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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 1,549 records · Page 86
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Size effect characteristics and influences on fatigue behavior of laser powder bed fusion of thin wall GRCop-42 copper alloy

Size effects, influencing a material's strength, elongation, fatigue limit, and longevity, depend on the operative and dominant deformation and failure mechanisms. This study explores the size effects in additive manufactured (AM) GRCop-42 (Cu-4at%Cr-2at%Nb) thin wall structures fabricated via laser-powder bed fusion (L-PBF) and their impact on fatigue life. The influence of internal defects and surface topography on the fatigue life of specimens in both as-built and hot isostatic pressed (HIP) conditions across different thicknesses is investigated. Where micro-computed tomography (μCT) was used to quantify the internal porosity of as-built, pristine HIP'd, and fatigued HIP'd specimens, and laser microscopy was employed to quantify the surface topography of specimens prior to fatigue. Additionally, quasi-static tests were used to establish baseline mechanical properties (i.e. yield strength (YS), ultimate tensile strength (UTS), and elongation) to frame fatigue testing conditions. Results indicate a significant enhancement in fatigue life for HIP'd specimens for both thicknesses, with internal defects depicting a greater impact than surface topography. Furthermore, fractographic analysis suggests that thicker specimens exhibit higher resistance to crack propagation during fatigue testing in the absence of substantial porosity. Thus, the size effects observed on the fatigue life of L-PBF GRCop-42 appears to be dominated by internal defects.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fatigue of additive manufactured Ti-6Al-4V, Part I: The effects of powder feedstock, manufacturing, and post-process conditions on the resulting microstructure and defects

Additive manufacturing provides an appealing means to process titanium alloy parts with new levels of conformability, complexity, and weight reduction. However, due to the heating/cooling rates and heat transfer associated with directed energy source material processing, the as-built AM parts contain unique material and microstructural features. In order to confidently manufacture fatigue critical additive manufactured (AM) Ti-6Al-4V parts, a better understanding of the interrelationships between powder feedstock, AM processes, structure of the processed parts, their resulting mechanical properties, and their performance under realistic loadings is necessary. Part I of this two-part collection focuses on the powder-process-structure relationships and how powder feedstock, manufacturing, and post-processing conditions can affect the microstructure and defect features that ultimately contribute to the fatigue performance of Ti-6Al-4V parts. The material and physical phenomena inherent to the AM process of Ti-6Al-4V are discussed in detail and related to the phase composition/structure, grain morphology, surface characteristics, defect size/distribution, and post-process treatments available for AM parts. This investigation is the foundation for the structure-performance relationships that will be covered in detail in Part II.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure, precipitates and hardness of selectively laser melted AlSi10Mg alloy before and after heat treatment

Highlights: • Microstructural characterization of SLM AlSi10Mg alloy and comparison with cast and powder AlSi10Mg • Effect of solution heat treatment and aging on the hardness change of SLM AlSi10Mg alloy • Evolution of strengthening precipitates and Fe-rich intermetallics in SLM AlSi10Mg during heat treatment - Abstract: The microstructure and precipitates within selectively laser melted (SLM) AlSi10Mg alloys in the as-built state and after T6 heat treatment were examined and correlated to the hardness evolution. The as-built alloy exhibited columnar patterns perpendicular to the build-direction and fish-scale pattern along the build-direction originating from the melt pool. The microstructure consisted of fine Al cells and eutectic structure with up to 4 μm in size. Tiny needle-like Si particles with highly faulted structure were identified within the Al cells and formed semi-coherent interface with the matrix. Nanoscale Si particles and π-Al{sub 8}Si{sub 6}Mg{sub 3}Fe phase were observed to segregate along the cell and grain boundary. Solution heat treatment (SHT) at 520 °C resulted in the dissolution of Al cellular microstructure. Precipitation and coarsening of the Si particles occurred, while the aspect ratio of Si particles remained nearly constant. The π-Al{sub 8}Si{sub 6}Mg{sub 3}Fe phase decomposed into plate-shaped β-Al{sub 5}SiFe. The artificial aging (AA) at 160 °C did not alter the microstructure but led to the formation of metastable Mg{sub 2}Si precipitates. The GP zones and β″ were identified through transmission electron microscopy after AA of 6 h, and β″ existed up to AA of 24 h. The hardness decreased after SHT due to the coarsening of the microstructure and reduced solid solution hardening. Hardness reached maximum magnitude after AA of 6–10 h due to the precipitation hardening, and remained relatively unchanged up to AA of 24 h. Microstructure and/or hardness of gas atomized powders and bulk cast AlSi10Mg alloys were also examined as references.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Three-dimensional ultrasonic imaging of concrete elements using different SAFT data acquisition and processing schemes

