees of slurry and dry sinter processed electrodes, to evaluate peak load voltage performance during generic load profile testing. These tests provide information for determining voltage and capacity fade (degradation) mechanisms, and their impact on nickel hydrogen cell cycle life. Comparison of peak load voltage fade, as a function of State of Charge and cycle life, with capacity data from HST indicates that the cycle life limiting mechanism is due to impedance growth, and formation of a second discharge plateau. With a second plateau on discharge, capacity from the cell is still available, but at an unacceptable low voltage of 0.8 V per cell (17.6 V battery). Data shows that cell impedance increases with cycle number and depth of discharge, as expected.

Hollandsworth, Roger P.↗

NASA NTRS1994

Matrix Fatigue Cracking Mechanisms of Alpha(2) TMC for Hypersonic Applications

The objective of this work was to understand matrix cracking mechanisms in a unidirectional alpha(sub 2) TMC in possible hypersonic applications. A (0)(sub 8) SCS-6/Ti-24Al-11Nb (at. percent) TMC was first subjected to a variety of simple isothermal and nonisothermal fatigue cycles to evaluate the damage mechanisms in simple conditions. A modified ascent mission cycle test was then performed to evaluate the combined effects of loading modes. This cycle mixes mechanical cycling at 150 and 483 C, sustained loads, and a slow thermal cycle to 815 C. At low cyclic stresses and strains more common in hypersonic applications, environment-assisted surface cracking limited fatigue resistance. This damage mechanism was most acute for out-of-phase nonisothermal cycles having extended cycle periods and the ascent mission cycle. A simple linear fraction damage model was employed to help understand this damage mechanism. Time-dependent environmental damage was found to strongly influence out-of-phase and mission life, with mechanical cycling damage due to the combination of external loading and CTE mismatch stresses playing a smaller role. The mechanical cycling and sustained loads in the mission cycle also had a smaller role.

Gabb, Timothy P.↗

NASA NTRS1974

Crack-growth behavior in thick welded plates of Inconel 718 at room and cryogenic temperatures

Results of mechanical-properties and axial-load fatigue and fracture tests performed on thick welded plates of Inconel 718 superalloy are presented. The test objectives were to determine the tensile strength properties and the crack-growth behavior in electron-beam, plasma-arc, and gas tungsten are welds for plates 1.90 cm (0.75 in) thick. Base-metal specimens were also tested to determine the flaw-growth behavior. The tests were performed in room-temperature-air and liquid nitrogen environments. The experimental crack-growth-rate data are correlated with theoretical crack-growth-rate predictions for semielliptical surface flaws.

Forman, R. G.↗

NASA NTRS1986

Fatigue of 1018 steel in hydrogen

Tests are performed at different hydrogen pressures and mechanical load parameter values (applied load, stress concentration factor, applied load frequency) to study enhanced fatigue crack growth in SAE 1018 steel. Oxygen was introduced as a hydrogen-oxygen gas mixture environment in order to compare the role of oxygen in crack inhibition with that previously reported for both static and cyclic loading of higher strength steels. In a number of experiments, a thin film of palladium was applied to the specimen surface to facilitate the study of steel-hydrogen interaction in the absence of any surface impedance to hydrogen entry. The kinetics of the diffusing atoms are found to be influenced by the stress field around the notch tip and the applied frequency. An increment in environmental effect occurred when applied load or stress concentration factor was increased.

Lo, S. H.↗

NASA NTRS1996

Determination of Small Animal Long Bone Properties Using Densitometry

Assessment of bone structural property changes due to loading regimens or pharmacological treatment typically requires destructive mechanical testing and sectioning. Our group has accurately and non-destructively estimated three dimensional cross-sectional areal properties (principal moments of inertia, Imax and Imin, and principal angle, Theta) of human cadaver long bones from pixel-by-pixel analysis of three non-coplanar densitometry scans. Because the scanner beam width is on the order of typical small animal diapbyseal diameters, applying this technique to high-resolution scans of rat long bones necessitates additional processing to minimize errors induced by beam smearing, such as dependence on sample orientation and overestimation of Imax and Imin. We hypothesized that these errors are correctable by digital image processing of the raw scan data. In all cases, four scans, using only the low energy data (Hologic QDR-1000W, small animal mode), are averaged to increase image signal-to-noise ratio. Raw scans are additionally processed by interpolation, deconvolution by a filter derived from scanner beam characteristics, and masking using a variable threshold based on image dynamic range. To assess accuracy, we scanned an aluminum step phantom at 12 orientations over a range of 180 deg about the longitudinal axis, in 15 deg increments. The phantom dimensions (2.5, 3.1, 3.8 mm x 4.4 mm; Imin/Imax: 0.33-0.74) were comparable to the dimensions of a rat femur which was also scanned. Cross-sectional properties were determined at 0.25 mm increments along the length of the phantom and femur. The table shows average error (+/- SD) from theory of Imax, Imin, and Theta) over the 12 orientations, calculated from raw and fully processed phantom images, as well as standard deviations about the mean for the femur scans. Processing of phantom scans increased agreement with theory, indicating improved accuracy. Smaller standard deviations with processing indicate increased precision and repeatability. Standard deviations for the femur are consistent with those of the phantom. We conclude that in conjunction with digital image enhancement, densitometry scans are suitable for non-destructive determination of areal properties of small animal bones of comparable size to our phantom, allowing prediction of Imax and Imin within 2.5% and Theta within a fraction of a degree. This method represents a considerable extension of current methods of analyzing bone tissue distribution in small animal bones.

