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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Femtosecond damage experiments and modeling of broadband mid-infrared dielectric diffraction gratings

High peak and average power lasers with high wall-plug efficiency, like the Big Aperture Thulium (BAT) laser, have garnered tremendous attention in laser technology. To meet the requirements of the BAT laser, we have developed low-dispersion reflection multilayer dielectric (MLD) gratings suitable for compression of high-energy pulses for operations at 2 micron wavelength. We carried out 10000-on-1 damage tests to investigate the fluence damage thresholds of the designed MLD gratings and mirrors, which were found between 100-230 mJ/cm 2 . An ultrashort pulsed laser (FWHM = 53 fs, λ = 1.9 μ m) operating at 500 Hz was used in the serpentine raster scans. The atomic force microscope images of the damage sites show blister formation of the underlying layers at lower fluences but ablation of the grating pillars at higher fluences. We simulated the dynamic electronic excitation in the MLD optics with a finite-difference in the time domain approach in 2D. The simulation results agree well with the LIDT measurements and the observed blister formation. This model is able to evaluate the absolute LIDT of MLD gratings.

42 ENGINEERING↗
NASA NTRS2013

Multi-Dimensional Damage Detection for Surfaces and Structures

Current designs for inflatable or semi-rigidized structures for habitats and space applications use a multiple-layer construction, alternating thin layers with thicker, stronger layers, which produces a layered composite structure that is much better at resisting damage. Even though such composite structures or layered systems are robust, they can still be susceptible to penetration damage. The ability to detect damage to surfaces of inflatable or semi-rigid habitat structures is of great interest to NASA. Damage caused by impacts of foreign objects such as micrometeorites can rupture the shell of these structures, causing loss of critical hardware and/or the life of the crew. While not all impacts will have a catastrophic result, it will be very important to identify and locate areas of the exterior shell that have been damaged by impacts so that repairs (or other provisions) can be made to reduce the probability of shell wall rupture. This disclosure describes a system that will provide real-time data regarding the health of the inflatable shell or rigidized structures, and information related to the location and depth of impact damage. The innovation described here is a method of determining the size, location, and direction of damage in a multilayered structure. In the multi-dimensional damage detection system, layers of two-dimensional thin film detection layers are used to form a layered composite, with non-detection layers separating the detection layers. The non-detection layers may be either thicker or thinner than the detection layers. The thin-film damage detection layers are thin films of materials with a conductive grid or striped pattern. The conductive pattern may be applied by several methods, including printing, plating, sputtering, photolithography, and etching, and can include as many detection layers that are necessary for the structure construction or to afford the detection detail level required. The damage is detected using a detector or sensory system, which may include a time domain reflectometer, resistivity monitoring hardware, or other resistance-based systems. To begin, a layered composite consisting of thin-film damage detection layers separated by non-damage detection layers is fabricated. The damage detection layers are attached to a detector that provides details regarding the physical health of each detection layer individually. If damage occurs to any of the detection layers, a change in the electrical properties of the detection layers damaged occurs, and a response is generated. Real-time analysis of these responses will provide details regarding the depth, location, and size estimation of the damage. Multiple damages can be detected, and the extent (depth) of the damage can be used to generate prognostic information related to the expected lifetime of the layered composite system. The detection system can be fabricated very easily using off-the-shelf equipment, and the detection algorithms can be written and updated (as needed) to provide the level of detail needed based on the system being monitored. Connecting to the thin film detection layers is very easy as well. The truly unique feature of the system is its flexibility; the system can be designed to gather as much (or as little) information as the end user feels necessary. Individual detection layers can be turned on or off as necessary, and algorithms can be used to optimize performance. The system can be used to generate both diagnostic and prognostic information related to the health of layer composite structures, which will be essential if such systems are utilized for space exploration. The technology is also applicable to other in-situ health monitoring systems for structure integrity.

Williams, Martha↗
NASA NTRS1989

Plating Repair Of Nickel-Alloy Pressure Vessels

Procedure for localized electrodeposition of nickel enables repair of small damaged nickel-based pressure vessels. Electrodeposition restores weakened areas of vessel wall to at least their former strength.

