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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 145 records · Page 8

Polyimide adhesive bonding

Adhesive systems which could be used to bond composite-to-composite, composite-to-titanium, and honeycomb sandwich structures with operational capability at 589K for a minimum of 125 hours were evaluated. Evaluations were based on mechanical property tests such as lap shear and flatwise tensile and on processability. Quasi-isotropic Celion 6000/PMR-15 composite adherend was used to construct lap shear and flatwise tensile specimens. Hexcel's HRH-327-3/16-6.0 glass polyimide honeycomb core was also utilized in the flatwise tensile specimens. Numerous processing variations were also studied that led to selected cure cycles for each adhesive. Shear specimens having either 12 mm or 75 mm overlaps were used to determine the effect of bond size on processability and lap shear properties. The data indicate that processing of FM-34, FM-34B-18, LARC-13 and NRO56X can be achieved using a cure compatible with the composite adherend. No significant differences in mechanical properties were observed among the three adhesive systems and all three are suitable candidates for 589K/125 hour service.

Progar, D.↗

Comparison Testings between Two High-temperature Strain Measurement Systems

An experimental evaluation was conducted at NASA Lewis Research Center to compare and contrast the performance of a newly developed resistance strain gage, the PdCr temperature-compensated wire strain gage, to that of a conventional high-temperature extensometry. The evaluation of the two strain measurement systems was conducted through the application of various thermal and mechanical loading spectra using a high-temperature thermomechanical uniaxial testing system equipped with quartz lamp heating. The purpose of the testing was not only to compare and contrast the two strain sensors but also to investigate the applicability of the PdCr strain gage to the testing environment typically employed when characterizing the high-temperature mechanical behavior of structural materials. Strain measurement capabilities to 8OO C were investigated with a nickel base superalloy IN100 substrate material, and application to titanium matrix composite (TMC) materials was examined with the SCS-6/Ti-15-3 08 system. PdCr strain gages installed by three attachment techniques, namely, flame spraying, spot welding and rapid infrared joining were investigated.

Lei, J.-F.↗

Blade Vibration Measurement System for Unducted Fans

With propulsion research programs focused on new levels of efficiency and noise reduction, two avenues for advanced gas turbine technology are emerging: the geared turbofan and ultrahigh bypass ratio fan engines. Both of these candidates are being pursued as collaborative research projects between NASA and the engine manufacturers. The high bypass concept from GE Aviation is an unducted fan that features a bypass ratio of over 30 along with the accompanying benefits in fuel efficiency. This project improved the test and measurement capabilities of the unducted fan blade dynamic response. In the course of this project, Mechanical Solutions, Inc. (MSI) collaborated with GE Aviation to (1) define the requirements for fan blade measurements; (2) leverage MSI's radar-based system for compressor and turbine blade monitoring; and (3) develop, validate, and deliver a noncontacting blade vibration measurement system for unducted fans.

Marscher, William↗

Preparation for Testing a Multi-Bay Box Subjected to Combined Loads

The COmbined Loads Test System (COLTS) facility at NASA Langley Research Center provides a test capability to help develop validated structures technologies. The test machine was design to accommodate a range of fuselage structures and wing sections and subject them to both quasistatic and cyclic loading conditions. The COLTS facility is capable of testing fuselage barrels up to 4.6 m in diameter and 13.7 m long with combined mechanical, internal pressure, and thermal loads. The COLTS facility is currently being prepared to conduct a combined mechanical and pressure loading for a multi-bay pressure box to experimentally verify the structural performance of a composite structure which is 9.1 meters long and representative of a section of a hybrid wing body fuselage section in support of the Environmentally Responsible Aviation Project at NASA. This paper describes development of the multi-bay pressure box test using the COLTS facility. The multi-bay test article will be subjected to mechanical loads and internal pressure loads up to design ultimate load. Mechanical and pressure loads will be applied independently in some tests and simultaneously in others.

