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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 1,747 records · Page 97
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Stress rupture of SiC/SiC composite tubes under high-temperature steam

SiC-fiber–reinforced SiC matrix composite cladding for light water reactor fuel elements must withstand high-temperature steam oxidation in a loss-of-coolant accident scenario (LOCA). Current composite designs include an outer monolithic SiC layer, in part, to increase steam oxidation resistance. However, it is not clear how such a structure would behave under high-temperature steam in the case when the monolithic layer cracks and carbon interphases and SiC fibers are exposed to the environment. To fill this knowledge gap, stress-rupture tests of prototypic SiC composite cladding at 1000°C under steam and inert environments were conducted. The applied stress was ~120 MPa, which was beyond the initial cracking stress. The failure lifetime under steam was 400–1300 s, while 75% of the composite specimens did not fail after 3 h of total exposure under inert gases. Microstructural observations suggest that steam oxidation activated slow crack growth in the fibers, which led to failure of the composite. The results from this study suggest that stress rupture in steam environments could be a limiting factor of the cladding under reactor LOCA conditions.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Analysis of a Hybrid Wing Body Center Section Test Article

The hybrid wing body center section test article is an all-composite structure made of crown, floor, keel, bulkhead, and rib panels utilizing the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) design concept. The primary goal of this test article is to prove that PRSEUS components are capable of carrying combined loads that are representative of a hybrid wing body pressure cabin design regime. This paper summarizes the analytical approach, analysis results, and failure predictions of the test article. A global finite element model of composite panels, metallic fittings, mechanical fasteners, and the Combined Loads Test System (COLTS) test fixture was used to conduct linear structural strength and stability analyses to validate the specimen under the most critical combination of bending and pressure loading conditions found in the hybrid wing body pressure cabin. Local detail analyses were also performed at locations with high stress concentrations, at Tee-cap noodle interfaces with surrounding laminates, and at fastener locations with high bearing/bypass loads. Failure predictions for different composite and metallic failure modes were made, and nonlinear analyses were also performed to study the structural response of the test article under combined bending and pressure loading. This large-scale specimen test will be conducted at the COLTS facility at the NASA Langley Research Center.

Wu, Hsi-Yung T.↗
NASA NTRS1974

Evaluation of a metal shear web selectively reinforced with filamentary composites for space shuttle application

A final program summary is reported for test and evaluation activities that were conducted for space shuttle web selection. Large scale advanced composite shear web components were tested and analyzed to evaluate application of advanced composite shear web construction to a space shuttle orbiter thrust structure. The shear web design concept consisted of a titanium-clad + or - 45 deg boron/epoxy web laminate stiffened with vertical boron-epoxy reinforced aluminum stiffeners and logitudinal aluminum stiffening. The design concept was evaluated to be efficient and practical for the application that was studied. Because of the effects of buckling deflections, a requirement is identified for shear buckling resistant design to maximize the efficiency of highly-loaded advanced composite shear webs.

Laakso, J. H.↗
NASA NTRS2002

The Velocity and Attenuation of Acoustic Emission Waves in SiC/SiC Composites Loaded in Tension

The behavior of acoustic waves produced by microfracture events and from pencil lead breaks was studied for two different silicon carbide fiber-reinforced silicon carbide matrix composites. The two composite systems both consisted of Hi-Nicalon (trademark) fibers and carbon interfaces but had different matrix compositions that led to considerable differences in damage accumulation and acoustic response. This behavior was primarily due to an order of magnitude difference in the interfacial shear stress for the two composite systems. Load/unload/reload tensile tests were performed and measurements were made over the entire stress range in order to determine the stress-dependence of acoustic activity for increasing damage states. It was found that using the extensional wave velocities from acoustic emission (AE) events produced from pencil lead breaks performed outside of the transducers enabled accurate measurements of the stiffness of the composite. The extensional wave velocities changed as a function of the damage state and the stress where the measurement was taken. Attenuation for AE waveforms from the pencil lead breaks occurred only for the composite possessing the lower interfacial shear stress and only at significantly high stresses. At zero stress after unloading from a peak stress, no attenuation occurred for this composite because of crack closure. For the high interfacial stress composite no attenuation was discernable at peak or zero stress over the entire stress-range of the composite. From these observations, it is believed that attenuation of AE waveforms is dependent on the magnitude of matrix crack opening.