Ricklefs, Steve K.↗
NASA NTRS2011

Burner Rig with an Unattached Duct for Evaluating the Erosion Resistance of Thermal Barrier Coatings

Extensive computational fluid dynamics (CFD) modeling backed by experimental observation has demonstrated the feasibility of using an unattached duct to increase the velocity and spatial spread of erodent particles exiting from a burner rig. It was shown that gas velocity and temperature are mostly retained if the inner diameter of the unattached duct equaled the exit diameter of the burner rig nozzle. For particles having a mean diameter of 550 millimeters, the modeled velocity attained at a distance 2.0 in. (50.8 millimeters) beyond the exit of a 12 in. (305 millimeters) long duct was approximately twice as large as the velocity the same distance from the nozzle when the duct was not present. For finer particles, the relative enhancement was somewhat less approximately 1.5 times greater. CFD modeling was also used to guide the construction of a device for slowing down the velocity of the particles being injected into the burner rig. This device used a simple 45 degree fitting to slow the particle velocity in the feed line from 20 meters per second, which is in the range needed to convey the particles, to about 3 meters per second just as they are injected into the burner. This lower injection velocity would lessen the severity of the collision of large particles with the wall of the burner liner opposite the injection port, thereby reducing potential damage to the burner liner by high-velocity particles.

Miller, Robert A.↗
NASA NTRS1990

Wrapped Wire Detects Rupture Of Pressure Vessel

Simple, inexpensive technique helps protect against damage caused by continuing operation of equipment after rupture or burnout of pressure vessel. Wire wrapped over area on outside of vessel where breakthrough most likely. If wall breaks or burns, so does wire. Current passing through wire ceases, triggering cutoff mechanism stopping flow in vessel to prevent further damage. Applied in other situations in which pipes or vessels fail due to overpressure, overheating, or corrosion.

Hunt, James B.↗
NASA NTRS1991

Hypervelocity impact response of aluminum multi-wall structures

The results of an investigation in which the perforation resistance of aluminum multiwall structures is analyzed under a variety of hypervelocity impact loading conditions are presented. A comparative analysis of the impact damage in structural systems with two or more bumpers and the damage in single-bumper systems of similar weight is performed to determine the advantages and disadvantages of employing more than one bumper in structural wall systems for long-duration spacecraft. A significant increase in protection against perforation by hypervelocity projectiles can be achieved if a single bumper is replaced by two bumpers of similar weight while the total wall spacing is kept constant. It is found that increasing the number of bumpers beyond two while keeping the total stand-off distance constant does not result in a substantial increase in protection over that offered by two bumpers of similar weight.

Schonberg, William P.↗
NASA NTRS2019

A Meteoroid Handbook for Aerospace Engineers and Managers

At the beginning of the Space Age, spacecraft designers and mission planners were very concerned about meteoroids. They envisioned vehicles being ripped to pieces by streams of fast-moving space rocks, a notion promoted by the science fiction novels and movies of the time. The reality is, of course, different—the meteoroid streams that produce meteor showers are not dense by laypeople’s standards, having spatial densities of just a handful of particles per cubic kilometer, even during meteor outbursts. The ever-present, diffuse, sporadic background, which produces observed meteor rates of only 5 to 8 meteors per hour, makes up 90% of the meteoroid risk to spacecraft that spend at least a year in low Earth orbit (LEO), whereas the visually spectacular but short-lived meteor showers make up the other 10%. Still, meteoroids do pose a significant risk to spacecraft. At Earth, they can travel 12 to 72 km/s. These high speeds cause even small meteoroids to carry enormous kinetic energy, making them capable of doing serious damage to spacecraft. For example, a 1-mm-diameter meteoroid moving at 25 km/s can inflict the same damage as a bullet fired from a 0.357 Magnum pistol. An exterior wire can be severed by a 0.1-mm (100 mm) particle, a spacesuit can be penetrated by a 0.5-mm meteoroid, and an unshielded pressure wall (like the cabin of the Space Shuttle) can be perforated by centimeter-sized particles. Along with mechanical damage, meteoroids can also cause other types of spacecraft anomalies. Meteoroids can transfer their momentum to the spacecraft, which can destroy or damage equipment such as shunt resistors and charge-coupled device (CCD) detectors with a clear view of space. Meteoroid impacts can also generate plasma. The impact vaporizes material, producing a crater and an expanding plasma, which can in turn provide a conductive path for any charge accumulated on the spacecraft. This effect is thought to be responsible for the demise of a satellite in one case: the OLYMPUS communications satellite was sent tumbling out of control during the 1993 Perseid outburst, and a Perseid meteoroid strike has been posited as a possible cause (McDonnell et al. 1993; Caswell et al. 1995). Other researchers have suggested that very fast meteoroids could produce a small electromagnetic pulse capable of disrupting spacecraft function (Close et al. 2010).

