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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
DOE OSTI2026

Improvement of Drop‐Hammer Impact Testing for Safety Assessment of High Explosives Using 10‐mg Samples

Here, in this study, we established an improved method for drop-hammer impact testing of small quantities of high explosives (10 mg). We performed about seven hundred impact tests under various experimental conditions (e.g., sandpaper vs bare anvil, different sample masses, drop-weights, and striker diameters) to determine an optimal set of conditions and reaction detection methods (e.g., gas analysis, video, and sound recordings) that give the most statistically reliable results with 10 mg samples. We used both Frequentist and Bayesian statistical approaches to compare estimates of the drop height (DH50) that initiates a reaction 50% of the time, and to quantify the associated uncertainty. Gas analysis proved to be the most reliable reaction detection method, showing unambiguous rises in HE decomposition products (e.g., CO 2 ) even when the other indicators (e.g., sound, video) were inconclusive. The impact tests performed with a bare anvil showed much better reproducibility than those conducted with sandpaper, reducing the largest uncertainty observed in the data sets by a factor of 1.7. The DH 50 values obtained from three different sample masses (10, 20, and 35 mg) fell within the uncertainties of the measurements. We demonstrated the improved procedure (i.e., 10-mg samples, gas analysis, bare anvil, and Bayesian approach) on a variety of PETN samples having different surface areas and thermal histories.

PETN↗
DOE OSTI2026

The Explosive Hazards of Icosahedral Carboranes and Dodecaborate with Common Oxidizers and Salts

Carboranes find use in a wide variety of applications ranging from specialty catalysts to medicinal uses. Certain functionalized carboranes are described as explosive materials, although their nonfunctionalized precursors are regarded as inherently stable and not explosive. Herein, we report new findings on the sensitization of nonfunctionalized 12-vertex ortho-, meta-, and para-carboranes as well as dodecaborate in physical mixtures with several common inorganic salts. These mixtures were evaluated for explosive properties with drop hammer impact tests, friction tests, and differential scanning calorimetry thermal gravimetric analysis (DSC-TGA). Results indicate explosive sensitization to mechanical stimuli for the nonfunctionalized carboranes tested with a wide variety of inorganic salts, especially oxidizers. Sensitization of these compounds has not previously been reported, and raising awareness to the broader scientific community on this matter is warranted, especially as several of the mixtures evaluated are more sensitive to mechanical stimuli than primary explosives such as lead azide or pentaerythritol tetranitrate.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Inducer Hydrodynamic Forces in a Cavitating Environment

Marshall Space Flight Center has developed and demonstrated a measurement device for sensing and resolving the hydrodynamic loads on fluid machinery. The device - a derivative of the six-component wind tunnel balance - senses the forces and moments on the rotating device through a weakened shaft section instrumented with a series of strain gauges. This rotating balance was designed to directly measure the steady and unsteady hydrodynamic loads on an inducer, thereby defining the amplitude and frequency content associated with operating in various cavitation modes. The rotating balance was calibrated statically using a dead-weight load system in order to generate the 6 x 12 calibration matrix later used to convert measured voltages to engineering units. Structural modeling suggested that the rotating assembly first bending mode would be significantly reduced with the balance s inclusion. This reduction in structural stiffness was later confirmed experimentally with a hammer-impact test. This effect, coupled with the relatively large damping associated with the rotating balance waterproofing material, limited the device s bandwidth to approximately 50 Hertz Other pre-test validations included sensing the test article rotating assembly built-in imbalance for two configurations and directly measuring the assembly mass and buoyancy while submerged under water. Both tests matched predictions and confirmed the device s sensitivity while stationary and rotating. The rotating balance was then demonstrated in a water test of a full-scale Space Shuttle Main Engine high-pressure liquid oxygen pump inducer. Experimental data was collected a scaled operating conditions at three flow coefficients across a range of cavitation numbers for the single inducer geometry and radial clearance. Two distinct cavitation modes were observed symmetric tip vortex cavitation and alternate-blade cavitation. Although previous experimental tests on the same inducer demonstrated two additional cavitation modes at lower inlet pressures, these conditions proved unreachable with the rotating balance installed due to the intense dynamic environment. The sensed radial load was less influenced by flow coefficient than by cavitation number or cavitation mode although the flow coefficient range was relatively narrow. Transition from symmetric tip vortex to alternate-blade cavitation corresponded to changes in both radial load magnitude and radial load orientation relative to the inducer. Sensed moments indicated that the effective load center moved downstream during this change in cavitation mode. An occurrence of "higher+rdex cavitation" was also detected in both the stationary pressures and the rotating balance data although the frequency of the phenomena was well above the reliable bandwidth of the rotating balance. In summary the experimental tests proved both the concept and device s capability despite the limitations and confirmed that hydrodynamically-induced forces and moments develop in response to the unbalanced pressure field, which is, in turn, a product of the cavitation environment.