Morscher, Gregory N.↗
DOE OSTI2015

Structure and mechanical properties of coatings fabricated by nonvacuum electron beam cladding of Ti-Ta-Zr powder mixtures

In this paper structural investigations and mechanical tests of Ti-Ta-Zr coatings obtained on surfaces of cp-titanium workpieces were carried out. It was found that the coatings had a dendrite structure; investigations at high-power magnifications revealed a platelet structure. An increase of tantalum concentration led to refinement of structural components. The microhardness level of all coatings, excepting a specimen with the maximum tantalum content, was 370 HV. The microhardness of this coating reached 400 HV. The ultimate tensile strength of cladded layers varied from 697 to 947 MPa. Adhesion tests showed that bimetallic composites were characterized by high bond strength of cladded layers to the substrate, which exceeded cp-titanium strength characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Molten Salt-Carbon Nanotube Thermal Energy Storage for Concentrating Solar Power Systems (Final Report)

We demonstrated that adding nanoparticles to a molten salt would increase its utility as a thermal energy storage medium for a concentrating solar power system. Specifically, we demonstrated that we could increase the specific heat of nitrate and carbonate salts containing 1% or less of alumina nanoparticles. We fabricated the composite materials using both evaporative and air drying methods. We tested several thermophysical properties of the composite materials, including the specific heat, thermal conductivity, latent heat, and melting point. We also assessed the stability of the composite material with repeated thermal cycling and the effects of adding the nanoparticles on the corrosion of stainless steel by the composite salt. Our results indicate that stable, repeatable 25-50% improvements in specific heat are possible for these materials. We found that using these composite salts as the thermal energy storage material for a concentrating solar thermal power system can reduce the levelized cost of electricity by 10-20%. We conclude that these materials are worth further development and inclusion in future concentrating solar power systems.

14 SOLAR ENERGY↗
NASA NTRS2005

Evaluation of Thermal Protection Tile Transmissibility for Ground Vibration Test

Transmissibility analyses and tests were conducted on a composite panel with thermal protection system foams to evaluate the quality of the measured frequency response functions. Both the analysis and the test results indicate that the vehicle dynamic responses are fully transmitted to the accelerometers mounted on the thermal protection system in the normal direction below a certain frequency. In addition, the in-plane motions of the accelerometer mounted on the top surface of the thermal protection system behave more actively than those on the composite panel due to the geometric offset of the accelerometer from the panel in the test set-up. The transmissibility tests and analyses show that the frequency response functions measured from the accelerometers mounted on the TPS will provide accurate vehicle responses below 120 Hz for frequency and mode shape identification. By confirming that accurate dynamic responses below a given frequency can be obtained, this study increases the confidence needed for conducting the modal testing, model correlation, and model updating for a vehicle installed with TPS. '

Chung, Y. T.↗
NASA NTRS2014

Processing and Characterization of Basalt Fiber Reinforced Ceramic Composites for High Temperature Applications Using Polymer Precursors

The development of high temperature structural composite materials has been very limited due to the high cost of the materials and the processing needed. Polymer Derived Ceramics (PDCs) begin as a polymer matrix, which allows a shape to be formed prior to the cure, and is then pyrolized in order to obtain a ceramic with the associated thermal and mechanical properties. The two PDCs used in this development are polysiloxane and polycarbosilane. Basalt fibers are used for the reinforcement in the composite system. The use of basalt in structural and high temperature applications has been under development for over 50 years, yet there has been little published research on the incorporation of basalt fibers as a reinforcement in composites. Continuous basalt fiber reinforced PDCs have been fabricated and tested for the applicability of this composite system as a high temperature structural composite material.

High Temperature Composites↗
NASA NTRS2015

Preliminary Weight Savings Estimate for a Commercial Transport Wing Using Rod-Stiffened Stitched Composite Technology

A structural concept called pultruded rod stitched efficient unitized structure (PRSEUS) was developed by the Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body (HWB) aircraft configuration. While PRSEUS was an enabling technology for the pressurized HWB structure, limited investigation of PRSEUS for other aircraft structures, such as circular fuselages and wings, has been done. Therefore, a study was undertaken to investigate the potential weight savings afforded by using the PRSEUS concept for a commercial transport wing. The study applied PRSEUS to the Advanced Subsonic Technology (AST) Program composite semi-span test article, which was sized using three load cases. The initial PRSEUS design was developed by matching cross-sectional stiffnesses for each stringer/skin combination within the wing covers, then the design was modified to ensure that the PRSEUS design satisfied the design criteria. It was found that the PRSEUS wing design exhibited weight savings over the blade-stiffened composite AST Program wing of nearly 9%, and a weight savings of 49% and 29% for the lower and upper covers, respectively, compared to an equivalent metallic wing.