Moorhead, A.↗
DOE OSTI2023

Earthquake-induced impact of base-isolated buildings: theory, numerical modeling, and design solutions

Earthquake shaking more intense than that used to size the horizontal clearance between a base–isolated building and near–rigid perimeter moat wall will result in hard impact, producing high–frequency, high–amplitude acceleration response in the structure and supported equipment. Herein this paper provides a design solution for the damaging effects of hard impact by installing a compliant engineered element in the load path between the base–isolated building and the moat wall, resulting in soft impact and a much smaller acceleration response. The engineered element assumed herein is a commercial–off–the–shelf marine fender with mechanical properties determined by physical testing. The attachment of a flexible engineered element, with well–defined stiffness and damping, to a near–rigid moat wall, simplifies the numerical modeling of the building–moat wall system and eliminates the need to bound the lateral stiffness of the wall for impact calculations. The simple model of the engineered element can be implemented in commercial finite element codes. Theory is developed for two–sided impact of a single–degree–of–freedom oscillator. Analytical solutions are derived for the shifted first–mode frequency of the impacted oscillator and for its free–vibration response. The shifted first–mode frequency is a function of the composite lateral stiffness of the isolator–engineered element assembly and its earthquake–induced displacement. Local peaks in the spectral response of the impacted oscillator form at odd integer multiples of the shifted first–mode frequency. The analytical solutions can be used to verify, in part, the numerical model used for impact analysis.

42 ENGINEERING↗
NASA NTRSDate not supplied

Sensitivity Analysis of Geometric Imperfection Sources in Honeycomb Cores on Flatwise Compression Behavior

Manufacturing aluminum honeycomb core material using the expansion process can lead to geometric imperfections in the cellular core structures. These imperfections arise due to irregularities introduced in the initial foil bonding, variations in foil thickness, and residual stresses from manufacturing processes. Such geometric imperfections include cell shape distortions, cell wall waviness, non-uniform cell wall thickness, and variability in the shape and height of the adhesive fillet. Imperfections in the cell walls negatively affect the transverse compression and shear strength, while also reducing the resistance to damage under impact loads. Previous work presented the identification and quantification of these manufactured imperfections using high resolution X-ray computed tomography (CT) scans of honeycomb cores in co-cured composite sandwich panels. The present paper presents a sensitivity analysis of individual components of the sources of geometric imperfections on the flatwise compression of aluminum honeycomb cores. The initial geometric imperfections in honeycomb cells are decomposed into three components, namely cell shape (cell edge length and cell internal angles) in-plane cell wall waviness, and out-of-plane waviness along the core thickness. A sensitivity analysis is conducted using finite element (FE) models of the decomposed imperfections to understand how each component affects compression failure.

aluminum honycomb↗
NASA NTRS1994

Detection of Cracks at Welds in Steel Tubing Using Flux Focusing Electromagnetic Probe