Breit, Gregory A.↗

NASA NTRS2004

Thermal-Structural Optimization of Integrated Cryogenic Propellant Tank Concepts for a Reusable Launch Vehicle

A next generation reusable launch vehicle (RLV) will require thermally efficient and light-weight cryogenic propellant tank structures. Since these tanks will be weight-critical, analytical tools must be developed to aid in sizing the thickness of insulation layers and structural geometry for optimal performance. Finite element method (FEM) models of the tank and insulation layers were created to analyze the thermal performance of the cryogenic insulation layer and thermal protection system (TPS) of the tanks. The thermal conditions of ground-hold and re-entry/soak-through for a typical RLV mission were used in the thermal sizing study. A general-purpose nonlinear FEM analysis code, capable of using temperature and pressure dependent material properties, was used as the thermal analysis code. Mechanical loads from ground handling and proof-pressure testing were used to size the structural geometry of an aluminum cryogenic tank wall. Nonlinear deterministic optimization and reliability optimization techniques were the analytical tools used to size the geometry of the isogrid stiffeners and thickness of the skin. The results from the sizing study indicate that a commercial FEM code can be used for thermal analyses to size the insulation thicknesses where the temperature and pressure were varied. The results from the structural sizing study show that using combined deterministic and reliability optimization techniques can obtain alternate and lighter designs than the designs obtained from deterministic optimization methods alone.

Johnson, Theodore F.↗

NASA NTRS2015

James Webb Space Telescope (JWST) Integrated Science Instruments Module (ISIM) Electronics Compartment (IEC) Conformal Shields Composite Bond Structure Qualification Test Method

The JWST IEC conformal shields are mounted onto a composite frame structure that must undergo qualification testing to satisfy mission assurance requirements. The composite frame segments are bonded together at the joints using epoxy, EA 9394. The development of a test method to verify the integrity of the bonded structure at its operating environment introduces challenges in terms of requirements definition and the attainment of success criteria. Even though protoflight thermal requirements were not achieved, the first attempt in exposing the structure to cryogenic operating conditions in a thermal vacuum environment resulted in approximately 1 bonded joints failure during mechanical pull tests performed at 1.25 times the flight loads. Failure analysis concluded that the failure mode was due to adhesive cracks that formed and propagated along stress concentrated fillets as a result of poor bond squeeze-out control during fabrication. Bond repairs were made and the structures successfully re-tested with an improved LN2 immersion test method to achieve protoflight thermal requirements.

Thermal Vacuum Testing Chamber↗

NASA NTRS2025

The Shape Effect: Influence of 1D and 2D Boron Nitride Nanostructures on the Radiation Shielding, Thermal, and Damping Properties of High-Temperature Epoxy Composites

