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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 1,639 records · Page 91
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

LCF Life of As-Deposited and Annealed NiCr-Y Coatings for Oxidation and Hot Corrosion Protection of Disk Alloys

Increasing temperatures in aero gas turbines is resulting in oxidation and hot corrosion attack of turbine disks. Since disks are sensitive to low cycle fatigue (LCF), any environmental attack, and especially hot corrosion pitting, can seriously degrade the life of the disk. Application of metallic coatings is one means of protecting disk alloys from this environmental attack. However, the presence of a metallic coating can degrade the LCF life of a disk alloy. Therefore, coatings must be designed which are not only resistant to oxidation and corrosion attack, but do not significantly degrade the LCF life of the alloy.Three different NiCr-Y coating compositions (29, 35.5, 44 wt.% Cr, all with 0.1 wt.% Y) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One Ni-35.5Cr-0.1Y coating also received a thin ZrO2 overcoat. The coated samples were also given a short thermal anneal in a low PO2 environment to encourage bonding of the coating and substrate as well as initiating formation of a chromia scale. Without further environmental exposure, the LCF life of coated and uncoated samples was evaluated at 760°C in air. The LCF lifetime of all coated samples was less than that of uncoated samples. The LCF life scaled with the Cr content and the high-Cr, thin coating showed the highest LCF life. Pre and post-test characterization of the various coatings, including identification of crack initiation sites, will be presented and the effect of the coating on the LCF life discussed.

low cycle fatigue↗
NASA NTRS1977

Lifetimes of fiber composites under sustained tensile loading

Results are presented for a study intended to summarize lifetime data on several fiber/epoxy composite materials subjected to sustained uniaxial tensile loading, to report preliminary results of an accelerated test method for predicting the life of simple composites, and to describe related work in progress on pressure vessels and other filament-wound structures. The lifetime performance of the tested composites was compared by plotting the percent of ultimate strength (applied fiber stress normalized with respect to fiber failure stress in a composite) versus lifetime. In terms of performance in long-term tensile applications, the tested composites are ranked in the following order: graphite/epoxy, Be wire/epoxy, Aramid/epoxy, and S-glass/epoxy. The accelerated test using temperature and stress to simulate the passage of time proves to be encouraging, at least in the case of the Aramid/epoxy composite. The potential of a statistical analysis based on Weibull distribution analyses or a power law relationship is demonstrated.

Chiao, T. T.↗
NASA NTRS1993

The infeasibility of quantifying the reliability of life-critical real-time software

This paper affirms that the quantification of life-critical software reliability is infeasible using statistical methods, whether these methods are applied to standard software or fault-tolerant software. The classical methods of estimating reliability are shown to lead to exorbitant amounts of testing when applied to life-critical software. Reliability growth models are examined and also shown to be incapable of overcoming the need for excessive amounts of testing. The key assumption of software fault tolerance - separately programmed versions fail independently - is shown to be problematic. This assumption cannot be justified by experimentation in the ultrareliability region, and subjective arguments in its favor are not sufficiently strong to justify it as an axiom. Also, the implications of the recent multiversion software experiments support this affirmation.

Butler, Ricky W.↗
DOE OSTI2019

Surface Treatment of Powder-Bed Fusion Additive Manufactured Metals for Improved Fatigue Life

High-cycle fatigue (HCF) tests were conducted on samples fabricated by two powder-bed additive manufacturing techniques. Samples were tested with as-produced surfaces and after various non-contact surface improvement treatments. Ti-6Al-4V samples were made using both electron beam melting (EBM) and selective laser melting (SLM), while Inconel 625 was fabricated using SLM. Ti-6Al-4V was treated with a commercial chemically accelerated vibratory polishing process, with target material removal of approximately 200 µm from each surface for EBM samples and 100 µm for SLM samples. This technique led to increases in both the number of cycles before failure at a given loading condition and endurance limit (at 10{sup 7} cycles) compared to samples with as-produced surfaces. The results are interpreted as the reduction in elastic stress concentration factor associated with surface defects where fatigue cracks initiate. SLM 625 was treated with both an abrasive polishing method and laser surface remelting. Both methods led to improvements in surface roughness, but these did not lead to improvements in fatigue properties of SLM 625. For abrasive polished samples, the combination of improved measured surface roughness without fatigue property enhancement suggests that surface material is removed, but the roots of surface defects, where fatigue cracks initiate, were left intact. For laser treatment, the remelted surface layer retained a rapidly solidified microstructure that did not increase the number of cycles before crack initiation even though the surface was smoother compared to the surface prior to polishing.