Ultrasonic testing systems using transducer arrays and the SAFT (Synthetic Aperture Focusing Technique) reconstruction allow for imaging the internal structure of concrete elements. At one-sided access, three-dimensional representations of the concrete volume can be reconstructed in relatively great detail, permitting to detect and localize objects such as construction elements, built-in components, and flaws. Different SAFT data acquisition and processing schemes can be utilized which differ in terms of the measuring and computational effort and the reconstruction result. In this contribution, two methods are compared with respect to their principle of operation and their imaging characteristics. The first method is the conventional single-channel SAFT algorithm which is implemented using a virtual transducer that is moved within a transducer array by electronic switching. The second method is the Combinational SAFT algorithm (C-SAFT), also named Sampling Phased Array (SPA) or Full Matrix Capture/Total Focusing Method (TFM/FMC), which is realized using a combination of virtual transducers within a transducer array. Five variants of these two methods are compared by means of measurements obtained at test specimens containing objects typical of concrete elements. The automated SAFT imaging system FLEXUS is used for the measurements which includes a three-axis scanner with a 1.0 m × 0.8 m scan range and an electronically switched ultrasonic array consisting of 48 transducers in 16 groups. On the basis of two-dimensional and three-dimensional reconstructed images, qualitative and some quantitative results of the parameters image resolution, signal-to-noise ratio, measurement time, and computational effort are discussed in view of application characteristics of the SAFT variants.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

The Past, Present and Future of Structural Health Monitoring: An Overview of Three Ages

This paper presents an overview of the discipline of structural health monitoring (SHM), organised in terms of three proposed ages. The first age is delineated by the prehistory of SHM and the period where nondestructing testing methods evolved into an organised set of principles built upon physics-based models; this age ended when the model-based approaches reached an impasse in terms of their ability to properly deal with real-world problems. The second age of SHM began with a transition to data-based methods based on statistical pattern recognition, which provided a holistic approach to SHM problems for the first time. This age arguably ended when the methods foundered in situations where the necessary training data were scarce. It is argued here that the third age began with the development of population-based SHM, which has been designed to overcome the problem of data scarcity. As there is very limited space in a single article to provide a comprehensive overview, an appendix has been provided here that gives a very systematic bibliography of SHM reviews—a meta-bibliography.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Easing the Control System Application Development for CMS Detector Control System with Automatic Production Environment Reproduction

The Detector Control System (DCS) is one of the main pieces involved in the operation of the Compact Muon Solenoid (CMS) experiment at the LHC. The system is built using WinCC Open Architecture (WinCC OA) and the Joint Controls Project (JCOP) framework which was developed on top of WinCC at CERN. Following the JCOP paradigm, CMS has developed its own framework which is structured as a collection of more than 200 individual installable components each providing a different feature. Everyone of the systems that the CMS DCS consists of is created by installing a different set of these components. By automating this process, we are able to quickly and efficiently create new systems in production or recreate problematic ones, but also, to create development environments that are identical to the production ones. This latter one results in smoother development and integration processes, as the new/reworked components are developed and tested in production-like environments. Moreover, it allows the central DCS support team to easily reproduce systems that the users/developers report as being problematic, reducing the response time for bug fixing and improving the support quality.

43 PARTICLE ACCELERATORS↗
NASA NTRS1976

Design principles of a rotating medium speed mechanism

Design principles of a medium speed mechanism (MSM) are presented, including discussion on the relative merits of beryllium and aluminium as structural materials. Rotating at a speed of 60 rpm, the application envisaged for the MSM was as a despin bearing for the despun platform or despun antenna of a spin stabilized satellite. The MSM was built and tested to qualification level and is currently undergoing real time life testing.

