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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development of Computational Materials Workflows for Additively Manufactured Metallic Materials to Enable Accelerated Prediction of Fatigue Performance

The maturation of computational materials approaches for fatigue performance prediction in a qualification and certification process is stifled by the ability to validate complex, microstructure-based simulations. Such a validation strategy bears immediate challenges including generating accurate virtual microstructures, efficiently solving physics-based mechanical simulations over relevant spatial and temporal scales, and acquiring high-fidelity calibration and validation data at the appropriate length scale. This presentation will overview these common challenges and present a case study to demonstrate a computational materials workflow for additively manufactured metallic materials. In this study, process-specific defects are characterized using segmented X-Ray micro-computed tomography measurements and overlaid on virtual microstructures. Accelerated crystal plasticity-based fatigue simulations are performed to demonstrate cyclic evolution and localization of mechanical fields in the vicinity of defects in response to their precise spatial configuration. An example of how this computational materials workflow may support next-generation qualification is discussed.

computational materials↗
NASA NTRS1993

Effect of mission cycling on the fatigue performance of SiC-coated carbon-carbon composites

The effects of thermal and pressure cycling on the fatigue performance of carbon-carbon composites, and the influence of mission cycling on these effects, were investigated by subjecting both virgin and mission-cycled two-dimensional specimens of SiC-coated carbon-carbon composites to fatigue tests, conducted at room temperature in three-point bending, with a stress ratio of 0.2 and a frequency of 1 Hz. It was found that the fatigue strength of C-C composites is high (about 90 percent of the ultimate flexural strength), but decreased with the mission cycling. The lowering of the fatigue strength with mission cycling is attributed to the increase in interfacial bond strength due to thermal and pressure cycling of the material. The already high sensitivity of C-C composites to stress during cyclic loading increases further with the amount of mission cycling. Results of NDE suggest that the damage growth in virgin C-C, in the high-cycle range, is slow at the initial stage of the cyclic life, but propagates rapidly after certain threshold cycles of the fatigue life.

Mahfuz, H.↗
NASA NTRSDate not supplied

Evaluation of Performance, Fatigue and Workload During Real-time, Reactive Telerobotic Mission Control Operations

Real-time, reactive telerobotic mission control operations require personnel to actively operate and manage remotely controlled vehicles or robots in real time. Due to the physical separation of the vehicle from the operator, such operations present many additional factors that can influence fatigue (i.e., degraded mental performance) and workload (i.e., mental and physical cost of task requirements), making it difficult to assess how long an individual can safely and accurately conduct operations. The upcoming Volatiles Investigating Polar Exploration Rover (VIPER) mission involves remotely controlling a lunar vehicle from an Earth-based mission control station. METHODS: In order to determine how long personnel could successfully maintain alertness and performance while operating a rover, we studied seven trained operators (i.e., 5 drivers, 2 real-time scientists) in a simulated mission control environment. We further assessed workload in order to determine whether perceived workload levels would change relative to time on task and by time of day. Operators completed two five-hour simulations in a randomized order, beginning at noon and at midnight. Performance was evaluated every 30 minutes using the psychomotor vigilance task (PVT), Karolinska Sleepiness Scale (KSS), and NASA Task Load Index (NASA-TLX). RESULTS: On average, participants rated themselves as sleepier (5.06 ± 2.28) on the night drives compared to the day drives (3.12 ± 1.44; P < .0001). Workload was rated higher during the day drives (37.93 ± 20.09) compared to night (32.09 ± 21.74; P < .01). Lastly, participants had no change in average reaction time between the two drives. CONCLUSIONS: From the analysis, we observed performance began to degrade after approximately three hours of driving. Our findings suggest that rotating drivers at least every three hours would be prudent to allow for breaks, and to minimize performance degradation, particularly during night shifts.

fatigue↗
NASA NTRS1980

Thermal fatigue performance of integrally cast automotive turbine wheels

Fluidized bed thermal fatigue testing was conducted on 16 integrally cast automotive turbine wheels for 1000-10,000 (600 sec total) thermal cycles at 935/50 C. The 16 wheels consisted of 14 IN-792 + 1% Hf and 2 gatorized AF2-1DA wheels; 6 of the IN-792 + Hf wheels contained crack arrest pockets inside the blade root flange. Temperature transients during the thermal cycling were measured in three calibration tests using either 18 or 30 thermocouples per wheel. Thermal cracking based on crack length versus accumulated cycles was greatest for unpocketed wheels developing cracks in 8-13 cycles compared to 75-250 cycles for unpocketed wheels. However, pocketed wheels survived up to 10,000 cycles with crack lengths less than 20 mm, whereas two unpocketed wheels developed 45 mm long cracks in 1000-2000 cycles.

