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NASA NTRS2015

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↗

DOE OSTI2025

Structural Design and Modeling of MARVEL Primary Coolant System Using the ASME Section III, Division 5, Code

This paper presents the structural design and supporting analysis for the Microreactor Applications Research Validation and Evaluation (MARVEL) primary coolant system (PCS) using the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section III, Division 5, rules. MARVEL is a liquid metal–cooled microreactor intended to provide experimental capabilities for the rapid testing and development of microreactor technologies. The PCS utilizes high-temperature sodium-potassium liquid metal as the primary coolant and operates at a design temperature of 570°C, necessitating the consideration of creep-related failure mechanisms. The base metal for the PCS is 316H stainless steel, and the weldments are made with a 16-8-2 filler. The design approach incorporates the current base code rules along with ASME code cases N-924, N-861, and N-862 to address primary load, ratcheting, and creep-fatigue evaluations, respectively. The reactor’s operation involves complex thermal and mechanical interactions due to natural convective flow and differential thermal expansion between components. In conclusion, this paper discusses the structural engineering challenges encountered, such as managing thermal stresses in the distribution plenum and guard vessel, and outlines the strategies implemented to meet the code requirements, including design modifications and operational constraints.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

NASA NTRS1993

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.↗

NASA NTRS1996

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.

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NASA NTRS2012

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↗

NASA NTRS2001

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.↗

DOE OSTI2026

FY26 Progress Report on the Operation of the Activated Materials Laboratory at the Advanced Photon Source as a Nuclear Science User Facilities Partner Facility

The Activated Materials Laboratory (AML), located in the Long Beamline Building of the Advanced Photon Source (APS) at Argonne National Laboratory (ANL), provides a centralized radiological capability for preparing, handling, and supporting synchrotron experiments on activated materials. As a Nuclear Science User Facilities (NSUF) partner facility, the AML enables the receipt of radioactive shipments, open-form sample handling, encapsulation, transport of specimens to and from APS beamlines, and experimentation with dedicated equipment. The partnership includes the APS 1-ID and 20-ID beamlines, which provide high-energy x-ray scattering, tomography, and diffraction microscopy techniques for ex-situ, in-situ, and grainresolved three-dimensional (3D) characterization. All samples supported through the AML and partner beamlines must meet radiological limits of less than 100 mrem/h at 30 cm. This FY26 progress report summarizes the first full year of AML operations as an NSUF partner facility and highlights progress in both user support and capability development. By the end of FY26, the AML had received a total of 10 NSUF-awarded projects, including 2 Consolidated Innovative Nuclear Research (CINR), 7 Rapid Turnaround Experiment (RTE), and 1 Super RTE projects. Beamtime was fully delivered for 3 RTE projects and partially delivered for 1 CINR project, demonstrating successful workflows for receipt, encapsulation, beamline transfer, and radiological experiment execution. These efforts demonstrated safe radiological experiments at APS beamlines for samples with dose rates above the historical 5 mrem/h threshold and now up to 100 mrem/h at 30 cm, marking an important milestone for neutron-irradiated materials research. During FY26, the AML also expanded its experimental capabilities. A Psylotech xTS load frame with in-grip rotation was deployed for room-temperature mechanical testing with threedimensional x-ray characterization during interrupted loading. A Linkam TS1500V vacuum heater was commissioned for thermally driven studies, and temperature calibration experiments were performed to establish specimen-relevant thermal profiles. In parallel, a customized split-tube furnace for high-temperature mechanical testing entered commissioning, and initial work began on robotic sample handling to reduce worker dose and improve operational efficiency. Data workflow and beamline operations continued to mature. Together, these developments demonstrate that the AML is becoming a unique national resource for safe, efficient, and scientifically advanced characterization of activated materials at the APS.