Rouse, Marshall↗

Technical Capability Upgrades to the NASA Langley Research Center 8 ft. by 15 ft. Thermal Vacuum Chamber

The 8 ft. by 15 ft. thermal vacuum chamber (TVAC), housed in Building 1250 at the NASA Langley Research Center (LaRC), and managed by the Systems Integration and Test Branch within the Engineering Directorate, has undergone several significant modifications to increase testing capability, safety, and quality of measurements of articles under environmental test. Significant modifications include: a new nitrogen distribution manifold for supplying the shroud and other cold surfaces to liquid nitrogen temperatures; a new power supply and distribution system for accurately controlling a quartz IR lamp suite; a suite of contamination monitoring sensors for outgassing measurements and species identification; a new test article support system; signal and power feed-throughs; elimination of unnecessary penetrations; and a new data acquisition and control commanding system including safety interlocks. This paper will provide a general overview of the LaRC 8 ft. by 15 ft. TVAC chamber, an overview of the new technical capabilities, and will illustrate each upgrade in detail, in terms of mechanical design and predicted performance. Additionally, an overview of the scope of tests currently being performed in the chamber will be documented, and sensor plots from tests will be provided to show chamber temperature and pressure performance with actual flight hardware under test.

Thornblom, Mark N.↗

Pyrotechnically Actuated Gas Generator Utilizing Aqueous Methanol

A gas-generating device was developed to supplement the ram-air inflation of a supersonic ballute. The device is designed to initially pressurize the ballute following deployment, exposing and orienting its ram-air inlets to free-stream air for complete inflation. The supplemental pressurization decreases the total inflation time, and increases the likelihood of a successful inflation. The device contains a reservoir filled with an aqueous mixture of methanol that, when released in to the interior of the ballute, rapidly vaporizes due to the low ambient pressure. Upon activation of the device, a pair of redundant ring mechanisms initiate pyrotechnic charges that pressurize and rupture the reservoir, resulting in ejection of the methanol in to the ballute. In addition to its role in inflation, the device serves as the structural connection to the ballute. Analytical models were developed for the inflation capability of the device, which were verified using vacuum chamber testing of developmental hardware. Static, deployment, and environmental testing demonstrated the functionality of the ring mechanism and reservoir under several temperature and pressure conditions. Finally, the device was successfully operated during the first Supersonic Flight Dynamics Test (SFDT) of NASA's Low Density Supersonic Decelerator (LDSD) project. The design architecture is scalable to accommodate different quantities of gas generation, can be adjusted to operate in a variety of temperature and atmospheric pressure regimes, and provides a robust device that may be installed with minimal risk to personnel or hardware.

IA↗

NDE of titanium alloy MMC rings for gas turbine engines

Progress in the processing and fabrication of metal matrix composites (MMC's) requires appropriate mechanical and nondestructive testing methods. These methods are needed to characterize properties, assess integrity, and predict the life of engine components such as compressor rotors, blades, and vanes. Capabilities and limitations of several state-of-the-art nondestructive evaluation (NDE) technologies are investigated for characterizing titanium MMC rings for gas turbine engines. The use of NDE technologies such as x-ray computed tomography, radiography, and ultrasonics in identifying fabrication-related problems that caused defects in components is examined. Acousto-ultrasonics was explored to assess degradation of material mechanical properties by using stress wave factor and ultrasonic velocity measurements before and after the burst testing of the rings.

Baaklini, George Y.↗

Thermomechanical Multiaxial Fatigue Testing Capability Developed

Structural components in aeronautical gas turbine engines typically experience multiaxial states of stress under nonisothermal conditions. To estimate the durability of the various components in the engine, one must characterize the cyclic deformation and fatigue behavior of the materials used under thermal and complex mechanical loading conditions. To this end, a testing protocol and associated test control software were developed at the NASA Lewis Research Center for thermomechanical axial-torsional fatigue tests. These tests are to be performed on thin-walled, tubular specimens fabricated from the cobalt-based superalloy Haynes 188. The software is written in C and runs on an MS-DOS based microcomputer.

Source record↗

Hypervelocity Impact Experiments on Epoxy/Ultra-High Molecular Weight Polyethylene Composite Panels Reinforced with Nanotubes