The inspection of weldments in critical pressure vessel joints is a major concern in the nuclear power industry. Corrosive environments can speed the fatigue process and access to the critical area is often limited. Eddy current techniques have begun to be used to help overcome these obstacles [1]. As direct contact and couplants are not required, remote areas can be inspected by simply snaking an eddy current coil into the intake tube of the vessel. The drawback of the eddy current method has been the high sensitivity to small changes in the conductivity and permeability of the test piece which are known to vary at weldments [1]. The flaw detection mechanism of the flux focusing electromagnetic probe can help alleviate these difficulties and provide a unique capability for detecting longitudinal fatigue cracks in critical tube structures. The Flux Focusing Electromagnetic Flaw Detector, originally invented for the detection of fatigue and corrosion damage in aluminum plates [2-3], has been adapted for use in testing steel tubing for longitudinal fatigue cracks. The modified design allows for the probe to be placed axisymmetrically into the tubing, inducing eddy currents in the tube wall. The pickup coil of the probe is fixed slightly below the primary windings and is rotated 90 so that its axis is normal to the tube wall. The magnetic flux of the primary coil is focused through the use of ferromagnetic material so that in the absence of fatigue damage there will be no flux linkage with the pickup coil. The presence of a longitudinal fatigue crack will cause the eddy currents induced in the tube wall to flow around the flaw and directly under the pickup coil. The magnetic field associated with these currents will then link the pickup coil and an unambiguous increase in the output voltage of the probe will be measured. The use of the flux focusing electromagnetic probe is especially suited for the detection of flaws originating at or near tube welds. The probe is shown to discriminate against signals due solely to the weld joint so that flaw signals are not hidden in the background in these locations. Experimental and finite element modeling results are presented for the flaw detection capabilities of the probe in stainless steel tubes.

Wincheski, Buzz↗
DOE OSTI2021

Nondestructive Evaluation (NDE) of Cable Moisture Exposure using Frequency Domain Reflectometry (FDR)

This Pacific Northwest National Laboratory (PNNL) milestone report assesses the capability of frequency domain reflectometry (FDR) to determine electrical cable submergence using PNNL’s Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable/motor test bed. This work includes a review of relevant literature as well as experimental tests. Nuclear power facilities have experienced various electrical cable failures related to water exposure. The current industry response involves actions to de-water cable vaults, manholes, and other cable locations. These efforts require considerable expenditure of resources, which makes it desirable for the industry to have information on cable condition and history regarding their submergence and water exposure (Mantey 2012). Two tests that are gaining favor within the nuclear industry are time-domain reflectometry (TDR) and FDR. These are low-voltage nondestructive tests that can be applied at a cable end. Testing from the cable end is important because local inspection along the cable length is very difficult due to cables being routed within trays, conduits, underground, and through walls. Both TDR and FDR techniques have been shown to locate cable insulation damage due to thermal, radiation, and mechanical damage. FDR measurements are also more sensitive than TDR to temperature changes, low-bend radius bends, and cable contact with various materials, including conductive materials like steel and water. This work evaluates the feasibility to extend FDR testing to characterizing whether an electrical cable is submerged or not and where it may be submerged using PNNL’s ARENA cable/motor test bed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1966

Bench vise adapter grips tubing securely and safely

Plastic self-compressing adapter with grooves, attached to the jaws of a bench vise, secures thin-wall tubing vertically or horizontally during cutting and flaring operations without marring or damaging it. Magnets incorporated in both sections of the adapter prevent detachment from the jaws when the vise is opened.

Howland, B. T.↗
NASA NTRS2021

Demonstration of Multilayer Insulation, Vapor Cooling of Structure, and Mass Gauging for Large Scale Upper Stages: Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) Final Report