Zhang, Xuan↗

DOE OSTI2024

High Temperature Mechanical Behavior of Refractory Alloys with Digital Image Correlation

Gas turbine efficiency is typically limited by the maximum allowable temperature for components at the inlet side and in the hot gas flow. Refractory alloys and SiC/SiC ceramic-matrix composites (CMCs) are promising candidates for advancing operating temperatures beyond those of Ni-based alloys (>1200 °C). Refractory alloys are more suitable than SiC/SiC CMCs for dynamic components, due to the latter's low toughness and ductility. However, it is well known that refractory alloys suffer from poor oxidation behavior under service lifetimes and conditions, leading to embrittlement concerns. The ARPA-E ULTIMATE program has set out to combine new alloys with advanced coatings to mitigate oxidation/embrittlement effects, while increasing the mechanical performance benefits of refractory materials. Low oxygen (inert gas) or vacuum systems are needed to assess high temperature mechanical performance of developed alloys. To investigate the environmental sensitivity of candidate alloys and develop high temperature testing capabilities, four argon tensile frames were upgraded as well as a single vacuum system at Oak Ridge National Laboratory. Digital image correlation was incorporated into the vacuum frame allowing for surface strain determination and refined insight into thermomechanical response. Creep testing was performed at 1300 °C on two alloys, C-103 and MHC in vacuum and high purity argon environments. The Mo-based alloy showed less sensitivity to oxygen, indicating that testing in well-controlled argon environments may be suitable. The C-103 alloy demonstrated a stronger sensitivity to oxygen in the well-controlled argon environment, illustrating the need for the developed vacuum testing capabilities. “Small” 25 mm and “large” 76 mm MHC specimens showed comparable results in terms of strain rate during creep testing and ultimate tensile strength during tensile testing, suggesting the viability of smaller geometries that use less material of advanced developmental alloys.

Bell, Sam↗

NASA NTRS1970

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

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NASA NTRS1990

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↗

NASA NTRS1999

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.↗

NASA NTRS1996

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

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NASA NTRS1997

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.

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NASA NTRS1994

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.↗

NASA NTRS2014

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.↗

DOE OSTI2024

Advanced Characterization Capabilities for Nuclear Materials via Nuclear Science User Facilities (NSUF)

Advanced post-irradiation examination (PIE) techniques are required to design new or improved nuclear materials, characterize, and understand in-core behavior of fuel and materials, and support the qualification of new reactor materials. The Nuclear Science User Facilities (NSUF) is the U.S. Department of Energy Office of Nuclear Energy's only designated nuclear science user facility. NSUF provides researchers access to PIE capabilities at Idaho National Laboratory and at a diverse mix of university, national laboratory and industrial partner institutions. The PIE capabilities include novel destructive and non-destructive techniques for radiation damage characterization, such as advanced diffraction techniques (X-ray, electron, or neutron) coupled to extreme environments; in-situ observation of microstructural evolution under irradiation; in-situ irradiation to monitor corrosive attack in coolant environments; in-situ irradiation and mechanical testing; and test methods for synergistic effects of superimposed extreme environments (temperature, irradiation, stress, corrosion) on materials behaviors. This talk will provide an overview of NSUF PIE capabilities.

36 MATERIALS SCIENCE↗

NASA NTRS2021

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↗

NASA NTRS1988

Coastal Zone Color Scanner

The Coastal Zone Color Scanner (CZCS) spacecraft ocean color instrument is capable of measuring and mapping global ocean surface chlorophyll concentration. It is a scanning radiometer with multiband capability. With new electronics and some mechanical, and optical re-work, it probably can be made flight worthy. Some additional components of a second flight model are also available. An engineering study and further tests are necessary to determine exactly what effort is required to properly prepare the instrument for spaceflight and the nature of interfaces to prospective spacecraft. The CZCS provides operational instrument capability for monitoring of ocean productivity and currents. It could be a simple, low cost alternative to developing new instruments for ocean color imaging. Researchers have determined that with global ocean color data they can: specify quantitatively the role of oceans in the global carbon cycle and other major biogeochemical cycles; determine the magnitude and variability of annual primary production by marine phytoplankton on a global scale; understand the fate of fluvial nutrients and their possible affect on carbon budgets; elucidate the coupling mechanism between upwelling and large scale patterns in ocean basins; answer questions concerning the large scale distribution and timing of spring blooms in the global ocean; acquire a better understanding of the processes associated with mixing along the edge of eddies, coastal currents, western boundary currents, etc., and acquire global data on marine optical properties.

Johnson, B.↗