Advanced composites with multi-functional capabilities are of great interest to the designers of aerospace structures. Polymer matrix composites (PMCs) reinforced with high strength fibers provide a lightweight and high strength alternative to metals and metal alloys conventionally used in aerospace architectures. Novel reinforcements such as nanofillers offer potential to improve the mechanical properties and add multi-functionality such as radiation resistance and sensing capabilities to the PMCs. This paper reports the hypervelocity impact (HVI) test results on ultra-high molecular weight polyethylene (UHMWPE) fiber composites reinforced with single-walled carbon nanotubes (SWCNT) and boron nitride nanotubes (BNNT). Woven UHMWPE fabrics, in addition to providing excellent impact properties and high strength, also offer radiation resistance due to inherent high hydrogen content. SWCNT have exceptional mechanical and electrical properties. BNNT (figure 1) have high neutron cross section and good mechanical properties that add multi-functionality to this system. In this project, epoxy based UHMWPE composites containing SWCNT and BNNT are assessed for their use as bumper shields and as intermediate plates in a Whipple Shield for HVI resistance. Three composite systems are prepared to compare against one another: (I) Epoxy/UHMWPE, (II) Epoxy/UHMWPE/SWCNT and (III) Epoxy/UHMWPE/SWCNT/BNNT. Each composite is a 10.0 by 10.0 by 0.11 cm3 panel, consisting of 4 layers of fabrics arranged in cross-ply orientation. Both SWCNT and BNNT are 0.5 weight % of the fabric preform. Hypervelocity impact tests are performed using a two-stage light gas gun at Rice University

Khatiwada, Suman↗

Corner Wrinkling at a Square Membrane Due to Symmetric Mechanical Loads

Thin-film membrane structures are under consideration for use in many future gossamer spacecraft systems. Examples include sunshields for large aperture telescopes, solar sails, and membrane optics. The development of capabilities for testing and analyzing pre-tensioned, thin film membrane structures is an important and challenging aspect of gossamer spacecraft technology development. This paper presents results from experimental and computational studies performed to characterize the wrinkling behavior of thin-fi[m membranes under mechanical loading. The test article is a 500 mm square membrane subjected to symmetric comer loads. Data is presented for loads ranging from 0.49 N to 4.91 N. The experimental results show that as the load increases the number of wrinkles increases, while the wrinkle amplitude decreases. The computational model uses a finite element implementation of Stein-Hedgepeth membrane wrinkling theory to predict the behavior of the membrane. Comparisons were made with experimental results for the wrinkle angle and wrinkled region. There was reasonably good agreement between the measured wrinkle angle and the predicted directions of the major principle stresses. The shape of the wrinkle region predicted by the finite element model matches that observed in the experiments; however, the size of the predicted region is smaller than that determined in the experiments.

Blandino, Joseph R.↗

Design and Manufacture of Wheels for A Dual-Mode (Manned - Automatic) Lunar Surface Roving Vehicle. Volume 1: Detailed Technical Report

The concept development, testing, evaluation, and the selection of a final wheel design concept for a dual-mode lunar surface vehicle (DLRV) is detailed. Four wheel configurations were fabricated (one open wheel and three closed wheel) (and subjected to a series of soft soil, mechanical, and endurance tests. Results show that the open wheel has lower draw-bar pull (slope climbing) capability in loose soil due to its higher ground pressure and tendency to dig in at high wheel slip. Endurance tests indicate that a double mesh, fully enclosed wheel can be developed to meet DLRV life requirements. There is, however, a 1.0 to 1.8 lb/wheel weight penalty associated with the wheel enclosure. Also the button cleats used as grousers for the closed-type wheels result in local stress concentration and early fatigue failure of the wire mesh. Load deflection tests indicate that the stiffness of the covered wheel increased by up to 50% after soil bin testing, due to increased friction between the fabric and the wire mesh caused by the sand. No change in stiffness was found for the open wheel. The single woven mesh open wheel design with a chevron tread is recommended for continued development

Source record↗

Insight to human and robotic parallels in spacecraft and space tool design

The parallels between human space activity and robotics and the role of their compatibility in the design of critical spacecraft elements are discussed with reference to current manned spacecraft programs, such as the Shuttle and Space Station Freedom. In particular, it is noted that the human variable may be the limiting factor with regards to repetition, fatigue, and possibly strength. This limiting factor serves as the natural constraint in the design of compatible interfaces. However, the mechanism or tool, not the capability of the robot, is constrained to human limits. Results of a limited test to study the robotic compatibility of the EVA-suitable connectors are reported.

