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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 NTRS2007

Replica-based Crack Inspection

A surface replica-based crack inspection method has recently been developed for use in Space Shuttle main engine (SSME) hydrogen feedline flowliners. These flowliners exist to ensure favorable flow of liquid hydrogen over gimble joint bellows, and consist of two rings each containing 38 elongated slots. In the summer of 2002, multiple cracks ranging from 0.1 inches to 0.6 inches long were discovered; each orbiter contained at least one cracked flowliner. These long cracks were repaired and eddy current inspections ensured that no cracks longer than 0.075 inches were present. However, subsequent fracture-mechanics review of flight rationale required detection of smaller cracks, and was the driving force for development of higher-resolution inspection method. Acetate tape surface replicas have been used for decades to detect and monitor small cracks. However, acetate tape replicas have primarily been limited to laboratory specimens because complexities involved in making these replicas - requiring acetate tape to be dissolved with acetone - are not well suited for a crack inspection tool. More recently developed silicon-based replicas are better suited for use as a crack detection tool. A commercially available silicon-based replica product has been determined to be acceptable for use in SSME hydrogen feedlines. A method has been developed using this product and a scanning electron microscope for analysis, which can find cracks as small as 0.005 inches and other features (e.g., pits, scratches, tool marks, etc.) as small as 0.001 inches. The resolution of this method has been validated with dozens of cracks generated in a laboratory setting and this method has been used to locate 55 cracks (ranging in size from 0.040 inches to 0.004 inches) on space flight hardware. These cracks were removed by polishing away the cracked material and a second round of replicas confirmed the repair.

Newman, John A.↗
NASA NTRS1975

Replica grating study

Methods are outlined which were used to test the response of replica diffraction gratings to a space environment, specifically the response of the replica gratings to thermal-vacuum and electron irradiation stress. It is concluded that there probably is some degradation to thermal stress, but that there is probably no significant degradation due to a vacuum environment. It is further concluded that the degradation of performance of replica gratings because of electron irradiation is due to the interaction of the electrons and the replica grating substrate and not to the replication material itself. Replica and original gratings on the same substrate material should thus respond to particle irradiation in the same manner. A study is presented on the variation of refraction index of a space-related material, Nd:CaF2, with wavelength, percent neodymium doping, and temperature.

Gunter, R. C., Jr.↗
NASA NTRS1984

On the use of marker loads and replicas for measuring growth rates for small cracks

The initiation and growth of small cracks (5-500 microns) from edge notches in 2024-T3 aluminum alloy sheets were studied under constant-amplitude loading. Two methods were used to measure crack shape and size. In the first method, striation marker bands were periodically formed along the crack front by interrupting the constant-amplitude loading by either an elevated R-ratio load sequence, or by an overload sequence. In each case the marker loading was selected so as to have minimal influence on the growth rate under the primary loading. In the second method, the surface crack length was monitored by taking surface replicas at regular intervals. The marker band techniques did not provide reliable crack length and crack shape information for cracks smaller than 2 mm. The replica technique provided accurate information for surface crack length at all crack lengths, and fracture tests on specimens with small cracks provided crack-shape information.

Swain, M. H.↗
NASA NTRS1984

On the use of marker loads and replicas for measuring growth rates for small cracks

The initiation and growth of small cracks (5-500 microns m) from edge notches in 2024-T3 aluminum alloy sheets were studied under constant amplitude loading. Two methods were used to measure crack shape and size. In the first method, striation marker bands were periodically formed along the crack front by interrupting the constant amplitude loading by either an elevated R-ratio load sequence, or by an overload sequence. In the second method, the surface crack length was monitored by taking surface replicas at regular intervals. The marker band techniques did not provide reliable crack length and crack shape information for cracks smaller than 2 mm. The replica technique provided accurate information for surface crack length at all crack lengths, and fracture tests on specimens with small cracks provided crack-shape information. Crack growth rates were plotted against the stress intensity factor ranges. The results exhibited the small crack effect, in that the small cracks grew faster than large cracks at the same stress-intensity factor range. A crack closure model was also used to analyze the growth of small cracks from small (inclusion) defects at the notch surface.

Swain, M. H.↗
NASA NTRS2024

Real-Time Temperature Field State Observer and Digital Replica to Support Cyber-Physical Testing

Cyber-physical testing is a class of experimental methods in which a system is partitioned into physical and numerical components to study its overall behavior. Transfer systems are typically needed to capture relevant interactions by enforcing appropriate interface conditions between the physical and numerical portions. While cyber-physical testing is often performed using lumped-parameter systems, thermomechanical cyber-physical testing requires the use of thermal actuators as transfer systems to apply a thermal condition over a spatially distributed region or surface. Thus, the interactions between the numerical and physical components are of a distributed nature, i.e., a field rather than point values. In this paper, we develop and experimentally validate a state observer for temperature fields to enable thermomechanical cyber-physical testing. The state observer provides continuous estimates of temperature over a surface of the thermal actuator using only temperature measurements at discrete locations. The estimated temperature field is then leveraged to account for localized mechanical defects in the interface condition. The method consists of building a digital replica of one portion of the control plant. By imposing defects in the digital replica it is used to generate and output the response of a thermal load pattern that represents that of a physical system with mechanical defects.