Testing was completed on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) between August 2019 and January 2020. SHIIVER was designed to be a test bed for the scaling of cryogenic fluid management technologies as applied to large upper stages and long duration in-space stages. The hardware consists of a 4 meter diameter stainless steel tank, structural skirts supporting the tank in the aft direction, and an aluminum forward skirt with vapor cooling channels bolted to it. The initial testing of the SHIIVER hardware was with liquid hydrogen and liquid nitrogen (as a substitute fluid for liquid oxygen and liquid methane) and sought to demonstrate the use of boil-off vapor to intercept heat on a structural skirt, multilayer insulation (MLI) on the tank domes, and the radio frequency mass gauge (RFMG). Testing was completed in four stages: a baseline thermal vacuum test prior to installation of the MLI, a thermal vacuum test after the MLI installation, a reverberant acoustic test, and a subsequent thermal vacuum test to verify that no damage occurred during the reverberant acoustic testing. Each thermal vacuum test with chamber wall at ambient temperature and vacuum level in the 10-6 torr range was conducted continuously between approximately 90% full and 25% full. Test results showed that the vapor cooling reduced the heat load to the tank by approximately 10%, but the boil-off by less than 3% at 50% full with no MLI on the domes. It reduced the heat load to the tank by approximately 10%, but the boil-off was essentially unchanged at 50% full whether or not vapor cooling was operational with MLI on the domes. The MLI reduced the heat load to the tank by approximately 40% at all fill levels, but the boil-off by approximately 25% at 90% full and 45% below 65% full. The RFMG performed well over all fill ranges, and several RF tank modes were used to gauge the mass of fluid in the tank. SHIIVER was then exposed to an acoustic environment of 147 dB OASPL (overall sound pressure level) in a reverberant chamber. The acoustic environment and profile envelopes the upper stage internal acoustic level of several different modern launch vehicles. No structural or thermal performance changes were observed as a result of acoustic testing. Final thermal vacuum testing after the acoustic testing showed no degradation to the MLI due to the acoustic environment as measured via system heat loads.

SHIIVER↗
NASA NTRSDate not supplied

Summary of Testing Results for the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Testing was completed on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) between August 2019 and January 2020. SHIIVER was designed to be a test bed for the scaling of cryogenic fluid management technologies as applied to large upper stages and long duration in-space stages. The baseline SHIIVER design consists of uninsulated structural skirts attached to a propellant tank insulated with polyurethane Spray-On Foam Insulation (SOFI). The initial testing of the SHIIVER hardware was with liquid hydrogen and sought to demonstrate the use of boil-off vapor to intercept heat on a structural skirt, multilayer insulation (MLI) on the tank domes, and the radio frequency mass gauge (RFMG). Testing was completed in four stages: a baseline thermal vacuum test prior to installation of the MLI on the tank domes, a thermal vacuum test after the MLI installation, a reverberant acoustic test, and a subsequent thermal vacuum test to verify that no damage occurred during the reverberant acoustic testing. Each thermal vacuum test with chamber wall at ambient temperature and vacuum level in the 10-6 torr range was conducted continuously between approximately 90% full and 25% full. Test results showed that the vapor cooling reduced the heat load to the tank by approximately 10%, but the boil-off by less than 3% at 50% full, with and without MLI installed on the domes. The MLI installed on the domes reduced the heat load to the tank by approximately 40% at all fill levels, but the boil-off by approximately 25% at 90% full and 45% below 65% full. The RFMG performed well over all fill ranges, and several RF tank modes were used to gauge the mass of fluid in the tank. SHIIVER was then exposed to an acoustic environment of 147 dB OASPL (overall sound pressure level) in a reverberant chamber. The acoustic environment envelopes the upper stage internal acoustic level of several different modern launch vehicles. No structural or thermal performance changes were observed after exposure to the acoustic environment. Final thermal vacuum testing after the acoustic testing showed no degradation to the MLI due to the acoustic environment as measured via system heat loads

SHIIVER↗
NASA NTRS1990

Characterization of space station multilayer insulation damage due to hypervelocity space debris impact

Four main tasks were accomplished. The first three tasks were related to the goal of measuring the degradation of the insulating capabilities of Space Station multilayer insulation (MLI) due to simulated space debris impacts at hypervelocities. The last task was associated with critically reviewing a Boeing document on the fracture characteristics of the Space Station pressure wall when subjected to a simulated hypervelocity space debris impact. In Task 1, a thermal test procedure for impact damaged MLI specimens was written. In Task 2, damaged MLI specimens were prepared. In Task 3, a computer program was written to simulate MLI thermal tests. In Task 4, the author reviewed a Boeing document describing hypervelocity impact testing on biaxially stressed plates.

