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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Comprehensive Shuttle Foam Debris Reduction Strategies

The Columbia Accident Investigation Board (CAIB) was clear in its assessment of the loss of the Space Shuttle Columbia on February 3, 2003. Foam liberated from the External Tank (ET) impacting the brittle wing leading edge (WLE) of the orbiter causing the vehicle to disintegrate upon re-entry. Naturally, the CAB pointed out numerous issues affecting this exact outcome in hopes of correcting systems of systems failures any one of which might have altered the outcome. However, Discovery s recent return to flight (RTF) illustrates the primacy of erosion of foam and the risk of future undesirable outcomes. It is obvious that the original RTF focused approach to this problem was not equal to a comprehensive foam debris reduction activity consistent with the high national value of the Space Shuttle assets. The root cause is really very simple when looking at the spray-on foam insulation for the entire ET as part of the structure (e.g., actual stresses > materials allowable) rather than as some sort of sizehime limited ablator. This step is paramount to accepting the CAB recommendation of eliminating debris or in meeting any level of requirements due to the fundamental processes ensuring structural materials maintain their integrity. Significant effort has been expended to identify root cause of the foam debris In-Flight Anomaly (FA) of STS-114. Absent verifiable location specific data pre-launch (T-0) and in-flight, only a most probable cause can be identified. Indeed, the literature researched corroborates NASNTM-2004-2 13238 disturbing description of ill defined materials characterization, variable supplier constituents and foam processing irregularities. Also, foam is sensitive to age and the exposed environment making baseline comparisons difficult without event driven data. Conventional engineering processes account for such naturally occurring variability by always maintaining positive margins. Success in a negative margin range is not consistently achieved. Looking at the ET S spray-on foam insulation as part of the structural system (e.g., glass half full mentality) will create an environment where ET debris levels as low as reasonably achievable (ALARA) can be realized. ALARA is a NASA requirements philosophy deployed for the complex, mission altering radiation exposure requirements for life safety of astronauts. In the Shuttle s case, reasonableness is established by exhaustive engineering rigor, allowable debris size/quantity, technology maturity and programmatic constraints. A more robust urethane foam thermal protection system (TPS) will enhance the hctionality of the new Ares I Crew Launch Vehicle (CLV) Upper Stage. This paper will outline the strategy for a comprehensive effort to reduce ET foam debris and outline steps leading to an improved foam TPS. The NASA must remain committed to such an approach no matter what becomes of the next flight s actual debris field lest we fall back into a false sense of security. This commitment along with full implementation of all the other CAB recommendations such as orbiter hardening will significantly improve the Shuttle system, the engineering workforce, future capabilities & alternate policy offramps, national human resource protection, high value national asset protection and increase the level of service to the overall NASA mission.

Semmes, Edmund B.↗
NASA NTRS2013

Elastic-Plastic J-Integral Solutions or Surface Cracks in Tension Using an Interpolation Methodology

No closed form solutions exist for the elastic-plastic J-integral for surface cracks due to the nonlinear, three-dimensional nature of the problem. Traditionally, each surface crack must be analyzed with a unique and time-consuming nonlinear finite element analysis. To overcome this shortcoming, the authors have developed and analyzed an array of 600 3D nonlinear finite element models for surface cracks in flat plates under tension loading. The solution space covers a wide range of crack shapes and depths (shape: 0.2 less than or equal to a/c less than or equal to 1, depth: 0.2 less than or equal to a/B less than or equal to 0.8) and material flow properties (elastic modulus-to-yield ratio: 100 less than or equal to E/ys less than or equal to 1,000, and hardening: 3 less than or equal to n less than or equal to 20). The authors have developed a methodology for interpolating between the goemetric and material property variables that allows the user to reliably evaluate the full elastic-plastic J-integral and force versus crack mouth opening displacement solution; thus, a solution can be obtained very rapidly by users without elastic-plastic fracture mechanics modeling experience. Complete solutions for the 600 models and 25 additional benchmark models are provided in tabular format.