In space exploration, lightweight multifunctional materials capable of shielding neutron radiation, dissipating heat, and providing damping are essential. Polymer composites reinforced with boron nitride (BN) nanomaterials—specifically one-dimensional boron nitride nanotubes (BNNTs) and two-dimensional boron nitride nanoplatelets (BNNPs)—offer promising solutions. This study investigates how BN nanomaterial morphology influences the performance of high-temperature (HT) epoxy composites. We developed ultralightweight, three-dimensional BN foams comprising 1D BNNTs, 2D BNNPs, and hybrid 1D BNNT/2D BNNP structures via freeze-drying, then infiltrated them with HT epoxy to form dense composites. The BNNT foam exhibited the highest neutron radiation shielding, with a mass absorption coefficient of 26.64 cm2 g −1 , outperforming the hybrid foam (18.18 cm 2 g −1 ) and the BNNP foam (11.12 cm 2 g −1 ). A similar trend was observed in the HT epoxy composites; incorporating these foams at least doubled the mass absorption coefficient compared to the neat polymer. In terms of thermal conductivity, the BNNT/BNNP foam-epoxy composite achieved the highest value of 0.34 W m −1 K −1 , a 2.13-fold increase over neat HT epoxy. The BNNT/BNNP foam-epoxy composites also improved by 1.88 and 1.75 times, respectively. Mechanical testing revealed that BNNP foams withstood the highest loads during nanoindentation (3.53 kN), followed by BNNT/BNNP foams (1.93 kN) and BNNT foams (1.56 kN). All BN foam-epoxy composites exhibited enhanced damping properties, with tan δ increasing by at least 30 % compared to neat HT epoxy. These findings elucidate the impact of BN nanomaterial morphology on the multifunctional performance of HT epoxy composites, offering insights for developing high-performance, tailorable materials for demanding environments.

Kazue Orikasa↗

NASA NTRS1995

Inlet flow test calibration for a small axial compressor rig. Part 2: CFD compared with experimental results

An axial compressor test rig has been designed for the operation of small turbomachines. A flow test was run to calibrate and determine the source and magnitudes of the loss mechanisms in the compressor inlet for a highly loaded two-stage axial compressor test. Several flow conditions and inlet guide vane (IGV) angle settings were established, for which detailed surveys were completed. Boundary layer bleed was also provided along the casing of the inlet behind the support struts and ahead of the IGV. Several computational fluid dynamics (CFD) calculations were made for selected flow conditions established during the test. Good agreement between the CFD and test data were obtained for these test conditions.

Miller, D. P.↗

NASA NTRS2005

Apparatus for Testing Flat Specimens of Thermal Insulation

An apparatus has been developed to implement an improved method of testing flat-plate specimens of thermal-insulation materials for cryogenic application. The method includes testing under realistic use conditions that could include vacuum and mechanical loading at a pressure up to 70 psi (=0.48 MPa). The apparatus can accommodate a rigid or flexible specimen having thickness up to 1.25 in. (=3.2 cm) and diameters between 6 and 10 in. (about 15.2 and 25.4 cm, respectively). Typical test conditions include boundary temperatures between 77 K and 373 K and vacuum/interstitial gas filling at a pressure between 10(exp -6) torr (=1.3 x 10(exp -4) Pa) and 760 torr (atmospheric pressure =0.1 MPa). The interstitial gas could be N2, He, CO2, or any other suitable gas to which the insulation is expected to be exposed in use. Relative to prior apparatuses and testing methods, this apparatus and the testing method that it implements offer advantages of relative simplicity and ease of use. The basic principle of operation of the apparatus is that of boil-off calorimetry, using liquid nitrogen or any other suitable liquid that boils at a desired temperature below ambient temperature. Comparative rates of flow of heat through the thicknesses of the specimens (heat-leak rates) and apparent-thermal-conductivity values are obtained from tests of specimens. Absolute values of heat-leak rates and apparent thermal conductivities are computed from a combination of (1) the aforementioned comparative values and (2) calibration factors obtained by testing reference specimens of materials that have known thermal-insulation properties. The apparatus includes a full complement of temperature sensors, a vacuum pump and chamber, a monitoring and control system, and tools and fixtures that enable rapid and reliable installation and removal of specimens. A specimen is installed at the bottom of the vacuum chamber, and a cold-mass assembly that includes a tank is lowered into position above and around the specimen (see figure). A spring-based compensating fixture helps to ensure adequate thermal contact with possibly irregular specimen surfaces. For a high-compression test, the springs can be replaced with spacers. A flat circular load cell at the bottom of the chamber measures the compressive load on the specimen. Once the desired compressive-load, temperature, and vacuum/gas-filling conditions are established, testing begins. During a test, all measurements are recorded by use of a portable data-acquisition system and a computer. The total heat-leak rate is measured and calculated as the boil-off flow rate multiplied by the latent heat of vaporization. The parasitic heat leak (to the side of the specimen and to the top and side of the cold-mass tank) is reduced to a small fraction of the total heat leak by use of a combination of multilayer-insulation (MLI) shield rings, reflective film, a fiberglass/epoxy centering ring, and a bulk fill of aerogel beads. This combination eliminates the need for a cryogenic guard chamber used in a typical prior apparatus to reduce the parasitic heat leak.