Lewis, Ruthan↗

Context-Specific Adaptation of Gravity-Dependent Vestibular Reflex Responses

Stabilization of the eyes and head during body movements is important for maintaining balance and keeping the images of objects stationary on our retinas. Impairment of this ability can lead to disorientation and reduced performance in sensorimotor tasks such as piloting of spacecraft. In the absence of a normal earth gravity field, the dynamics of head stabilization, and the interpretation of vestibular signals that sense gravity and linear acceleration, are subject to change. Transitions between different gravitoinertial force environments - as during different phases of space flight - provide an extreme test of the adaptive mechanisms that maintain these reflexive abilities. It is vitally important to determine human adaptive capabilities in such a circumstance, so that we can know to what extent the sensorimotor skills acquired in one gravity environment will transfer to others. Our work lays the foundation for understanding these capabilities, and for determining how we can aid the processes of adaptation and readaptation. An integrated set of experiments addresses this issue. We use the general approach of adapting some type of reflexive eye movement (saccades, the angular vestibulo-ocular reflex (AVOR), the linear vestibulo-ocular reflex (LVOR)), or the vestibulo-collic reflex (VCR), to a particular change in gain or phase in one condition of gravitoiner-tial force, and adapting to a different gain or phase (or asking for no change) in a second gravitoinertial force condition, and then seeing if the gravitoinertial force itself - the context cue - can recall the previously learned adapted responses. The majority of the experiments in the laboratory use the direction of vertical gaze or the direction of gravity (head tilt) as the context cue. This allows us to study context-specificity in a ground-based setting. One set of experiments, to be performed in parabolic flight, specifically uses the magnitude of gravitoinertial force as a context cue. This is a much better analog of the situation encountered in space flight. Various experiments investigate the behavioral properties, neurophysiological basis, and anatomical substrate of context-specific learning mechanisms. We use otolith (gravity) signals as the contextual cue for switching between adapted states of the saccadic system, the angular and linear vestibulo-ocular reflexes, and the VCR. (By LVOR we mean the oculomotor response - horizontal, vertical, and torsional - to linear translation of the head and body.) We are studying the effect of context on adaptation of saccade gain, phase and gain of the AVOR and LVOR, on ocular counterrolling (OCR) in response to static head tilt, and on head/neck reflexes (VCR) in response to rotation in different orientations. Such research is particularly germane to potential problems of postural and oculomotor control upon exposure to different gravitational environments.

Shelhamer, Mark J.↗

High-Temperature Extensometry and PdCr Temperature-Compensated Wire Resistance Strain Gages Compared

A detailed experimental evaluation is underway at the NASA Lewis Research Center to compare and contrast the performance of the PdCr/Pt dual-element temperature-compensated wire resistance strain gage with that of conventional high-temperature extensometry. The advanced PdCr gage, developed by researchers at Lewis, exhibits desirable properties and a relatively small and repeatable apparent strain to 800 C. This gage represents a significant advance in technology because existing commercial resistance strain gages are not reliable for quasi-static strain measurements above approximately 400 C. Various thermal and mechanical loading spectra are being applied by a high-temperature thermomechanical uniaxial testing system to evaluate the two strain-measurement systems. This is being done not only to compare and contrast the two strain sensors, but also to investigate the applicability of the PdCr strain gage to the coupon-level specimen testing environment typically employed when the high-temperature mechanical behavior of structural materials is characterized. Strain measurement capabilities to 800 C are being investigated with a nickel-base superalloy, Inconel 100 (IN 100), substrate material and application to TMC's is being examined with the model system, SCS-6/Ti-15-3. Furthermore, two gage application techniques are being investigated in the comparison study: namely, flame-sprayed and spot welding.

Source record↗

High-Temperature Extensometry and PdCr Temperature-Compensated Wire Resistance Strain Gages Compared