Rule, William Keith↗
NASA NTRS2005

Optical Sensing using Fiber Bragg Gratings for Monitoring Structural Damage in Composite Over-Wrapped Vessels

Composite Over-Wrap Vessels are widely used in the aerospace community. They are made of thin-walled bottles that are over wrapped with high strength fibers embedded in a matrix material. There is a strong drive to reduce the weight of space borne vehicles and thus pushes designers to adopt COPVs that are over wrapped with graphite fibers embedded in its epoxy matrix. Unfortunately, this same fiber-matrix configuration is more susceptible to impact damage than others and to make matters worse; there is a regime where impacts that damage the over wrap leave no visible scar on the COPV surface. In this paper FBG sensors are presented as a means of monitoring and detecting these types of damage. The FBG sensors are surface mounted to the COPVs and optically interrogated to explore the structural properties of these composite pressure vessels. These gratings optically inscribed into the core of a single mode fiber are used as a tool to monitor the stress strain relation in the composite matrix. The response of these fiber-optic sensors is investigated by pressurizing the cylinder up to its burst pressure of around 4500 psi. A Fiber Optic Demodulation System built by Blue Road Research, is used for interrogation of the Bragg gratings.

Grant, Joseph↗
NASA NTRS1998

Orbital Debris Impact Damage to Reusable Launch Vehicles

In an effort by the National Aeronautics and Space Administration (NASA), hypervelocity impact tests were performed on thermal protection systems (TPS) applied on the external surfaces of reusable launch vehicles (RLV) to determine the potential damage from orbital debris impacts. Three TPS types were tested, bonded to composite structures representing RLV fuel tank walls. The three heat shield materials tested were Alumina-Enhanced Thermal Barrier-12 (AETB-12), Flexible Reusable Surface Insulation (FRSI), and Advanced Flexible Reusable Surface Insulation (AFRSI). Using this test data, predictor equations were developed for the entry hole diameters in the three TPS materials, with correlation coefficients ranging from 0.69 to 0.86. Possible methods are proposed for approximating damage occurring at expected orbital impact velocities higher than tested, with references to other published work.

Robinson, Jennifer H.↗
DOE OSTI2023

Supplemental Structural Analyses Used in Support of Certification of the Defense Programs Package 3

The Defense Programs Package (DPP)-3 is to be certified by the National Nuclear Security Administration (NNSA) Packaging and Transportation Division (PTD). Certification is based on successful physical testing of the package, and six certification test units (CTUs) have been subjected to the normal conditions of transport (NCT) and hypothetical accident conditions (HAC) outlined in Title 10 of the Code of Federal Regulations Part 71 (10 CFR 71). During regulatory testing of one of the CTUs, the drum lid closure bolt closest to the impact surface failed during the HAC 30-ft side drop. One of the testing goals for this CTU was to minimize the thermal pathway from the drum exterior shell to the containment vessel (CV) flange and O-rings, leading to the maximum damage scenario in preparation for thermal testing at 1475 °F. Therefore, the puncture bar impact proceeded as originally planned by striking the side wall of the package exterior closest to the location of the CV flange. This puncture bar impact did not attempt to exploit the region of the failed drum lid closure bolt to potentially cause more damage to the package. After the conclusion of regulatory testing, the DPP-3 package finite element model was used to numerically evaluate the effects of puncture bar impacts to the drum exterior in the vicinity of the failed drum lid closure bolt to further demonstrate the robustness of the DPP-3 design. Three alternate puncture bar impact locations and orientations were evaluated to demonstrate that these puncture bar impacts would not substantially reduce the effectiveness of the DPP-3 packaging. This paper describes the supplemental finite element models performed and structural analysis results that demonstrate the alternate HAC 40-in. puncture bar impact tests would have no deleterious effect on the performance of the DPP-3.

Sakalaukus Jr., Peter J.↗