Skelley, Stephen E.↗
NASA NTRSDate not supplied

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot tall rocket assembly—consisting primarily of two fuel tanks, an engine section, and four RS-25 rocket engines—capable of sending crew and large payloads to the moon and beyond with 1.6 million pounds of thrust. Currently, the Core Stage is in the B2 Test Stand at Stennis Space Center, undergoing a series of structural and functional tests, designated the Green Run test series. The ultimate goal of Green Run is to verify analytical models and confirm proper subsystem operation of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test performed by the Marshal Space Flight Center modal test team. The desired free boundary condition of the Core Stage was achieved by suspending the massive spacecraft from the B2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound impact hammer for impact testing. Modal response was measured with 550 accelerometers channels distributed on both the Core Stage and the B2 Test Stand crane. Following one very long night of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 2.5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully extracted. The case-study presented in this paper will discuss the SLS Core Stage, the modal test setup and procedure, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Green Run↗
NASA NTRSDate not supplied

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot-tall rocket assembly—consisting primarily of two cryogenic propellant tanks, an engine section, and four RS-25 rocket engines—that will send crew and large payloads to the moon and beyond for NASA’s Artemis program. Prior to SLS assembly, the Core Stage completed a series of structural and functional tests in the B-2 Test Stand at Stennis Space Center, designated Green Run. The goal of Green Run was to verify analytical models, confirm proper subsystem operation, and test-fire all four RS-25 engines of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test, performed by the Marshal Space Flight Center modal test team. A free-boundary test condition of the Core Stage was simulated as close as possible by suspending the massive launch vehicle from the B-2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound instrumented hammer for impact testing. Modal response was measured with 550 accelerometer channels distributed on both the Core Stage and the B-2 Test Stand derrick crane. Following one very long day of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully estimated. The case-study presented in this paper will discuss Green Run, the SLS Core Stage, the modal test setup and execution, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Space Launch System↗
DOE OSTI2025

Effects of Central Cut Width on the Dynamical Characteristics of Box Assembly Structure

An investigation into the Box Assembly with Removable Component (BARC) structure is conducted by utilizing computational simulations and experimental structural testing in order to determine the complex dynamical responses instigated by the central cut of the system. Because the dynamics of the BARC system is complex, this study focuses primarily on analyzing the behavior of the box assembly (BA) system. The investigation explores the dynamics of the BA system by varying the central cut widths, ranging from a cut as wide as 0.5” cut to a 0.25” cut system, as well as a 0.1” cut and a system with no cut at all. Experimental testing is performed on each system including a free vibration test using an impact hammer to excite and identify the dominant frequencies of each structure. This testing is followed by pseudo-random vibration tests and swept sinusoidal excitation tests to determine the nonlinear aspects of these systems, such as the possible existence of nonlinear softening, hardening, and/or damping. The results show that nonlinear softening and nonlinear damping are present in each system. The no-cut system demonstrated the highest peak frequencies throughout all the tests, being the most rigid structure. The 0.25” cut system was shown to have the highest peak frequencies among all the cut systems in both the finite elemenet analysis (FEA) and impact testing. This trend did not continue, though, in the random and harmonic testing, possibly due to the added stiffness of the test setup with the slip table and stinger. The results show the importance of accurately measuring the central cut width and how possible geometric uncertainties change the overall dynamical behaviors of complex systems, such as natural characteristics, nonlinear responses, coupling of modes, and oscillating amplitudes.

Padilla, Christopher (ORCID:000900033446732X)↗
DOE OSTI2025

Insights on the Influence of the Central-Cut Width of the Box Assembly with Removable Component on Its Dynamical Responses