Allen, P. A.↗
NASA NTRS2013

Elastic-Plastic J-Integral Solutions or Surface Cracks in Tension Using an Interpolation Methodology. Appendix C -- Finite Element Models Solution Database File, Appendix D -- Benchmark Finite Element Models Solution Database File

No closed form solutions exist for the elastic-plastic J-integral for surface cracks due to the nonlinear, three-dimensional nature of the problem. Traditionally, each surface crack must be analyzed with a unique and time-consuming nonlinear finite element analysis. To overcome this shortcoming, the authors have developed and analyzed an array of 600 3D nonlinear finite element models for surface cracks in flat plates under tension loading. The solution space covers a wide range of crack shapes and depths (shape: 0.2 less than or equal to a/c less than or equal to 1, depth: 0.2 less than or equal to a/B less than or equal to 0.8) and material flow properties (elastic modulus-to-yield ratio: 100 less than or equal to E/ys less than or equal to 1,000, and hardening: 3 less than or equal to n less than or equal to 20). The authors have developed a methodology for interpolating between the goemetric and material property variables that allows the user to reliably evaluate the full elastic-plastic J-integral and force versus crack mouth opening displacement solution; thus, a solution can be obtained very rapidly by users without elastic-plastic fracture mechanics modeling experience. Complete solutions for the 600 models and 25 additional benchmark models are provided in tabular format.

Allen, Phillip A.↗
NASA NTRSDate not supplied

Additive Manufacturing Model-Based Process Metrics: Reduced Order Modeling of the Laser Powder Bed Fusion Process

The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. In this work, we describe a fully parallel reduced order modeling approach that has been developed to evaluate the evolution of AM processes, termed the AM moment measure method. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology and terminology of the approach will be described, and computed build maps will be calculated and compared for various laser powder bed fusion (LPBF) builds of Ti-6Al-4V. Such comparative results develop understanding of how the sequential process actions can affect the LPBF-AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
NASA NTRSDate not supplied

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
DOE OSTI2021

P- and S-Wave velocity and Indirect Tensile Measurements for Alluvium in Support of the Source Physics Experiments

Mechanical properties on alluvium blocks and core samples were determined to support the Source Physics Experiment Dry Alluvium Geology experimental series. Because material was not available directly from the experimental location, the alluvium blocks and core samples are intended to serve as surrogate material . P - and S - wave velocity was measured on cubes cut from the alluvium blocks and core with the intention to study variation from water content and measured direction (material anisotropy). Indirect tensile tests were conducted dry and with moisture ranging from 6 to 9.1%. For the range of water content tested, increasing moisture level resulted in slower P - and S - wave velocities. P - and S - wave variability is less influenced by material heterogeneity than moisture content. P - wave velocity ranges from 629 m/s to 2599 m/s and S - wave velocity ranges from 288 m/s to 1200 m/s. Counter to the velocity measurement findings, material variability on indirect tensile strength has a greater effect than moisture content. Compared to dry strength and at moisture levels from 6 to 9% the block's tensile strength was lowered by at least a factor of 5. Indirect tensile strength for the first block averaged 0.35 MPa and 0.25 MPa for dry and 8.9% moisture respectively. For the second block indirect tensile strength averaged 0.05 MPa for both dry and 6.4% moisture.

36 MATERIALS SCIENCE↗
NASA NTRS1982

An inventory of particles from stratospheric collectors - Extraterrestrial and otherwise

Examination of 526 particles in the 2-50 micron size range obtained from stratospheric impaction collectors has shown that most of them fit into one of three groups on a simple plot of Mg/Si versus Al/Si energy dispersive X ray peak ratios. The particles within a given group exhibit strong correlations in composition and mineralogy to one another, and the groups appear to largely consist either of earth crustal, manmade, or extraterrestrial materials. The temporal variability and relatively flat size distribution of material in the earth crustal group, in particular, suggests an aircraft-related, as opposed to stratospheric, source for these particles.