Humphreys, V. E.↗
NASA NTRS1975

Fatigue performance of metal-lined graphite/epoxy pressure vessels

Using an ultrahigh-strength graphite fiber, a program was started to develop a thin metal-lined fiber/epoxy pressure vessel that would have a fatigue life of over 1000 cycles. First, the performance factor of the fiber/epoxy composite was found to be 351 kN m/kg from the average of 18 rubber-lined pressure vessels. Then, both aluminum- and titanium-lined vessels were filament wound with the graphite fiber in an epoxy matrix. Several of these metal-lined vessels were subjected to hydraulic fatigue testing to about 50% of their expected burst pressures. The average fatigue life of the aluminum-lined vessels was 462 cycles; the average for the titanium-lined vessels was 2190 cycles.

Hamstad, M. A.↗
NASA NTRS2020

Evaluation of Performance, Fatigue and Workload during Real-time, Reactive Telerobotic Mission Control Operations

Telerobotic operations involve a user operating a robot from a different location from where the activity is taking place. It can be difficult for humans to maintain performance when faced with physiological stressors, such as fatigue or illness. Operations require vigilance for extended periods, raising safety concerns surrounding operator’s fatigue and workload. Every hour of wakefulness increases the drive to sleep, causing decreased reaction time (RT), increased lapses in attention (RT > 500 ms), and decreased memory capability. The NASA Task Load Index (NASA-TLX) was created to evaluate the multiple attributes surrounding workload (e.g., mental and physical demands). The upcoming Volatiles Investigating Polar Exploration Rover (VIPER) mission involves remotely controlling a lunar vehicle from an Earth-based mission control station. The goal of VIPER is to excavate the moon for volatiles (water) deep in the surface near the South Pole for a 100-day, continuous operation.

Fatigue↗
NASA NTRS1997

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

This report documents the progress achieved over the past 6 to 12 months on four graduate student projects conducted within the NASA-UVA Light Aerospace Alloy and Structures Technology Program. These studies were aimed specifically at light metallic alloy issues relevant to the High Speed Civil Transport. Research on Hydrogen-Enhanced Fracture of High-Strength Titanium Alloy Sheet refined successfully the high resolution R-curve method necessary to characterize initiation and growth fracture toughnesses. For solution treated and aged Low Cost Beta without hydrogen precharging, fracture is by ductile transgranular processes at 25 C, but standardized initiation toughnesses are somewhat low and crack extension is resolved at still lower K-levels. This fracture resistance is degraded substantially, by between 700 and 1000 wppm of dissolved hydrogen, and a fracture mode change is affected. The surface oxide on P-titanium alloys hinders hydrogen uptake and complicates the electrochemical introduction of low hydrogen concentrations that are critical to applications of these alloys. Ti-15-3 sheet was obtained for study during the next reporting period. Research on Mechanisms of deformation and Fracture in High-Strength Titanium Alloys is examining the microstructure and fatigue resistance of very thin sheet. Aging experiments on 0. 14 mm thick (0.0055 inch) foil show microstructural agility that may be used to enhance fatigue performance. Fatigue testing of Ti-15-3 sheet has begun. The effects of various thermo-mechanical processing regimens on mechanical properties will be examined and deformation modes identified. Research on the Effect of Texture and Precipitates on Mechanical Property Anisotropy of Al-Cu-Mg-X and Al-Cu alloys demonstrated that models predict a minor influence of stress-induced alignment of Phi, caused by the application of a tensile stress during aging, on the yield stress anisotropy of both modified AA2519 and a model Al-Cu binary alloy. This project is no longer included in the NASA-UVA LAST program. Research on the Creep Behavior and Microstructural stability of Al-Cu-Mg-Ag and Al-Cu-Li-Mg-Ag showed that the creep resistance of three candidate aluminum alloys (C415, C416 and ML377) was much superior compared to that of the current Concorde alloy, AA2618. Creep induced change in precipitates at grain boundaries was observed in the alloy which exhibits the highest creep strain of the three examined. The other two alloys developed no detectable microstructural changes at grain boundaries under the creep conditions tested.

