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NASA NTRS1985

Advanced latent heat of fusion thermal energy storage for solar power systems

The use of solar thermal power systems coupled with thermal energy storage (TES) is being studied for both terrestrial and space applications. In the case of terrestrial applications, it was found that one or two hours of TES could shift the insolation peak (solar noon) to coincide with user peak loads. The use of a phase change material (PCM) is attractive because of the higher energy storage density which can be achieved. However, the use of PCM has also certain disadvantages which must be addressed. Proof of concept testing was undertaken to evaluate corrosive effects and thermal ratcheting effects in a slurry system. It is concluded that the considered alkali metal/alkali salt slurry approach to TES appears to be very viable, taking into account an elimination of thermal ratcheting in storage systems and the reduction of corrosive effects. The approach appears to be useful for an employment involving temperatures applicable to Brayton or Stirling cycles.

Phillips, W. M.↗

NASA NTRS1976

Vacuum thermal-mechanical fatigue behavior of two iron-base alloys

The present study extends the concept of in-phase grain boundary ratcheting to two iron-base alloys (Type 304 stainless steel and A286 alloy) and provides a clearer interpretation of out-of-phase grain boundary ratcheting effects observed in the A286 alloy which does not exhibit geometric instability. Elevated-temperature low-cycle thermal-mechanical fatigue tests in an ion-pumped ultrahigh vacuum chamber revealed significant effects of frequency and combined temperature-strain cycling on fatigue life. In-phase thermal cycling (tension at high temperature and compression at low temperature) caused large life reductions in both materials due to grain boundary cavitation caused by unreversed grain boundary sliding (grain boundary ratcheting). Out-of-phase thermal cycling (tension at low temperature and compression at high temperature) also caused large cyclic life reductions in both materials. In the A286 alloy, out-of-phase life reductions are attributed to compressive ratcheting.

Sheffler, K. D.↗

NASA NTRS1981

Analysis of augmented aircraft flying qualities through application of the Neal-Smith criterion

The Neal-Smith criterion is examined for possible applications in the evaluation of augmented fighter aircraft flying qualities. Longitudinal and lateral flying qualities are addressed. Based on the application of several longitudinal flying qualities data bases, revisions are proposed to the original criterion. Examples are given which show the revised criterion to be a good discriminator of pitch flying qualities. Initial results of lateral flying qualities evaluation through application of the Neal-Smith criterion are poor. Lateral aircraft configurations whose flying qualities are degraded by roll ratcheting effects map into the Level 1 region of the criterion. A third dimension of the criterion for flying qualities specification is evident. Additional criteria are proposed to incorporate this dimension into the criterion structure for flying qualities analysis.

Bailey, R. E.↗

NASA NTRS1988

Life prediction modeling based on strainrange partitioning

Strainrange partitioning (SRP) is an integrated low-cycle-fatigue life predicting system. It was created specifically for calculating cyclic crack initiation life under severe high-temperature fatigue conditions. The key feature of the SRP system is its recognition of the interacting mechanisms of cyclic inelastic deformation that govern cyclic life at high temperatures. The SRP system bridges the gap between the mechanistic level of understanding that breeds new and better materials and the phenomenological level wherein workable engineering life prediction methods are in great demand. The system was recently expanded to address engineering fatigue problems in the low-strain, long-life, nominally elastic regime. This breakthrough, along with other advances in material behavior and testing technology, has permitted the system to also encompass low-strain thermomechanical loading conditions. Other important refinements of the originally proposed method include procedures for dealing with life-reducing effects of multiaxial loading, ratcheting, mean stresses, nonrepetitive (cumulative loading) loading, and environmental and long-time exposure. Procedure were also developed for partitioning creep and plastic strain and for estimating strainrange versus life relations from tensile and creep rupture properties. Each of the important engineering features of the SRP system are discussed and examples shown of how they help toward predicting high-temperature fatigue life under practical, although complex, loading conditions.

Halford, Gary R.↗

NASA NTRS1999

Analysis of Three-Dimensional Roller Performance in a Micro-g Environment

Approximately 960 hours of extravehicular activity (EVA), or spacewalks, are planned for the construction of the International Space Station over the next six years. This is over two-and-a-half times the total number of EVA hours accumulated by the National Aeronautics and Space Administration (NASA) in the past 35 years of U.S. spaceflight. Therefore, it is advantageous to explore ways to assist astronauts in being more efficient while working in space. The Space Systems Laboratory at the University of Maryland is investigating ways of improving conventional ratcheting tools that do not work effectively in confined spaces and have been seen to exhibit other limitations that restrict their use during EVA. By replacing the traditional ratchet mechanism with a NASA/Goddard Space Flight Center-developed three-dimensional (3-D) sprag and roller mechanism, ratcheting tools can be made more efficient. In October of 1998, a 3-D roller mechanism was flown on space shuttle mission STS-95 as part of the Space Experiment Module program. The goal of the experiment was to quantify the roller's performance when operating for an extended period in a micro-g environment. This paper discusses the design of the experiment, as well as the results obtained.