Hostenkamp, R. G.↗
NASA NTRS1979

Feasibility Study of Graphite Epoxy Antenna for a Microwave Limb Sounder Radiometer (MLSR)

Results are presented of a feasibility study to design graphite epoxy antenna reflectors for a jet propulsion laboratory microwave limb sounder instrument (MLSR). Two general configurations of the offset elliptic parabolic reflectors are presented that will meet the requirements on geometry and reflector accuracy. The designs consist of sandwich construction for the primary reflectors, secondary reflector support structure and cross-tie members between reflector pairs. Graphite epoxy materials of 3 and 6 plies are used in the facesheets of the sandwich. An aluminum honeycomb is used for the core. A built-in adjustment system is proposed to reduce surface distortions during assembly. The manufacturing and environmental effects are expected to result in surface distortions less than .0015 inch and pointing errors less than .002 degree.

Source record↗
NASA NTRS1989

Dynamic analysis of flexible mechanical systems using LATDYN

A 3-D, finite element based simulation tool for flexible multibody systems is presented. Hinge degrees-of-freedom is built into equations of motion to reduce geometric constraints. The approach avoids the difficulty in selecting deformation modes for flexible components by using assumed mode method. The tool is applied to simulate a practical space structure deployment problem. Results of examples demonstrate the capability of the code and approach.

Wu, Shih-Chin↗
NASA NTRS2009

Electrostatic Switching in Vertically Oriented Nanotubes for Nonvolatile Memory Applications

We have demonstrated electrostatic switching in vertically oriented nanotubes or nanofibers, where a nanoprobe was used as the actuating electrode inside an SEM. When the nanoprobe was manipulated to be in close proximity to a single tube, switching voltages between 10 V - 40 V were observed, depending on the geometrical parameters. The turn-on transitions appeared to be much sharper than the turn-off transitions which were limited by the tube-to-probe contact resistances. In many cases, stiction forces at these dimensions were dominant, since the tube appeared stuck to the probe even after the voltage returned to 0 V, suggesting that such structures are promising for nonvolatile memory applications. The stiction effects, to some extent, can be adjusted by engineering the switch geometry appropriately. Nanoscale mechanical measurements were also conducted on the tubes using a custom-built anoindentor inside an SEM, from which preliminary material parameters, such as the elastic modulus, were extracted. The mechanical measurements also revealed that the tubes appear to be well adhered to the substrate. The material parameters gathered from the mechanical measurements were then used in developing an electrostatic model of the switch using a commercially available finite-element simulator. The calculated pull-in voltages appeared to be in agreement to the experimentally obtained switching voltages to first order.

plasma-enhanced chemical vapor deposition (PECVD).↗
NASA NTRSDate not supplied

TriTruss Packaging and Deployment Trade Study

An architecture and feasibility study of next generation In-Space Assembled Telescopes (iSAT) concluded that robotic in-space assembly of modular components is necessary to enable large (>15-meter diameter) primary apertures. The iSAT study recommended that the foundational structure be assembled from modular TriTruss modules that are packaged for launch, deployed on-orbit and robotically assembled into the final configuration. This paper will describe and summarize the results of a trade study that investigated viable concept of operations (ConOps) for the packaging and deployment (P&D) of individual planar TriTruss modules that could be assembled to form a large aperture iSAT. The ideal TriTruss P&D concept is defined as one that: allows for efficient packaging; has sufficient geometric versatility to be launch vehicle independent; provides a stiff and lightweight structure; has low mechanical complexity; and has component modularity. The P&D concept should allow for prelaunch subsystem or utility integration if required. The concept would be kinematically simple and be robotically deployed using a minimum number of specialized tools. In this first phase of an ongoing more comprehensive trade study, concepts were proposed and then evaluated based on initial metrics representing features of an ideal P&D concept. The P&D concepts evaluated are categorized as: core collapse, face collapse, and erectable structures. Sub-scale models were constructed to help understand the kinematics and mechanical complexity required to enable P&D. Based on a weighting scale, the most promising candidate P&D concepts have selected and will undergo more rigorous structural design, analysis, and testing in the study’s next phase. The ultimate goal of the comprehensive trade study will be to recommend a single TriTruss design and associated P&D concept that will be built and evaluated at NASA Langley Research Center’s In-Space Assembly Laboratory.