Fraundorf, P.↗
DOE OSTI2020

Understanding Microstructure Variability in Vapor-Deposited Energetic Materials by Using Phase-Field Methods

Critical components, such as detonators, in Sandia's stockpile contain heterogeneous materials whose performance and reliability depend on accurate, predictive models of coupled, complex phenomena to predict their synthesis, processing, and operation. Ongoing research in energetic materials has shown that microstructural properties, such as density, pore-size, morphology, and specific surface area are correlated to their initiation threshold and detonation behavior. However, experiments to study these specific characteristics of energetic materials are challenging and time consuming. Therefore, in this work, we turn to mesoscale modeling methods that may be capable of reproducing some observed phenomena to refine and predict outcomes beforehand. Even so, we have no physics-based modeling capability to predict how the microstructure of an energetic material will evolve over near- and long-term time scales. Thus, the goal of this work is to (i) identify any knowledge gaps in how the underlying microstructure forms and evolves during the synthesis process, and (ii) develop and test a mesoscale phase-field model for vapor deposition to capture critical mechanisms of microstructure formation, evolution, and variability in vapor-deposited energetic materials, such as processing conditions, material properties, and substrate interactions. Based on this work, the phase-field method is shown to be a valuable tool for developing the necessary models containing coupled, complex phenomena to investigate and understand the synthesis and processing of energetic materials.

36 MATERIALS SCIENCE↗
NASA NTRS2005

An Approach to Evaluate Precision and Inter-Laboratory Variability of Flammability Test Methods for Aerospace Materials

Materials selection for spacecraft is based on conventional flammability or ignition sensitivity acceptance tests. Current procedures for determining the inter-laboratory repeatability and reproducibility of aerospace materials flammability tests are not considering the dependence of data variability on test conditions and consequently attempts to characterize the precision of these methods were not successful. The inter-laboratory data variability is determined with tests conducted under arbitrary conditions, which consequently may not provide sufficient information to enable adequate determination of a method's precision. For evaluating the precision of NASA's flammability test methods, the protocol recommended includes selecting critical parameters and determining the 50% failure point by considering the specific failure criteria of each method using the critical parameter as a variable. Upon performing inter-laboratory round robin testing using this approach, the laboratories' performance could be evaluated by comparing the repeatability of the 50% failure point and/or the repeatability of critical conditions where the probabilities of passing and failing are unity, i.e., the transition zone repeatability. When a sufficient amount of data has been acquired with this method, an adequate estimation of precision of aerospace materials flammability test methods will be possible.

Hirsch, David↗
DOE OSTI2025

Machine-Learning-Based Multiscale Methods for 3D Modelling of Granular Materials by Incorporating History-Dependent State Variables

Over the past decades, the prevalence of machine learning (ML) methods has made the development of ML-based constitutive models for granular materials undoubtedly a popular subject. Numerous studies have been made to feature the loading path or history-dependent stress-strain response of granular media using neural networks. In this work, a novel finite element method (FEM)–ML multiscale approach was developed by incorporating internal variables to improve the simulation accuracy of 3D history-dependent granular materials for the first time. To this end, a surrogate constitutive model based on the single-step-based multi-layer perceptron (MLP) neural network was used to replace representative volume element (RVE) simulations conducted by the discrete element method (DEM) in the multiscale FEM–DEM approach. Although the prediction principle of the MLP aligns with the FEM algorithm, artificially added internal variables are required to differentiate the loading history. To address this issue, history variables associated with the Frobenius norm are proposed to be fed into the MLP coupled with the strain tensor to extract the history-dependent behaviour of granular assemblies. The developed FEM–ML approach was demonstrated in 3D conventional triaxial compression (CTC) simulations. Compared to the multiscale FEM–DEM approach, the proposed FEM–ML method exhibits a significantly improved computational efficiency.

granular materials↗
NASA NTRS1988

Helicopter crashworthiness research program

Results are presented from the U.S. Army-Aerostructures Directorate/NASA-Langley Research Center joint research program on helicopter crashworthiness. Through the on-going research program an in-depth understanding was developed on the cause/effect relationships between material and architectural variables and the energy-absorption capability of composite material and structure. Composite materials were found to be efficient energy absorbers. Graphite/epoxy subfloor structures were more efficient energy absorbers than comparable structures fabricated from Kevlar or aluminum. An accurate method predicting the energy-absorption capability of beams was developed.