Gangloff, Richard P.↗
NASA NTRS2020

A Summary Of: Collecting Sleep, Circadian, Fatigue, and Performance Data in Complex Operational Environments

Sleep loss and circadian misalignment contribute to a meaningful proportion of operational accidents and incidents. Countermeasures and work scheduling designs aimed at mitigating fatigue are typically evaluated in controlled laboratory environments, but the effectiveness of translating such strategies to operational environments can be challenging to assess. This manuscript summarizes an approach for collecting sleep, circadian, fatigue, and performance data in a complex operational environment. We studied 44 airline pilots over 34 days while they flew a fixed schedule, which included a baseline data collection with 5 days of mid-morning flights, four early flights, four high-workload mid-day flights, and four late flights that landed after midnight. Each work block was separated by 3-4 days of rest. To assess sleep, participants wore a wrist-worn research-validated activity monitor continuously and completed daily sleep diaries. To assess the circadian phase, pilots were asked to collect all urine produced in four or eight hourly bins during the 24 h after each duty block for the assessment of 6-sulfatoxymelatonin (aMT6s), which is a biomarker of the circadian rhythm. To assess subjective fatigue and objective performance, participants were provided with a touchscreen device used to complete the Samn-Perelli Fatigue Scale and Psychomotor Vigilance Task (PVT) during and after each flight, and at wake-time, mid-day, and bedtime. Using these methods, it was found that sleep duration was reduced during early starts and late finishes relative to baseline. Circadian phase shifted according to duty schedule, but there was a wide range in the aMT6s peak between individuals on each schedule. PVT performance was worse on the early, high-workload, and late schedules relative to baseline. Overall, the combination of these methods was practical and effective for assessing the influence of sleep loss and circadian phase on fatigue and performance in a complex operational environment.

Arsintescu, Lucica↗
NASA NTRS2004

Summary of the key features of seven biomathematical models of human fatigue and performance

BACKGROUND: Biomathematical models that quantify the effects of circadian and sleep/wake processes on the regulation of alertness and performance have been developed in an effort to predict the magnitude and timing of fatigue-related responses in a variety of contexts (e.g., transmeridian travel, sustained operations, shift work). This paper summarizes key features of seven biomathematical models reviewed as part of the Fatigue and Performance Modeling Workshop held in Seattle, WA, on June 13-14, 2002. The Workshop was jointly sponsored by the National Aeronautics and Space Administration, U.S. Department of Defense, U.S. Army Medical Research and Materiel Command, Office of Naval Research, Air Force Office of Scientific Research, and U.S. Department of Transportation. METHODS: An invitation was sent to developers of seven biomathematical models that were commonly cited in scientific literature and/or supported by government funding. On acceptance of the invitation to attend the Workshop, developers were asked to complete a survey of the goals, capabilities, inputs, and outputs of their biomathematical models of alertness and performance. Data from the completed surveys were summarized and juxtaposed to provide a framework for comparing features of the seven models. RESULTS: Survey responses revealed that models varied greatly relative to their reported goals and capabilities. While all modelers reported that circadian factors were key components of their capabilities, they differed markedly with regard to the roles of sleep and work times as input factors for prediction: four of the seven models had work time as their sole input variable(s), while the other three models relied on various aspects of sleep timing for model input. Models also differed relative to outputs: five sought to predict results from laboratory experiments, field, and operational data, while two models were developed without regard to predicting laboratory experimental results. All modelers provided published papers describing their models, with three of the models being proprietary. CONCLUSIONS: Although all models appear to have been fundamentally influenced by the two-process model of sleep regulation by Borbely, there is considerable diversity among them in the number and type of input and output variables, and their stated goals and capabilities.