36 MATERIALS SCIENCE↗
NASA NTRS1977

The 6670-Newton attitude-control thruster using hydrogen-oxygen propellant

The development of a reusable, attitude-control propulsion system for the space transportation system is discussed. A flight weight, gaseous oxygen attitude control thruster assembly was tested to obtain data on cyclic life, thermal and hydraulic characteristics, pulse response, and performance. The basic thruster components were tested in excess of 51,000 pulses and 660 seconds, steady state, with no degradation of the 93 percent characteristic exhaust velocity efficiency level. Nominal operating conditions were a chamber pressure of 207 N sq cm (300 psia), a mixture ratio of 4.0, a pulse width of 100 ms, and a pulse frequency of 2 Hz.

Gordon, L. H.↗
NASA NTRS1985

Determining The Life Expectancy of Photovoltaic Systems

Several tests used to determine adequacy of photovoltaic systems, their modules, and materials to survive in real environments. Tests include outdoor testing of systems, real-time and accelerated outdoor testing of modules and materials, and laboratory testing of modules and materials.

Hoffman, A. R.↗
NASA NTRS1979

Strainrange partitioning life predictions of the long time metal properties council creep-fatigue tests

The method of strainrange partitioning is used to predict the cyclic lives of the Metal Properties Council's long time creep-fatigue interspersion tests of several steel alloys. Comparisons are made with predictions based upon the time- and cycle-fraction approach. The method of strainrange partitioning is shown to give consistently more accurate predictions of cyclic life than is given by the time- and cycle-fraction approach.

Saltsman, J. F.↗
NASA NTRS1979

Strainrange partitioning life predictions of the long time Metal Properties Council creep-fatigue tests

The method of Strainrange Partitioning is used to predict the cyclic lives of the Metal Properties Council's long time creep-fatigue interspersion tests of several steel alloys. Comparisons are made with predictions based upon the Time- and Cycle-Fraction approach. The method of Strainrange Partitioning is shown to give consistently more accurate predictions of cyclic life than is given by the Time- and Cycle-Fraction approach.

Saltsman, J. F.↗
NASA NTRS1977

Evaluation Program for Secondary Spacecraft Cells: Synchronous Orbit Testing of Sealed Nickel Cadmium Cells

Performance data concerning sealed nickel-cadmium cells operating under a synchronous orbit regime are presented. A space satellite maintaining a position over a fixed point on earth as the earth rotates on its axis and revolves about the sun was simulated. Results include: (1) exposure to synchronous orbit testing at a temperature of 40 C yields less than 6 years of life; (2) performance at -20 C presents a low capacity problem; (3) the capacity check, performed at the middle of each show period, provides a temporary red reconditioning effect on the cells in that the end-of-discharge voltages are higher, for approximately 7 to 10 days, following the capacity check than they were 7 to 10 days prior to the capacity check; (4) all the test packs at -20 C and 40 C have either failed or were discontinued because of low capacity; and (5) test packs at temperatures of 0 C and 10 C have delivered the best capacity during life and packs tested at 20 C showed better life capability than packs tested at -20 C and 40 C.