A detailed experimental evaluation is underway at the NASA Lewis Research Center to compare and contrast the performance of the PdCr/Pt dual-element temperature-compensated wire resistance strain gage with that of conventional high-temperature extensometry. The advanced PdCr gage, developed by researchers at Lewis, exhibits desirable properties and a relatively small and repeatable apparent strain to 800 C. This gage represents a significant advance in technology because existing commercial resistance strain gages are not reliable for quasi-static strain measurements above approx. 400 C. Various thermal and mechanical loading spectra are being applied by a high-temperature thermomechanical uniaxial testing system to evaluate the two strain-measurement systems. This is being done not only to compare and contrast the two strain sensors, but also to investigate the applicability of the PdCr strain gage to the coupon-level specimen testing environment typically employed when the high-temperature mechanical behavior of structural materials is characterized. Strain measurement capabilities to 800 C are being investigated with a nickel-base superalloy, Inconel 100 (IN 100), substrate material and application to TMC's is being examined with the model system, SCS-6/Ti-15-3. Furthermore, two gage application techniques are being investigated in the comparison study: namely, flame-sprayed and spot welding. The apparent strain responses of both the weldable and flame-sprayed PdCr wire strain gages were found to be cyclically repeatable on both IN 100 and SCS-6/Ti-15-3 [0]_8. In general, each gage exhibited some uniqueness with respect to apparent strain behavior. Gages mounted on the IN 100 specimens tended to show a repeatable apparent strain within the first few cycles, because the thermal response of IN 100 was stable. This was not the case, however, for the TMC specimens, which typically required several thermal cycles to stabilize the thermal strain response. Thus, progressive changes in the apparent strain behavior were corroborated by the extensometer, which unlike the mounted gage can distinguish quantitative changes in the material's thermal strain response. One specimen was instrumented with both a fixed and floating gage. From the difference in output of these two gages, the thermal expansion strains were calculated. These data, which are given in the figure, show excellent agreement with the values measured by the high-temperature extensometry.

Source record↗

Acoustic method of damage sensing in composite materials

The use of acoustic emission and acousto-ultrasonics to characterize impact damage in composite structures is being performed on both graphite epoxy and kevlar bottles. Further development of the acoustic emission methodology to include neural net analysis and/or other multivariate techniques will enhance the capability of the technique to identify failure mechanisms during fracture. The acousto-ultrasonics technique will be investigated to determine its ability to predict regions prone to failure prior to the burst tests. The combination of the two methods will allow for simple nondestructive tests to be capable of predicting the performance of a composite structure prior to being placed in service and during service.

Workman, Gary L.↗

Technical Capability Upgrades to the NASA Langley Research Center 6 ft. by 6 ft. Thermal Vacuum Chamber

The 6 ft. by 6 ft. thermal vacuum chamber (TVAC), housed in Building 1250 at the NASA Langley Research Center (LaRC), and managed by the Systems Integration and Test Branch within the Engineering Directorate, has undergone several significant modifications to increase testing capability, safety, and quality of measurements of articles under environmental test. Significant modifications include: a new nitrogen thermal conditioning unit for controlling shroud temperatures from -150degC to +150degC; two horizontal auxiliary cold plates for independent temperature control from -150degC to +200degC; a suite of contamination monitoring sensors for outgassing measurements and species identification; signal and power feed-throughs; new pressure gauges; and a new data acquisition and control commanding system including safety interlocks. This presentation will provide a general overview of the LaRC 6 ft. by 6 ft. TVAC chamber, an overview of the new technical capabilities, and illustrate each upgrade in detail, in terms of mechanical design and predicted performance. Additionally, an overview of the scope of tests currently being performed in the chamber will be documented, and sensor plots from tests will be provided to show chamber temperature and pressure performance with actual flight hardware under test.

Thornblom, Mark N.↗

Test Bed for Investigating Anomalous Pump Behavior in a Single Phase Mechanically Pumped Flow Loop and Lessons Learned

NASA’s Europa Clipper mission is tasked with investigating the habitability of this icy moon of Jupiter and determining if it is capable of supporting life. The suite of powerful instruments necessary for this mission, combined with the harsh environment, require an elaborate single phase, mechanically pumped flow loop (MPFL) to redistribute waste heat around the spacecraft, thus minimizing energy requirements and avoiding the need for constant heating of the propulsion tanks. At the heart of this MPFL is a pump which will circulate fluid for the entirety of the 12-year mission; however, during initial qualification testing, anomalous behavior raised serious concerns regarding the pump and system design. Due to the critical nature of the pump, a major investigation was launched to evaluate the pump, system design, and the testing methodology employed to investigate this anomaly. This investigation resulted in a highly detailed analysis of the test loop, revised procedures, and the isolation/removal of variables impacting the quality of the observed pump behavior. The resulting test loop permitted comprehensive monitoring of the pump in the MPFL, including: flow rate, inlet and outlet static pressures, temperature, power consumption, and pump speed. Additionally, the investigation of the anomaly revealed several key lessons learned and helped institute a new set of best practices for future MPFL tests.

Miers, Collier↗