in-space assembly (ISA)↗
NASA NTRSDate not supplied

TriTruss Packaging and Deployment Trade Study

A trade study was conducted that evaluated viable concepts of operation for the packaging and deployment (P&D) of novel deployable modular truss modules, called TriTruss modules, that can be assembled to form a large aperture In-Space Assembled Telescopes (iSAT). In this first phase of an ongoing more comprehensive trade study, concepts were proposed and then evaluated based on initial metrics representing features of an ideal P&D concept. The ideal TriTruss P&D concept is defined as one that: allows for efficient packaging, has sufficient geometric versatility to be launch vehicle independent, provides a stiff and lightweight structure, has low mechanical complexity, and has component modularity. The P&D concept should allow for prelaunch subsystem or utility integration if required. The concept should be kinematically simple and be robotically deployed using a minimum number of specialized tools. The P&D concepts evaluated are categorized as: core collapse, face collapse, and erectable structures. Sub-scale models were constructed to help understand the kinematics and mechanical complexity required to enable P&D. Based on a weighting scale, the most promising candidate P&D concepts have been selected and will undergo more rigorous structural design, analysis, and testing in the study’s next phase. The ultimate goal of the comprehensive trade study will be to recommend a single TriTruss design and associated P&D concept that will be built and evaluated at NASA Langley Research Center’s In-Space Assembly Laboratory.

in-space assembly (ISA)↗
NASA NTRSDate not supplied

A Microphone Phased Array for Launch Acoustics Application

A new, portable, phased array of microphones is built at NASA Ames Research Center specifically for the harsh environment encountered in launch pads of rocket vehicles. It uses 70 piezoresistive, dynamic pressure sensors, optimally distributed on a 10.5ft diameter open frame dome structure. The open frame is light yet robust to sustain the high wind load of typical seaside launch pads, and the blast and acoustic loads from the launch. A 200-ft long cable bundle carries the microphone signals to a weather-protected cabinet containing the data systems, and allows for the placement of the array tall structures. The array is equipped with an infra-red camera and a visible wavelength camera for imaging the launch pad. The beamformed noise maps will be superimposed on the video footages collected by the cameras for correct identification of the noise sources. The array is tested with very loud speaker sources to determine the beamforming ability using different schemes, such as the conventional beamforming, orthogonal-functional beamforming, and spectral element methods. A comparative study was conducted to determine the minimum attainable spatial resolution. Data from a validation test in an outdoor setup, where the array was placed on a Telehandler at several different heights and distances from either a single or a pair of speakers, is presented in this paper. The final goal is to use the array during NASA’s Artemis-II launch to determine the distribution of noise sources on the Mobile Launcher.

Acoustics↗
DOE OSTI2016

CHARACTERIZATION OF ADDITIVE MANUFACTURING FOR PROCESS TUBING

Additive Manufacturing has garnered significant levels of interest in recent years as a primary manufacturing method. While the general technology has been around for over 20 years, with increased computing capacity, higher powered directed energy sources, e.g., lasers and electron beams, it is coming of age as a viable technique for high value added, low production quantity components. The Savannah River National Laboratory is interested in AM as a technique to build hydrogen isotope separation components called Thermal Cycling Absorption Process (TCAP) columns. The TCAP operates from cryogenic to moderate temperatures in a cyclic manner and is a pressure boundary. The current technique for fabricating TCAP columns is to form a flat coil of 0.375 to 0.5 inch diameter tube and braze two coils together. During the brazing operation, the two nested coils often move and this movement results in gaps between the coils. Since one coil contains the working fluid, i.e., liquid nitrogen, and the other the process fluid, hydrogen isotopes, these gaps result in poor heat transfer. Additive manufacturing is being explored as a replacement technology since the adjacent tubes can be fabricated simultaneously and in intimate contact and they can also share a common wall to improve heat transfer. AM allows designers to develop unique tube structures that overcome several of the shortcomings of the coil and braze technique, such as the braze gap in fabrication and slow cooling during operation. Simple test samples with various internal geometries were designed and built from Type 316L stainless steel using a laser powder bed process. Three test article geometries that were built include a simple tube, a pair of stacked tubes, and a tube partially surrounded by two kidney shaped tubes with cooling fins that would extend into the process fluid, these tube sections incorporated thermowells or heat trace channels, selectively. The test samples will be subjected to heat transfer testing and burst testing. The samples were inspected using X-ray, computed tomography, and metallography. The results of the testing conducted on these samples are described in this paper.