Lovejoy, Andrew E.↗
NASA NTRS2019

Sub-Picometer Dynamic Measurements of a Diffuse Surface

Future space observatory missions are forecasting the need for sensing and controlling wave front error and system alignment stability to picometer scale. Picometer stability performance demands precision knowledge of the mirror and metering structure materials to the same degree. A high-speed electronic speckle pattern interferometer was designed and built to demonstrate measurements of both static and dynamic responses of picometer amplitudes in materials of diffuse surface subjected to very low energy disturbances. This paper describes the details of a test to impart a dynamic disturbance of picometer scale and measure the response of a composite material.The results of the test are also reported and show conclusively that sub-picometer scale effects can be accurately measured in an open test environment outside a vacuum chamber.

Saif, Babak↗
NASA NTRS1999

Aeroelastic Stability for Straight and Swept-Tip Rotor Blades in Hover and Forward Flight

Two isolated, hingeless rotors with identical fiber-reinforced composite root flexures were tested in hover and forward flight at realistic tip speeds. The rotors differed in blade planform and structure. The first blade set was of rectangular planform. The second set had blades of stiffer construction with swept-tips. The purpose of these tests was to measure the isolated rotor aeroelastic stability of bending/torsion coupled rotor blades over a range of flight conditions. The two soft inplane rotor systems were designed with low first torsion frequency to emphasize the effects of torsion. Regressing lag mode damping is shown in hover with precone and collective pitch variations and in forward flight with airspeed, shaft angle, precone and collective pitch variations. Correlation with comprehensive analysis for a number of test conditions is shown. Agreement in hover is excellent and forward flight correlation is reasonably good.

REGRESSING LAG MODE DAMPING↗
DOE OSTI2015

SU-C-213-03: Custom 3D Printed Boluses for Radiation Therapy

Purpose: To develop a clinical workflow and to commission the process of creating custom 3d printed boluses for radiation therapy. Methods: We designed a workflow to create custom boluses using a commercial 3D printer. Contours of several patients were deformably mapped to phantoms where the test bolus contours were designed. Treatment plans were created on the phantoms following our institutional planning guideline. The DICOM file of the bolus contours were then converted to stereoLithography (stl) file for the 3d printer. The boluses were printed on a commercial 3D printer using polylactic acid (PLA) material. Custom printing parameters were optimized in order to meet the requirement of bolus composition. The workflow was tested on multiple anatomical sites such as skull, nose and chest wall. The size of boluses varies from 6×9cm2 to 12×25cm2. To commission the process, basic CT and dose properties of the printing materials were measured in photon and electron beams and compared against water and soft superflab bolus. Phantoms were then scanned to confirm the placement of custom boluses. Finally dose distributions with rescanned CTs were compared with those computer-generated boluses. Results: The relative electron density(1.08±0.006) of the printed boluses resemble those of liquid tap water(1.04±0.004). The dosimetric properties resemble those of liquid tap water(1.04±0.004). The dosimetric properties were measured at dmax with an ion chamber in electron and photon open beams. Compared with solid water and soft bolus, the output difference was within 1% for the 3D printer material. The printed boluses fit well to the phantom surfaces on CT scans. The dose distribution and DVH based on the printed boluses match well with those based on TPS generated boluses. Conclusion: 3d printing provides a cost effective and convenient solution for patient-specific boluses in radiation therapy.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Grid-to-rod fretting wear study of SiC/SiC composite accident-tolerant fuel claddings using an autoclave fretting bench test

Grid-to-rod-fretting (GTRF) in pressurized water reactors (PWRs) is known to cause wear and surface damage on the fuel claddings, potentially leading to radioactive leakage. One of the accident-tolerant fuel (ATF) concepts is to use advanced cladding materials that could withstand higher temperatures. Here, we investigated the wear behavior of candidate silicon carbide (SiC)-based composite claddings with different levels of surface finish in fretting against a commercial ZIRLO alloy grid using a unique bench-scale autoclave GTRF rig. The experiments mimicked the environment in an industrial full-assembly PWR simulator. Fretting tests were conducted with a realistic load (~0.5 N) in deionized water under a pressure of 20–23 bar at 204 °C for 100 h. While the SiC/SiC composite claddings showed significantly higher wear resistance than the commercial ZIRLO alloy cladding as expected, the smoother versions experienced surprisingly higher wear than the much softer counterface, ZIRLO grid. The wear mechanism of the SiC/SiC cladding was attributed to the SiC wear debris that was trapped at the fretting interface causing both 3-body and 2-body (embedded into the grid surface) abrasion of the cladding. Rougher SiC/SiC claddings had less material loss but caused more wear on the ZIRLO grid. Finally, pre-oxidized ZIRLO grid showed better compatibility with the SiC/SiC cladding to protect both the cladding and grid as a result of reduced wear debris trapping.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Inelastic response of metal matrix composites under biaxial loading