Harkness, J. D.↗
NASA NTRS1984

Long life nickel electrodes for a nickel-hydrogen cell. III - Results of an accelerated test and failure analyses

Nineteen different designs of nickel electrodes were tested in Ni/H2 boiler plate cells in an accelerated low earth orbit cycle regime to the end of their life. The failure analyses of these cells showed that the major performance changes due to the cycling was a severe reduction of their high rate discharge capability rather than an absolute capacity reduction. Many physical changes of the nickel electrodes were observed after the cycling test. These changes include dimensional expansion, sinter rupture, loose black powdering of the active material, morphology changes, active material migration, increase of pore volume, change of pore distribution, and increase of surface area. All of these were caused by active material expansion with cycling. Among these changes, the morphology change which involves migration of active material away from the current collecting nickel sinter appears to be that most responsible for the reduction of the rate capability.

Lim, H. S.↗
NASA NTRS2016

Z-2 Architecture Description and Requirements Verification Results

The Z-2 Prototype Planetary Extravehicular Space Suit Assembly is a continuation of NASA's Z series of spacesuits. The Z-2 is another step in NASA's technology development roadmap leading to human exploration of the Martian surface. The suit was designed for maximum mobility at 8.3 psid, reduced mass, and to have high fidelity life support interfaces. As Z-2 will be man-tested at full vacuum in NASA JSC's Chamber B, it was manufactured as Class II, making it the most flight-like planetary walking suit produced to date. The Z-2 suit architecture is an evolution of previous EVA suits, namely the ISS EMU, Mark III, Rear Entry I-Suit and Z-1 spacesuits. The suit is a hybrid hard and soft multi-bearing, rear entry spacesuit. The hard upper torso (HUT) is an all-composite structure and includes a 2-bearing rolling convolute shoulder with Vernier sizing mechanism, removable suit port interface plate (SIP), elliptical hemispherical helmet and self-don/doff shoulder harness. The hatch is a hybrid aluminum and composite construction with Apollo style gas connectors, custom water pass-thru, removable hatch cage and interfaces to primary and auxiliary life support feed water bags. The suit includes Z-1 style lower arms with cam brackets for Vernier sizing and government furnished equipment (GFE) Phase VI gloves. The lower torso includes a telescopic waist sizing system, waist bearing, rolling convolute waist joint, hard brief, 2 bearing soft hip thigh, Z-1 style legs with ISS EMU style cam brackets for sizing, and conformal walking boots with ankle bearings. The Z-2 Requirements Verification Plan includes the verification of more than 200 individual requirements. The verification methods include test, analysis, inspection, demonstration or a combination of methods. Examples of unmanned requirements include suit leakage, proof pressure testing, operational life, mass, isometric man-loads, sizing adjustment ranges, internal and external interfaces such as in-suit drink bag, partial pressure relief valve, purge valve, donning stand and ISS Body Restraint Tether (BRT). Examples of manned requirements include verification of anthropometric range, suit self-don/doff, secondary suit exit method, donning stand self-ingress/egress and manned mobility covering eight functional tasks. The eight functional tasks include kneeling with object pick-up, standing toe touch, cross-body reach, walking, reach to the SIP and helmet visor. This paper will provide an overview of the Z-2 design. Z-2 requirements verification testing was performed with NASA at the ILC Houston test facility. This paper will also discuss pre-delivery manned and unmanned test results as well as analysis performed in support of requirements verification.