This investigation focuses on the dynamical effects caused by varying the central-cut width within the Box Assembly with Removable Component (BARC) system. The central-cut widths included in this study are a 0.5″ cut, a 0.25″ cut, a thin 0.1″ cut, and a structure that did not have a cut at all. Finite element analysis was conducted to determine the mode shapes and natural frequencies of each of the BARC structures. Structural dynamics experiments were run to examine the effects of the central-cut width on the dynamical responses and nonlinear characteristics of the BARC system. Free vibration testing with an impact hammer was carried out to excite the system and extract the dominant frequencies and directions of the significant responses. A pseudorandom vibration test that allows for the qualitative determination of any nonlinear behavior within the system was performed. This type of behavior can include nonlinear softening, nonlinear hardening, and the most common, nonlinear damping due to the presence of several bolted-joint connections and the possible activation of geometric and inertia nonlinearities. To quantitatively investigate the impacts of the central-cut width on the dynamics of the system, swept sinusoidal testing was conducted. It is determined that almost all systems with central cuts demonstrate the presence of nonlinear softening, but at times, nonlinear hardening trends are seen, particularly in the 0.1″ cut and no-cut systems when testing harmonically. Each of the central-cut systems displays nonlinear damping, with the amount of damping generally increasing as the central cut decreases in size. The effect of the central cut of the BARC system on the mode-switching ability of the system is negligible; however, mode switching takes place when comparing the central-cut configurations to the no-cut one. These results show the significance of accurately measuring the central-cut width and how geometric uncertainty may change the dynamical responses and nonlinear properties of the system.

Padilla, Christopher (ORCID:000900033446732X)↗
NASA NTRS2002

Composite Bending Box Section Modal Vibration Fault Detection

One of the primary concerns with Composite construction in critical structures such as wings and stabilizers is that hidden faults and cracks can develop operationally. In the real world, catastrophic sudden failure can result from these undetected faults in composite structures. Vibration data incorporating a broad frequency modal approach, could detect significant changes prior to failure. The purpose of this report is to investigate the usefulness of frequency mode testing before and after bending and torsion loading on a composite bending Box Test section. This test article is representative of construction techniques being developed for the recent NASA Blended Wing Body Low Speed Vehicle Project. The Box section represents the construction technique on the proposed blended wing aircraft. Modal testing using an impact hammer provides an frequency fingerprint before and after bending and torsional loading. If a significant structural discontinuity develops, the vibration response is expected to change. The limitations of the data will be evaluated for future use as a non-destructive in-situ method of assessing hidden damage in similarly constructed composite wing assemblies. Modal vibration fault detection sensitivity to band-width, location and axis will be investigated. Do the sensor accelerometers need to be near the fault and or in the same axis? The response data used in this report was recorded at 17 locations using tri-axial accelerometers. The modal tests were conducted following 5 independent loading conditions before load to failure and 2 following load to failure over a period of 6 weeks. Redundant data was used to minimize effects from uncontrolled variables which could lead to incorrect interpretations. It will be shown that vibrational modes detected failure at many locations when skin de-bonding failures occurred near the center section. Important considerations are the axis selected and frequency range.

Werlink, Rudy↗
NASA NTRS2003

Vibration Modal Characterization of a Stirling Convertor via Base-Shake Excitation

The U.S. Department of Energy (DOE), Lockheed Martin (LM), Stirling Technology Company (STC), and NASA John H. Glenn Research Center (GRC) are currently developing a high-efficiency Stirling convertor for use in a Stirling Radioisotope Generator (SRG). NASA and DOE have identified the SRG for potential use as an advanced power system for future NASA Space Science missions, providing spacecraft onboard electric power for deep space missions and power for unmanned Mars rovers. Low-level, baseshake sine vibration tests were conducted on the Stirling Technology Demonstration Convertor (TDC), at NASA GRC's Structural Dynamics Laboratory, in February 2001, as part of the development of this Stirling technology. The purpose of these tests was to provide a better understanding of the TDC's internal dynamic response to external vibratory base excitations. The knowledge obtained can therein be used to help explain the success that the TDC enjoyed in its previous random vibration qualification tests (December 1999). This explanation focuses on the TDC s internal dynamic characteristics in the 50 to 250 Hz frequency range, which corresponds to the maximum input levels of its qualification random vibration test specification. The internal dynamic structural characteristics of the TDC have now been measured in two separate tests under different motoring and dynamic loading conditions: (1) with the convertor being electrically motored, under a vibratory base-shake excitation load, and (2) with the convertor turned off, and its alternator internals undergoing dynamic excitation via hammer impact loading. This paper addresses the test setup, procedure and results of the base-shake vibration testing conducted on the motored TDC, and will compare these results with those results obtained from the dynamic impact tests (May 2001) on the nonmotored TDC.

Suarez, Vicente J.↗
NASA NTRS2015

Modeling of Local BEAM Structure for Evaluation of MMOD Impacts to Support Development of a Health Monitoring System

This report summarizes initial modeling of the local response of the Bigelow Expandable Activity Module (BEAM) to micrometeorite and orbital debris (MMOD) impacts using a structural, non-linear, transient dynamic finite element code. Complementary test results for a local BEAM structure are presented for both hammer and projectile impacts. Review of these data provided guidance for the transient dynamic model development. The local model is intended to support predictions using the global BEAM model, described in a companion report. Two types of local models were developed. One mimics the simplified Soft-Goods (fabric envelop) part of the BEAM NASTRAN model delivered by the project. The second investigates through-the-thickness modeling challenges for MMOD-type impacts. Both the testing and the analysis summaries contain lessons learned and areas for future efforts.