Korinko, John S.↗
DOE OSTI2016

Magnetic phases in Pt/Co/Pt films induced by single and multiple femtosecond laser pulses

Ultrathin Pt/Co/Pt trilayers with initial in-plane magnetization were irradiated with femtosecond laser pulses. In this way, an irreversible structural modification was introduced, which resulted in the creation of numerous pulse fluence-dependent magnetic phases. This was particularly true with the out-of-plane magnetization state, which exhibited a submicrometer domain structure. This effect was studied in a broad range of pulse fluences up to the point of ablation of the metallic films. In addition to this single-pulse experiment, multiple exposure spots were also investigated, which exhibited an extended area of out-of-plane magnetization phases and a decreased damage threshold. Using a double exposure with partially overlapped spots, a two-dimensional diagram of the magnetic phases as a function of the two energy densities was built, which showed a strong inequality between the first and second incoming pulses.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Charge state-dependent symmetry breaking of atomic defects in transition metal dichalcogenides

Abstract The functionality of atomic quantum emitters is intrinsically linked to their host lattice coordination. Structural distortions that spontaneously break the lattice symmetry strongly impact their optical emission properties and spin-photon interface. Here we report on the direct imaging of charge state-dependent symmetry breaking of two prototypical atomic quantum emitters in mono- and bilayer MoS 2 by scanning tunneling microscopy (STM) and non-contact atomic force microscopy (nc-AFM). By changing the built-in substrate chemical potential, different charge states of sulfur vacancies (Vac S ) and substitutional rhenium dopants (Re Mo ) can be stabilized. $${\mathrm{Vac}}_{{{{{{{{\rm{S}}}}}}}}}^{-1}$$ Vac S − 1 as well as $${{\mathrm{Re}}}_{{{{{{{{\rm{Mo}}}}}}}}}^{0}$$ Re Mo 0 and $${\mathrm{Re}}_{{\rm{Mo}}}^{-1}$$ Re Mo − 1 exhibit local lattice distortions and symmetry-broken defect orbitals attributed to a Jahn-Teller effect (JTE) and pseudo-JTE, respectively. By mapping the electronic and geometric structure of single point defects, we disentangle the effects of spatial averaging, charge multistability, configurational dynamics, and external perturbations that often mask the presence of local symmetry breaking.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRSDate not supplied

Modal Test and Model Correlation of NASA Plum Brook Station Mechanical Vibration Facility Head Expander –Lessons Learned from the Perspective of an Early-Career Engineer

In preparation for the Sierra Nevada Corporation’s (SNC) Dream Chaser spacecraft vibration test campaign at the Mechanical Vibration Facility (MVF) at NASA Plum Brook Station (PBS) in Sandusky, Ohio, a test-verified model of MVF is needed in order to be able to perform accurate pretest analysis used for determining response limits and abort levels. MVF was designed to vibration test MPCV Orion and was used to perform the system level vibration test of the European Service Module Structural Test Article (E-STA) in 2016. MVF is comprised of an 18 ft diameter annulus table that is driven with sixteen hydraulic vertical actuator assemblies and four hydraulic horizontal actuator assemblies, which allow it to perform single axis vibration testing in the vertical axis and in each of the two orthogonal horizontal axes without the need for reconfiguring the test article. A head expander for the MVF Table has been designed and built that fills in the center opening providing a continuous flat mounting surface with a maximum diameter of 16.25feet that expands the vibration testing capabilities of MVF. The MVF Table with this head expander will be used during the SNC Dream Chaser spacecraft vibration test campaign. Therefore, a critical element in a test-verified model of the MVF will be a test correlated finite element model (FEM) of the head expander. To obtain this, engineers from the Structural Dynamics Lab (SDL) at NASA Glenn Research Center (GRC) in Cleveland, Ohio performed a modal pretest analysis, conducted a modal test in July 2019, and most recently correlated the head expander finite element model to the modal test data up to 300 Hz. From the initial test preparations to the final delivery of a correlated finite element model, all efforts mentioned were led by the same early-career engineers at NASA GRC. From the viewpoint of an early-career engineer, lessons learned about modal pretest analysis, modal testing, and finite element model correlation of the MVF Table expander head will be presented and discussed. This will include the importance of understanding the limitations of using uncorrelated finite element models in the modal pretest analysis and planning, the importance of orthogonality metrics in judging adequacy and accuracy of test mode shapes, and the importance of having the FEM match the as built hardware in the model correlation effort.

Emma L Pierson↗