Farley, Gary L.↗
NASA NTRS1987

Energy absorption of composite material and structure

Results are presented from a joint research program on helicopter crashworthiness conducted by the U.S. Army Aerostructures Directorate and NASA Langley. Through the ongoing research program an in-depth understanding has been developed on the cause/effect relationships between material and architectural variables and the energy-absorption capability of composite material and structure. Composite materials were found to be efficient energy absorbers. Graphite/epoxy subfloor structures were more efficient energy absorbers than comparable structures fabricated from Kevlar or aluminum. An accurate method of predicting the energy-absorption capability of beams was developed.

Farley, Gary L.↗
NASA NTRS2015

Temperature-Dependent Refractive Index Measurements of Caf2, Suprasil 3001, and S-FTM16 for the Euclid Near Infrared Spectrometer and Photometer

Using the Cryogenic High Accuracy Refraction Measuring System (CHARMS) at NASA's Goddard Space Flight Center, we measured absolute refractive indices at temperatures from 100 to 310 K at wavelengths from 0.42 to 3.6 microns for CaF2, Suprasil 3001 fused silica, and S-FTM16 glass in support of lens designs for the Near Infrared Spectrometer and Photometer (NISP) for ESA's Euclid dark energy mission. We report absolute refractive index, dispersion (dn/dλ), and thermo-optic coefficient (dn/dT) for these materials. In this study, materials from different melts were procured to understand index variability in each material. We provide temperature-dependent Sellmeier coefficients based on our data to allow accurate interpolation of index to other wavelengths and temperatures. For calcium fluoride (CaF2) and S-FTM16, we compare our current measurements with CHARMS measurements of these materials made in the recent past for other programs. We also compare Suprasil 3001's indices to those of other forms of fused silica we have measured in CHARMS.

geometrical optics↗
DOE OSTI2020

Variation of lead isotopic composition and atomic weight in terrestrial materials (IUPAC Technical Report)

The isotopic composition and atomic weight of lead are variable in terrestrial materials because its three heaviest stable isotopes are stable end-products of the radioactive decay of uranium ( 238 U to 206 Pb; 235 U to 207 Pb) and thorium ( 232 Th to 208 Pb). The lightest stable isotope, 204 Pb, is primordial. These variations in isotope ratios and atomic weights provide useful information in many areas of science, including geochronology, archaeology, environmental studies, and forensic science. While elemental lead can serve as an abundant and homogeneous isotopic reference, deviations from the isotope ratios in other lead occurrences limit the accuracy with which a standard atomic weight can be given for lead. In a comprehensive review of several hundred publications and analyses of more than 8000 samples, published isotope data indicate that the lowest reported lead atomic weight of a normal terrestrial materials is 206.1462 ± 0.0028 (k = 2), determined for a growth of the phosphate mineral monazite around a garnet relic from an Archean high-grade metamorphic terrain in north-western Scotland, which contains mostly 206 Pb and almost no 204 Pb. The highest published lead atomic weight is 207.9351 ± 0.0005 (k = 2) for monazite from a micro-inclusion in a garnet relic, also from a high-grade metamorphic terrain in north-western Scotland, which contains almost pure radiogenic 208 Pb. When expressed as an interval, the lead atomic weight is [206.14, 207.94]. It is proposed that a value of 207.2 be adopted for the single lead atomic-weight value for education, commerce, and industry, corresponding to previously published conventional atomic-weight values.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS1992

Fracture toughness testing of polymer matrix composites

A review of the interlaminar fracture indicates that a standard specimen geometry is needed to obtain consistent fracture toughness measurements in polymer matrix composites. In general, the variability of measured toughness values increases as the toughness of the material increases. This variability could be caused by incorrect sizing of test specimens and/or inconsistent data reduction procedures. A standard data reduction procedure is therefore needed as well, particularly for the tougher materials. Little work has been reported on the effects of fiber orientation, fiber architecture, fiber surface treatment or interlaminar fracture toughness, and the mechanisms by which the fibers increase fracture toughness are not well understood. The little data that is available indicates that woven fiber reinforcement and fiber sizings can significantly increase interlaminar fracture toughness.

Grady, Joseph E.↗