Lyle, Karen H.↗
NASA NTRS2018

Modal Test and Analysis of the NASA Tiltrotor Test Rig

The Tiltrotor Test Rig (TTR) is being developed at the NASA Ames Research Center for testing full-scaleproprotors in the National Full-scale Aerodynamics Complex (NFAC) wind tunnel. The TTR is currentlyundergoing checkout testing to ensure its proper functionality. Part of the checkout process is a groundvibration test, or shake test, to characterize the modal characteristics of the test rig once it is installed in the wind tunnel. This paper presents a summary of the shake test procedure and an overview of the test results. The results include frequency response functions for a number of different test configurations as well as visualizations of the major mode shapes. Excitation methods included random and swept sine shaking as well as hammer impacts. At the conclusion of this paper, some recommendations are given for future shake tests.

Tiltrotor Test Rig↗
NASA NTRS2003

Viscoelastic Vibration Dampers for Turbomachine Blades

Simple viscoelastic dampers have been invented for use on the root attachments of turbomachine blades. These dampers suppress bending- and torsion-mode blade vibrations, which are excited by unsteady aerodynamic forces during operation. In suppressing vibrations, these dampers reduce fatigue (thereby prolonging blade lifetimes) while reducing noise. These dampers can be installed in new turbomachines or in previously constructed turbomachines, without need for structural modifications. Moreover, because these dampers are not exposed to flows, they do not affect the aerodynamic performances of turbomachines. Figure 1 depicts a basic turbomachine rotor, which includes multiple blades affixed to a hub by means of dovetail root attachments. Prior to mounting of the blades, thin layers of a viscoelastic material are applied to selected areas of the blade roots. Once the blades have been installed in the hub and the rotor is set into rotation, centrifugal force compresses these layers between the mating load-bearing surfaces of the hub and the blade root. The layers of viscoelastic material provide load paths through which the vibration energy of the blade can be dissipated. The viscoelasticity of the material converts mechanical vibration energy into shear strain energy and then from shear strain energy to heat. Of the viscoelastic materials that have been considered thus far for this application, the one of choice is a commercial polyurethane that is available in tape form, coated on one side with an adhesive that facilitates bonding to blade roots. The thickness of the tape can be chosen to suit the specific application. The typical thickness of 0.012 in. (.0.3 mm) is small enough that the tape can fit in the clearance between the mating blade-root and hub surfaces in a typical turbomachine. In an experiment, a blade was mounted in a test fixture designed to simulate the blade-end conditions that prevail in a turbocompressor. Vibrations were excited in the blade by use of an impact hammer, and damping of the vibrations was measured by use of a dynamic signal analyzer. Tests were performed without and with viscoelastic dampers installed in the dovetail root attachment. The results of the measurements, some of which are presented in Figure 2, show that the viscoelastic dampers greatly increased the rate of damping of vibrations. Accordingly, dynamic stresses on rotor blades were significantly reduced, as shown in Figure 2.

Nguyen, Nhan↗
NASA NTRS2014

Characterization and Comparison of Vibration Transfer Paths in a Helicopter Gearbox and a Fixture Mounted Gearbox

Health monitoring of rotorcraft components, currently being performed by Health and Usage Monitoring Systems through analyses of vibration signatures of dynamic mechanical components, is very important for their safe and economic operation. HUMS analyze vibration signatures associated with faults and quantify them as condition indicators to predict component behavior. Vibration transfer paths are characterized by frequency response functions derived from the input/output relationship between applied force and dynamic response through a structure as a function of frequency. With an objective to investigate the differences in transfer paths, transfer path measurements were recorded under similar conditions in the left and right nose gearboxes of an AH-64 helicopter and in an isolated left nose gearbox in a test fixture at NASA Glenn Research Center. The test fixture enabled the application of measured torques-common during an actual operation. An impact hammer as well as commercial and lab piezo shakers, were used in conjunction with two types of commercially available accelerometers to collect the vibration response under various test conditions. The frequency response functions measured under comparable conditions of both systems were found to be consistent. Measurements made on the fixture indicated certain real-world installation and maintenance issues, such as sensor alignments, accelerometer locations and installation torques, had minimal effect. However, gear vibration transfer path dynamics appeared to be somewhat dependent on the presence of oil, and the transfer path dynamics were notably different if the force input was on the internal ring gear rather than on the external gearbox case.