Graziosi, Dave↗
DOE OSTI2023

Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints

In this study, WPI and its partners sought to understand galvanic corrosion in Mg-Al friction stir weld (FSW) joints. Unlike fusion welds, FSW is done in the solid state. This limits (but does not eliminate) the formation of brittle Al-Mg intermetallics, resulting in better joint strength and corrosion resistance. This study aimed to understand corrosion behavior of Mg-Al FSW joints by using a Cahn-Hilliard phase field electrochemistry model based on the work of Pongsaksawad et al. Its context challenge problem was an ultra-light door designed by Magna with 6061-Al sheet outer and ZEK100-Mg sheet inner panels, joined by an adhesive and FSW. Unlike most FSW joints, which weld through the softer material into the harder one, the Al sheet’s hem joint around Mg required the FSW tool to through the harder Al into the softer Mg, which was itself a challenge. Despite this challenge, PNNL succeeded in consistently making very strong FSW lap joints, by using a triflute tool and power control. Characterization showed mostly separate Al and Mg regions in the weld, usually with a hook protruding from Al into Mg, which likely contributed to high joint strength. Nanohardness mapping showed higher hardness in thin Mg swirls into the Al nugget, likely due to the intermetallics. The study used the industry standard SAE J2334 Cyclic Corrosion Test (CCT) to simulate corrosion conditions over the life of a vehicle, as well as linear polarization testing and ASTM G71 pitting corrosion testing. Corrosion reactions were: H 2 O + ½O 2 + 2e - → 2OH - at the Al cathode, and either Mg → Mg 2+ + 2e - or Mg + 2OH - → Mg(OH) 2 + 2e - at the Mg anode, with electron transfer through the joint. Mass loss increased with Al section length, supporting the hypothesis that galvanic corrosion in Al-Mg joints is limited by the cathodic reaction. Both pitting corrosion (first anode reaction) and hydroxide film formation (second reaction) were observed. The J2334 CCT test method was slightly modified, adding a chromium solution cleaning step after each week of corrosion testing, in order to remove Mg oxides and hydroxides and accurately measure mass loss over time. That said, FSW joints treated in this way did not did not exhibit significant reduction in lap shear strength of the joints vs. newly welded samples which had not undergone corrosion. Corrosion appeared to consist mainly of pitting in Mg in a way which did not directly affect the bond between the materials where the joints failed. A Cahn-Hilliard phase field model coupled with electrical potential described the electronically mediated galvanic corrosion electrochemical reactions described above in the four-component Al-Mg-H 2 O-(H 2 O+½O 2 ) system. This 2-D model successfully predicted Mg(OH)₂ formation at the anode in some circumstances, and Mg pitting corrosion in others, and showed the correct electric field directions in both cases. The model predicted Mg pit corrosion depth within a factor of two of measured pits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2009

Evaluation of Dowfrost(TM) HD as a Thermal Control Fluid for Constellation Vehicles

A test was conducted from November 2008 to January 2009 to help determine the compatibility of an inhibited propylene glycol/water solution with planned Constellation vehicles. Dowfrost(TradeMark) HD was selected as the baseline for Orion, as well as other Constellation systems. Therefore, the same Dowfrost(TradeMark) HD/Water solution planned for Orion was chosen for this test. The fluid was subjected to a thermal fluid loop that had flightlike properties, as compared to Orion. The fluid loop had similar wetted materials, temperatures, flow rates, and aluminum wetted surface area to fluid volume ratio. The test was designed to last for 10 years, the life expectancy of the lunar habitat. However, the test lasted less than two months. System filters became clogged with precipitate, rendering the fluid system inoperable. Upon examination of the precipitate, it was determined that the precipitate composition contained aluminum, which could have only come from materials in the test stand, as aluminum is not part of the Dowfrost(TradeMark HD composition. Also, the fluid pH was determined to have increased from 10.1, at the first test sample, to 12.2, at the completion of the test. This high of a pH is corrosive to aluminum and was certainly a contributing factor to the development of precipitate. Chemical analyses and bench-top tests are currently ongoing to determine the underlying cause for this rapid degradation of the fluid. Hamilton Sundstrand, the contractor developing the Orion thermal fluid loop, is performing a parallel effort to not only understand the cause of fluid degradation in the test, but also to investigate solutions to avoid this problem in the Orion s thermal control system. JSC also consulted with the Hamilton Sundstrand team in the development of this test and the subsequent analysis.