Elements of the analytical/experimental program to characterize the response of silicon carbide titanium (SCS-6/Ti-15-3) composite tubes under biaxial loading are outlined. The analytical program comprises prediction of initial yielding and subsequent inelastic response of unidirectional and angle-ply silicon carbide titanium tubes using a combined micromechanics approach and laminate analysis. The micromechanics approach is based on the method of cells model and has the capability of generating the effective thermomechanical response of metal matrix composites in the linear and inelastic region in the presence of temperature and time-dependent properties of the individual constituents and imperfect bonding on the initial yield surfaces and inelastic response of (0) and (+ or - 45)sub s SCS-6/Ti-15-3 laminates loaded by different combinations of stresses. The generated analytical predictions will be compared with the experimental results. The experimental program comprises generation of initial yield surfaces, subsequent stress-strain curves and determination of failure loads of the SCS-6/Ti-15-3 tubes under selected loading conditions. The results of the analytical investigation are employed to define the actual loading paths for the experimental program. A brief overview of the experimental methodology is given. This includes the test capabilities of the Composite Mechanics Laboratory at the University of Virginia, the SCS-6/Ti-15-3 composite tubes secured from McDonnell Douglas Corporation, a text fixture specifically developed for combined axial-torsional loading, and the MTS combined axial-torsion loader that will be employed in the actual testing.

Mirzadeh, F.↗
NASA NTRS1994

Chemical recycling of scrap composites

There are no well-developed technologies for recycling composite materials other than grinding to produce fillers. New approaches are needed to reclaim these valuable resources. Chemical or tertiary recycling, conversion of polymers into low molecular weight hydrocarbons for reuse as chemicals or fuels, is emerging as the most practical means for obtaining value from waste plastics and composites. Adherent Technologies is exploring a low-temperature catalytic process for recycling plastics and composites. Laboratory results show that all types of plastics, thermosets as well as thermoplastics, can be converted in high yields to valuable hydrocarbon products. This novel catalytic process runs at 200 C, conversion times are rapid, the process is closed and, thus, nonpolluting, and no highly toxic gas or liquid products have been observed so no negative environmental impact will result from its implementation. Tests on reclamation of composite materials show that epoxy, imide, and engineering thermoplastic matrices can be converted to low molecular weight hydrocarbons leaving behind the reinforcing fibers for reuse as composite reinforcements in secondary, lower-performance applications. Chemical recycling is also a means to dispose of sensitive or classified organic materials without incineration and provides a means to eliminate or reduce mixed hazardous wastes containing organic materials.

Allred, Ronald E.↗
NASA NTRS1991

Structural characterization of high temperature composites

Glass, ceramic, and carbon matrix composite materials have emerged in recent years with potential properties and temperature resistance which make them attractive for high temperature applications such as gas turbine engines. At the outset of this study, only flexural tests were available to evaluate brittle matrix composites at temperatures in the 600 to 1000 C range. The results are described of an ongoing effort to develop appropriate tensile, compression, and shear test methods for high temperature use. A tensile test for unidirectional composites was developed and used to evaluate the properties and behavior of ceramic fiber reinforced glass and glass-ceramic matrix composites in air at temperatures up to 1000 C. The results indicate generally efficient fiber reinforcement and tolerance to matrix cracking similar to polymer matrix composites. Limiting properties in these materials may be an inherently very low transverse strain to failure, and high temperature embrittlement due to fiber/matrix interface oxidation.

Mandell, J. F.↗
NASA NTRS1988

A test for interfacial effects and stress transfer in ceramic matrix composites

The efforts to fabricate single embedded filament specimens of carbon and SiC fibers were unsuccessful largely due to the thermal stresses resulting from differences in thermal coefficient of expansion. Other factors appear to have been involved including embrittlement of the metal substrate by the H2 gas in the chemical vapor deposition flow stream and reaction layers formed between the silicon carbide and the metal substrate. The carbon fiber may have been attacked by the CVD reactant. It is concluded that these differential stresses are so large as to make the embedded fiber test impractical for the study of interphase effects and stress transfer in fiber ceramic matrix systems.

Bascom, Willard D.↗