Roberts, B.↗

NASA NTRS1973

Experimental evaluation of thermal ratcheting behavior in UO2 fuel elements

The effects of thermal cycling of UO2 at high temperatures has been experimentally evaluated to determine the rates of distortion of UO2/clad fuel elements. Two capsules were rested in the 1500 C range, one with a 50 C thermal cycle, the other with a 100 C thermal cycle. It was observed that eight hours at the lower cycle temperature produced sufficient UO2 redistribution to cause clad distortion. The amount of distortion produced by the 100 C cycle was less than double that produced by the 50 C, indicating smaller thermal cycles would result in clad distortion. An incubation period was observed to occur before the onset of distortion with cycling similar to fuel swelling observed in-pile at these temperatures.

Phillips, W. M.↗

NASA NTRS1996

Mechanisms of High-Temperature Fatigue Failure in Alloy 800H

The damage mechanisms influencing the axial strain-controlled Low-Cycle Fatigue (LCF) behavior of alloy 800H at 850 C have been evaluated under conditions of equal tension/compression ramp rates (Fast-Fast (F-F): 4 X 10(sup -3)/s and Slow-Slow (S-S): 4 X 10(sup -5)/s) and asymmetrical ramp rates (Fast-Slow (F-S): 4 x 10(sup -3)/s / 4 X 10(sup -5/s and Slow-Fast (S-F): 4 X 10(sup -5) / 4 X 10(sup -3)/s) in tension and compression. The fatigue life, cyclic stress response, and fracture modes were significantly influenced by the waveform shape. The fatigue lives displayed by different loading conditions were in the following order: F-F greater than S-S greater than F-S greater than S-F. The fracture mode was dictated by the ramp rate adopted in the tensile direction. The fast ramp rate in the tensile direction led to the occurrence of transgranular crack initiation and propagation, whereas the slow ramp rate caused intergranular initiation and propagation. The time-dependent processes and their synergistic interactions, which were at the basis of observed changes in cyclic stress response and fatigue life, were identified. Oxidation, creep damage, dynamic strain aging, massive carbide precipitation, time-dependent creep deformation, and deformation ratcheting were among the several factors influencing cyclic life. Irrespective of the loading condition, the largest effect on life was exerted by oxidation processes. Deformation ratcheting had its greatest influence on life under asymmetrical loading conditions. Creep damage accumulated the greatest amount during the slow tensile ramp under S-F conditions.

BhanuSankaraRao, K.↗

NASA NTRS2014

Assessment of Shape Memory Alloys - From Atoms To Actuators - Via In Situ Neutron Diffraction

As shape memory alloys (SMAs) become an established actuator technology, it is important to identify the fundamental mechanisms responsible for their performance by understanding microstructure performance relationships from processing to final form. Yet, microstructural examination of SMAs at stress and temperature is often a challenge since structural changes occur with stress and temperature and microstructures cannot be preserved through quenching or after stress removal, as would be the case for conventional materials. One solution to this dilemma is in situ neutron diffraction, which has been applied to the investigation of SMAs and has offered a unique approach to reveal the fundamental micromechanics and microstructural aspects of bulk SMAs in a non-destructive setting. Through this technique, it is possible to directly correlate the micromechanical responses (e.g., internal residual stresses, lattice strains), microstructural evolutions (e.g., texture, defects) and phase transformation properties (e.g., phase fractions, kinetics) to the macroscopic actuator behavior. In this work, in situ neutron diffraction was systematically employed to evaluate the deformation and transformation behavior of SMAs under typical actuator conditions. Austenite and martensite phases, yield behavior, variant selection and transformation temperatures were characterized for a polycrystalline NiTi (49.9 at. Ni). As the alloy transforms under thermomechanical loading, the measured textures and lattice plane-level variations were directly related to the cyclic actuation-strain characteristics and the dimensional instability (strain ratcheting) commonly observed in this alloy. The effect of training on the shape memory characteristics of the alloy and the development of two-way shape memory effect (TWSME) were also assessed. The final conversion from a material to a useful actuator, typically termed shape setting, was also investigated in situ during constrained heatingcooling and subsequent shape recovery experiments. Neutron diffraction techniques are also being applied to the investigation of novel high temperature SMAs with the objective of designing alloys with better stability, higher transition temperatures and ultimately superior durability.

Shape Memory Alloys↗

NASA NTRS1992

Solder creep-fatigue interactions with flexible leaded parts

With flexible leaded parts, the solder-joint failure process involves a complex interplay of creep and fatigue mechanisms. To better understand the role of creep in typical multi-hour cyclic loading conditions, a specialized non-linear finite-element creep simulation computer program has been formulated. The numerical algorithm includes the complete part-lead-solder-PWB system, accounting for strain-rate dependence of creep on applied stress and temperature, and the role of the part-lead dimensions and flexibility that determine the total creep deflection (solder strain range) during stress relaxation. The computer program has been used to explore the effects of various solder creep-fatigue parameters such as lead height and stiffness, thermal-cycle test profile, and part/board differential thermal expansion properties. One of the most interesting findings is the strong presence of unidirectional creep-ratcheting that occurs during thermal cycling due to temperature dominated strain-rate effects. To corroborate the solder fatigue model predictions, a number of carefully controlled thermal-cycle tests have been conducted using special bimetallic test boards.