structures↗
NASA NTRS2024

X-57 Cruise Motor GVT Using Fixed-Base Correction Technique

The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) completed a modal survey of the X-57 Maxwell aircraft cruise motor system to help inform cruise motor redesign efforts. X-57 Maxwell was an electric propulsion demonstrator aircraft developed by NASA to inform airworthiness standards for electrified-aircraft. The cruise motor system modal survey was completed in spring of 2023 utilizing the fixed-base correction (FBC) ground vibration test (GVT) technique developed by ATA Engineering, to decouple the motor modes from the aircraft modes. Previously during the full aircraft GVT, a detailed modal assessment of the cruise motors was not performed. Owing to the X-57 project’s phase in the aircraft development cycle when the motor redesign effort occurred, the cruise motor GVT could only be performed with the cruise motor system installed on the aircraft, with most of its installation hardware (wiring, baffling, sensors, etc.) attached. An impact hammer was used to provide excitation input at various locations within the tight confines of the cruise motor installation. To better support motor redesign efforts, the FBC methodology was utilized to fix, separate and de-couple the cruise motor modes from aircraft modal response. During the GVT, this required additional impact tap tests on candidate fixed-boundary points for each degree of freedom (DOF) to be fixed. Additional triaxial accelerometers installed at the candidate points were used to compute frequency response functions (FRFs) in X, Y, and Z directions to enable those DOFs to be numerically fixed. Test data was acquired using Hottinger Brüel & Kjær’s LAN-XI data acquisition hardware and BK Connect software. FBC post-test processing was performed using the Structural Modification Using Frequency Response Functions (SMURF) technique with ATA Engineering’s Interface between MATLAB, Analysis, Test (IMAT) software. Utilizing the FBC technique relieved test engineers from having to instrument the entire aircraft to identify and separate aircraft response from cruise motor modes of interest. The FBC technique also permitted structural analysis engineers to omit secondary components from their finite element model (FEM) of the cruise motor system. This FBC modal survey was successful, and the first time NASA AFRC utilized the FBC method on an aircraft rather than a test fixture, and also using an impact hammer rather than multiple shakers allowing significant project schedule and cost savings

Modal Survey↗
NASA NTRS1984

Insulation bonding test system

A method and a system for testing the bonding of foam insulation attached to metal is described. The system involves the use of an impacter which has a calibrated load cell mounted on a plunger and a hammer head mounted on the end of the plunger. When the impacter strikes the insulation at a point to be tested, the load cell measures the force of the impact and the precise time interval during which the hammer head is in contact with the insulation. This information is transmitted as an electrical signal to a load cell amplifier where the signal is conditioned and then transmitted to a fast Fourier transform (FFT) analyzer. The FFT analyzer produces energy spectral density curves which are displayed on a video screen. The termination frequency of the energy spectral density curve may be compared with a predetermined empirical scale to determine whether a igh quality bond, good bond, or debond is present at the point of impact.

Beggs, J. M.↗
NASA NTRS1982

The dynamic flexural response of propeller blades

The determination of the torsional constants of three blade models having NACA four-digit symmetrical airfoil cross sections is presented. Values were obtained for these models analytically and experimentally. Results were also obtained for three other models having rectangular, elliptical, and parabolic cross sections. Complete modal analyses were performed for five blade models. The identification of modal parameters was done for cases when the blades were modeled as either undamped or damped multi-degree-of-freedom systems. For the experimental phase of this study, the modal testing was performed using a Dual Channel FFT analyzer and an impact hammer (which produced an impulsive excitation). The natural frequency and damping of each mode in the frequency range up to 2 kHz were measured. A small computer code was developed to calculate the dynamic response of the blade models for comparison with the experimental results. A comparison of the undamped and damped cases was made for all five blade models at the instant of maximum excitation force. The program was capable of handling models where the excitation forces were distributed arbitrarily along the length of the blade.

Djordjevic, S. Z.↗
NASA NTRS2001

Membrane Vibration Studies Using a Scanning Laser Vibrometer

This paper summarizes on-going experimental work at NASA Langley Research Center to measure the dynamics of a 1.016 m (40 in.) square polyimide film Kapton membrane. A fixed fully automated impact hammer and Polytec PSV-300-H scanning laser vibrometer were used for non-contact modal testing of the membrane with zero-mass-loading. The paper discusses the results obtained by testing the membrane at various tension levels and at various excitation locations. Results obtained by direct shaker excitation to the membrane are also discussed.

Gaspar, James L.↗