Fesmire, James E.↗

NASA NTRS1979

The role of crack blunting in sustained load crack growth

Sustained load crack growth occurs in metals following critical crack extension above KIc and in aggressive environments while maintaining a constant load below KIc. In this paper, crack arrest measurements are performed on precracked, 0.0254-m thick, side-grooved WOL specimens exposed to 34.5 MN/sq m hydrogen at ambient temperature. The specimens are loaded inside a pressure vessel while in contact with the high pressure hydrogen environment. Crack growth is observed with each loading increment. The crack blunting observed in the fracture mechanics tests on 321 stainless steel is found to be similar to that produced in the 321 stainless steel tensile specimens. Rounding and branching of the crack decreases the effective stress intensity at the crack tip. It is possible, for materials in which cracks tend to blunt or branch in hydrogen, that although cracks will arrest at a relatively high stress intensity in decreasing stress intensity test, a crack may begin to grow at a lower stress intensity when loaded in hydrogen, and the crack may continue to grow when the stress intensity is continually increasing.

Walter, R. J.↗

NASA NTRS1991

Mechanical behavior of a ceramic matrix composite material

Monolithic ceramic materials have been used in industry for hundreds of years. These materials have proven their usefulness in many applications, yet, their potential for critical structural applications is limited. The existence of an imperfection in a monolithic ceramic on the order of several microns in size may be critical, resulting in catastrophic failure. To overcome this extreme sensitivity to small material imperfections, reinforced ceramic materials were developed. A ceramic matrix which has been reinforced with continuous fibers is not only less sensitive to microscopic flaws, but is also able to sustain significant damage without suffering catastrophic failure. A borosilicate glass reinforced with several layers of plain weave silicon carbide cloth (Nicalon) was studied. The mechanical testing which was performed included both flexural and tensile loading configurations. This testing was done not only to determine the material properties, but also to initiate a controlled amount of damage within each specimen. Several nondestructive testing techniques, including acousto-ultrasonics (AU), were performed on the specimens periodically during testing. The AU signals were monitored through the use of an IBM compatible personal computer with a high speed data acquisition board. Software was written which manipulates the AU signals in both the time and frequency domains, resulting in quantitative measures of the mechanical response of the material. The measured AU parameters are compared to both the mechanical test results and data from other nondestructive methods including ultrasonic C-scans and penetrant enhanced x ray radiography.

Grosskopf, Paul P.↗

NASA NTRS2015

Proportional and Integral Thermal Control System for Large Scale Heating Tests

The National Aeronautics and Space Administration Armstrong Flight Research Center (Edwards, California) Flight Loads Laboratory is a unique national laboratory that supports thermal, mechanical, thermal/mechanical, and structural dynamics research and testing. A Proportional Integral thermal control system was designed and implemented to support thermal tests. A thermal control algorithm supporting a quartz lamp heater was developed based on the Proportional Integral control concept and a linearized heating process. The thermal control equations were derived and expressed in terms of power levels, integral gain, proportional gain, and differences between thermal setpoints and skin temperatures. Besides the derived equations, user's predefined thermal test information generated in the form of thermal maps was used to implement the thermal control system capabilities. Graphite heater closed-loop thermal control and graphite heater open-loop power level were added later to fulfill the demand for higher temperature tests. Verification and validation tests were performed to ensure that the thermal control system requirements were achieved. This thermal control system has successfully supported many milestone thermal and thermal/mechanical tests for almost a decade with temperatures ranging from 50 F to 3000 F and temperature rise rates from -10 F/s to 70 F/s for a variety of test articles having unique thermal profiles and test setups.

Thermal Control System↗

NASA NTRS2018

Freeze Casting of LAGP for 3D Textured Solid-State Structural Electrolytes

In this study, all-solid-state structural lithium-ion batteries, a type of load bearing electrochemical energy storage that provides systems-level weight savings is being pursued for the realization of inherently safe next generation hybrid-electric and all-electric green aerospace propulsion systems. Currently investigated all-solid-state batteries do not meet the requirements for specific power and mechanical stability. To address these issues, freeze casting of lithium aluminum germanium phosphate (LAGP) electrolyte material has been explored for the creation of a textured 3D electrolyte scaffold with large interfacial surface area for high power discharge and hierarchical porosity for accommodation of active material volume changes during electrochemical cycling. We report the effects of freeze casting processing parameters on the microstructural development and mechanical performance of the scaffolds, characterized through scanning electron microscopy and ring-on-ring mechanical testing. Slurry composition and casting parameters such as solids loading, casting speed, tape angle, and temperature gradients have been modified to determine the impact on density, lamellar morphology, and final load-bearing performance.

ceramics↗