Lee, Steve↗
NASA NTRS2007

Performance of Low Temperature Electrolytes in Experimental and Prototype Li-Ion Cells

Due to their attractive properties and proven success, Li-ion batteries have become identified as the battery chemistry of choice for a number of future NASA missions. A number of these applications would be greatly benefited by improved performance of Li-ion technology over a wider operating temperature range, especially at low temperatures, such as future ESMD missions. In many cases, these technology improvements may be mission enabling, and at the very least mission enhancing. In addition to aerospace applications, the DoE has interest in developing advanced Li-ion batteries that can operate over a wide temperature range to enable terrestrial HEV applications. Thus, our focus at JPL in recent years has been to extend the operating temperature range of Li-ion batteries, especially at low temperatures. To accomplish this, the main focus of the research has been devoted to developing improved lithium-ion conducting electrolytes. In the present paper, we would like to present some of the results we have obtained with ethylene carbonate-based electrolytes optimized for low temperature in experimental MCMB-LiNixCo1_x0 2 cells. In addition to obtaining discharge and charge rate performance data at various temperatures, electrochemical measurements were performed on individual electrodes (made possible by the incorporation of Li reference electrodes), including EIS, linear polarization and Tafel polarization measurements. The combination of techniques enables the elucidation of various trends associated with electrolyte composition. In addition to investigating the behavior in experimental cells, the performance of many promising low temperature electrolytes was demonstrated in large capacity, aerospace quality Li-ion prototype cells. These cells were subjected to a number of performance tests, including discharge rate characterization, charge rate characterization, cycle life performance at various temperatures, and power characterization tests.

Li-ion batteries↗
NASA NTRS2008

Assessment of Various Low Temperature Electrolytes in Prototype Li-Ion Cells Developed for ESMD Applications

Due to their attractive properties and proven success, Li-ion batteries have become identified as the battery chemistry of choice for a number of future NASA missions. A number of these applications would be greatly benefited by improved performance of Li-ion technology over a wider operating temperature range, especially at low temperatures, such as future ESMD missions. In many cases, these technology improvements may be mission enabling, and at the very least mission enhancing. In addition to aerospace applications, the DoE has interest in developing advanced Li-ion batteries that can operate over a wide temperature range to enable terrestrial HEV applications. Thus, our focus at JPL in recent years has been to extend the operating temperature range of Li-ion batteries, especially at low temperatures. To accomplish this, the main focus of the research has been devoted to developing improved lithium-ion conducting electrolytes. In the present paper, we would like to present some of the results we have obtained with six different ethylene carbonate-based electrolytes optimized for low temperature. In addition to investigating the behavior in experimental cells initially, the performance of these promising low temperature electrolytes was demonstrated in large capacity, aerospace quality Li-ion prototype cells, manufactured by Yardney Technical Products and Saft America, Inc. These cells were subjected to a number of performance tests, including discharge rate characterization, charge rate characterization, cycle life performance at various temperatures, and power characterization tests.

Wide Operating Temperature Electrolytes↗
NASA NTRS1987

Technology demonstrator program for Space Station Environmental Control Life Support System

The main objectives and requirements of the NASA/Marshall Space Flight Center Technology Demonstration Program are discussed. The program consists of a comparative test and a 90-day manned system test to evaluate an Environmental Control and Life Support System (ECLSS). In the comparative test phase, 14 types of subsystems which perform oxygen and water reclamation functions are to be examined in terms of performance maintenance/service requirements, reliability, and safety. The manned chamber testing phase involves a four person crew using a partial ECLSS for 90 days. The schedule for the program and the program hardware requirements are described.

Adams, Alan M.↗
NASA NTRS2005

Searching for Life with Rovers: Exploration Methods & Science Results from the 2004 Field Campaign of the "Life in the Atacama" Project and Applications to Future Mars Missions

The Life In The Atacama (LITA) project develops and field tests a long-range, solarpowered, automated rover platform (Zo ) and a science payload assembled to search for microbial life in the Atacama desert. Life is barely detectable over most of the driest desert on Earth. Its unique geological, climatic, and biological evolution have created a unique training site for designing and testing exploration strategies and life detection methods for the robotic search for life on Mars.

Cabrol, N. A.a↗