Manuel Salmeron↗
NASA NTRS1986

Measurement and prediction of flow through a replica segment of a mildly atherosclerotic coronary artery of man

Pressure distributions were measured along a hollow vascular axisymmetric replica of a segment of the left circumflex coronary artery of man with mildly atherosclerotic diffuse disease. A large range of physiological Reynolds numbers from about 60 to 500, including hyperemic response, was spanned in the flows investigation using a fluid simulating blood kinematic viscosity. Predicted pressure distributions from the numerical solution of the Navier-Stokes equations were similar in trend and magnitude to the measurements. Large variations in the predicted velocity profiles occurred along the lumen. The influence of the smaller scale multiple flow obstacles along the wall (lesion variations) led to sharp spikes in the predicted wall shear stresses. Reynolds number similarity was discussed, and estimates of what time averaged in vivo pressure drop and shear stress might be were given for a vessel segment.

Back, L. H.↗
NASA NTRS2003

The 2003 Goddard Rocket Replica Project

A group of volunteers from Marshall Space Flight Center using information and records available,construct a working, flying replica of Robert Goddard's 1926 liquid rocket as well as accurate static display version. Document the effort for posterity.

Farr, Rebecca A.↗
NASA NTRS2003

The 2003 Goddard Rocket Replica Project: A Reconstruction of the World's First Functional Liquid Rocket System

As a part of NASA s 2003 Centennial of Flight celebration, engineers and technicians at Marshall Space Flight Center (MSFC), Huntsville, Alabama, in cooperation with the Alabama-Mississippi AIAA Section, have reconstructed historically accurate, functional replicas of Dr. Robert H. Goddard s 1926 first liquid- fuel rocket. The purposes of this project were to clearly understand, recreate, and document the mechanisms and workings of the 1926 rocket for exhibit and educational use, creating a vital resource for researchers studying the evolution of liquid rocketry for years to come. The MSFC team s reverse engineering activity has created detailed engineering-quality drawings and specifications describing the original rocket and how it was built, tested, and operated. Static hot-fire tests, as well as flight demonstrations, have further defined and quantified the actual performance and engineering actual performance and engineering challenges of this major segment in early aerospace history.

R. A. Farr↗
NASA NTRS2008

Replica-Based Crack Inspection

Surface replication has been proposed as a method for crack detection in space shuttle main engine flowliner slots. The results of a feasibility study show that examination of surface replicas with a scanning electron microscope can result in the detection of cracks as small as 0.005 inch, and surface flaws as small as 0.001 inch, for the flowliner material.

Newman, John A.↗
NASA NTRS2024

Contributions of irrigation modeling, soil moisture and snow data assimilation to high-resolution water budget estimates over the Po basin: progress towards digital replicas

High-resolution water budget estimates benefit from modeling of human water management and satellite data assimilation (DA) in river basins with a large human footprint. Utilizing the Noah-MP land surface model with dynamic vegetation growth and river routing, in combination with an irrigation module, Sentinel-1 backscatter and snow depth retrievals, we produce a set of 0.7-km2 water budget estimates of the Po river basin (Italy) for 2015–2023. The results demonstrate that irrigation modeling improves the seasonal soil moisture variation and summer streamflow at all gauges in the valley after withdrawal of irrigation water from the streamflow in postprocessing (12% error reduction relative to observed low summer streamflow), even if the basin-wide irrigation amount is underestimated. Sentinel-1 backscatter DA for soil moisture updating strongly interacts with irrigation modeling: when both are activated, the soil moisture updates are limited, and the simulated irrigation amounts are reduced. Backscatter DA systematically reduces soil moisture in the spring, which improves downstream spring streamflow. Assimilating Sentinel-1 snow depth retrievals over the surrounding Alps and Apennines further improves spring streamflow in a complementary way (2% error reduction relative to observed high spring streamflow). Despite the seasonal improvements, irrigation modeling and Sentinel-1 backscatter DA cannot significantly improve short-term or interannual variations in soil moisture, irrigation modeling causes a systematically prolonged high vegetation productivity, and snow depth DA only impacts the deep snowpacks. This study helps advancing the design of digital water budget replicas for river basins.

Gabrielle J M De Lannoy↗