Fatigue/physiopathology↗
NASA NTRS2016

Task Demand Variation in Air Traffic Control: Implications for Workload, Fatigue, and Performance

In air traffic control, task demand and workload have important implications for the safety and efficiency of air traffic, and remain dominant considerations. Within air traffic control, task demand is dynamic. However, research on demand transitions and subsequent controller perception and performance is limited. This research uses an air traffic control simulation to investigate the effect of task demand transitions, and the direction of those transitions, on workload and fatigue and one efficiency performance measure. Results indicate that a change in task demand appears to affect both workload and fatigue ratings, although not necessarily performance. In addition, participants' workload and fatigue ratings in equivalent task demand periods appear to change depending on the demand period preceding the time of the current ratings. Further research is needed to enhance understanding of demand transition and workload history effects on operator experience and performance, in both air traffic control and other safety-critical domains.

workload history↗
NASA NTRS2016

Task Demand Variation in Air Traffic Control: Implications for Controller Workload, Fatigue, and Performance

In air traffic control, task demand and workload have important implications for the safety and efficiency of air traffic, and remain dominant considerations. Within air traffic control, task demand is dynamic. However, research on demand transitions and subsequent controller perception and performance is limited. This research uses an air traffic control simulation to investigate the effect of task demand transitions, and the direction of those transitions, on workload and fatigue and one efficiency performance measure. Results indicate that a change in task demand appears to affect both workload and fatigue ratings, although not necessarily performance. In addition, participants workload and fatigue ratings in equivalent task demand periods appear to change depending on the demand period preceding the time of the current ratings. Further research is needed to enhance understanding of demand transition and workload history effects on operator experience and performance, in both air traffic control and other safety-critical domains.

workload history↗
NASA NTRS2019

The Relationship between Workload, Performance and Fatigue in a Short-Haul Airline

Short-haul flights are associated with irregular work schedules and increased workload, due to frequent takeoffs and landings. We examined the relationship between pilot workload, performance and subjective fatigue during normal short-haul operations. Ninety airline pilots (8 female), mean age 33 (±8 years) completed a NASA-Task Load Index (NASA-TLX), a Psychomotor Vigilance Task (PVT; a reaction time test sensitive to sleep loss) and a Samn-Perelli (SP) fatigue scale, over a period of 20 duty days at top-of-descent on 2762 short-haul flights. The duty days included either 2 or 4 flights per day starting at different times as scheduled during normal operations. Workload was measured using the six NASA-TLX scales: mental demand, physical demand, temporal demand, effort, performance and frustration. Lapses (reaction times [RT] > 500ms) were calculated for the PVT. Spearman correlations were calculated to identify relationships between the NASA-TLX, PVT lapses, and SP. The six scales of NASA-TLX were positively correlated with the PVT lapses (p < 0.01) showing an increase in workload when lapses increased. There was a positive correlation between subjective fatigue as measured by the SP fatigue scale and each of the six scales of NASA-TLX (p < 0.001) suggesting that pilots reported higher workload when perceived levels of fatigue were higher. Of the six workload scales, mental demand and performance were rated the highest (mental: M = 40.99, SD = 20.32; performance: M = 41.61, SD = 20.71) and effort was rated the lowest (M = 15.59, SD = 8.98). Preliminary analyses suggest that high workload is associated with poorer PVT performance and increased self-reported fatigue in this population of short-haul pilots. Future studies should explore how other workload factors (i.e. flight hours, time of day) influence self-reported and objective fatigue measures.

TLX↗
NASA NTRSDate not supplied

Human Performance and Fatigue

This presentation summarizes some of the work completed by the Fatigue Countermeasures Lab work for the System-wide Safety Technical Challenge 1. Highlights include the development of the NASA PVT+ application, which includes a validated psychomotor vigilance task, fatigue ratings, hassle factors, fatigue countermeasures, and workload measures. The NASA PVT+ has been used in numerous studies in short and long-haul aviation operations. Two examples of how these have been used in the real world are described.

human performance↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗
NASA NTRS1978

Advanced fabrication techniques for cooled engine structures

An improved design for regeneratively cooled engine structures was identified. This design uses photochemically machined (PCM) coolant passages. It permits the braze joint to be placed in a relatively cool area, remote from the critical hot face sheet. The geometry of the passages at the face sheet also minimizes stress concentration and, therefore, enhances the low cycle fatigue performance. The two most promising alloys identified for this application are Inconel 617 and Nickel 201. Inconel 617 was selected because it has excellent creep rupture properties, while Nickel 201 was selected because of its predicted good performance under low cycle fatigue loading. The fabrication of the PCM coolant passages in both Inconel 617 and Nickel 201 was successfully developed. During fabrication of Inconel 617, undesirable characteristics were observed in the braze joints. A development program to resolve this condition was undertaken and led to definition of an isothermal solidification process for joining Inconel 617 panels. This process produced joints which approach parent metal strength and homogeneity.

Buchmann, O. A.↗