Ross, R. G., Jr.↗

NASA NTRS2014

Development of Cryogenic Filter Wheels for the HERSCHEL Photodetector Array Camera & Spectrometer (PACS)

This paper describes the two PACS Filter Wheels that are direct-drive rotational mechanisms operated at a temperature below 5K inside the PACS focal plane unit of the Herschel Satellite. The purpose of the mechanisms is to switch between filters. The rotation axis is pivoted to the support structure via a slightly preloaded pair of ball bearings and driven by a Cryotorquer. Position sensing is realized by a pair of Hall effect sensors. Powerless positioning at the filter positions is achieved by a magnetic ratchet system. The key technologies are the Cryotorquer design and the magnetic ratchet design in the low temperature range. Furthermore, we will report on lessons learned during the development and qualification of the mechanism and the paint.

Koerner, Christian↗

NASA NTRS1966

Hand tool permits shrink sizing of assembled tubing

Portable tool sizes tubing ends without disassembling the tubing installation. The shrink sizing tool is clamped to the tubing and operated by a ratchet wrench. A gear train forces the tubing end against an appropriate die or mandrel to effect the sizing.

Millett, A.↗

NASA NTRS1986

Investigation of limb-sidestick dynamic interaction with roll control

A fixed-base simulation was performed to identify and quantify interactions between the pilot's hand/arm neuromuscular subsystem and such features of typical modern fighter aircraft roll rate command control system mechanization as: (1) force sensing side-stick type manipulator; (2) vehicle effective roll time constant; and (3) flight control system effective time delay. The simulation results provide insight to high frequency pilot induced oscillations (PIO) (roll ratchet), low frequency PIO, and roll-to-right control and handling problems previously observed in experimental and production fly-by-wire control systems. The simulation configurations encompass and/or duplicate several actual flight situations, reproduce control problems observed in flight, and validate the concept that the high frequency nuisance mode known as roll ratchet derives primarily from the pilot's neuromuscular subsystem. The simulations show that force-sensing side-stick manipulator force/displacement/command gradients, command prefilters, and flight control system time delays need to be carefully adjusted to minimize neuromuscular mode amplitude peaking (roll ratchet tendency) without restricting roll control bandwidth (with resulting sluggish or PIO prone control).

Johnston, D. E.↗

NASA NTRS1986

Investigation of interactions between limb-manipulator dynamics and effective vehicle roll control characteristics

A fixed-base simulation was performed to identify and quantify interactions between the pilot's hand/arm neuromuscular subsystem and such features of typical modern fighter aircraft roll rate command control system mechanization as: (1) force sensing side-stick type manipulator; (2) vehicle effective role time constant; and (3) flight control system effective time delay. The simulation results provide insight to high frequency pilot induced oscillations (PIO) (roll ratchet), low frequency PIO, and roll-to-right control and handling problems previously observed in experimental and production fly-by-wire control systems. The simulation configurations encompass and/or duplicate actual flight situations, reproduce control problems observed in flight, and validate the concept that the high frequency nuisance mode known as roll ratchet derives primarily from the pilot's neuromuscular subsystem. The simulations show that force-sensing side-stick manipulator force/displacement/command gradients, command prefilters, and flight control system time delays need to be carefully adjusted to minimize neuromuscular mode amplitude peaking (roll ratchet tendency) without restricting roll control bandwidth (with resulting sluggish or PIO prone control).

Johnston, D. E.↗

NASA NTRS1994

Micromechanical Modeling of the Thermal Expansion of Graphite/copper Composites with Nonuniform Microstructure

Two micromechanical models were developed to investigate the thermal expansion of graphite/copper (Gr/Cu) composites. The models incorporate the effects of temperature-dependent material properties, matrix inelasticity, initial residual stresses due to processing history, and nonuniform fiber distribution. The first model is based on the multiple concentric cylinder geometry, with each cylinder treated as a two-phase composite with a characteristic fiber volume fractions. By altering the fiber volume fraction of the individual cylinders, unidirectional composites with radially nonuniform fiber distributions can be investigated using this model. The second model is based on the inelastic lamination theory. By varying the fiber content in the individual laminae, composites with nonuniform fiber distribution in the thickness direction can be investigated. In both models, the properties of the individual regions (cylinders or laminae) are calculated using the method of cells micromechanical model. Classical incremental plasticity theory is used to model the inelastic response of the copper matrix at the microlevel. The models were used to characterize the effects of nonuniform fiber distribution on the thermal expansion of Gr/Cu. These effects were compared to the effects of matrix plasticity, choice of stress-free temperature, and slight fiber misalignment. It was found that the radially nonuniform fiber distribution has little effect on the thermal expansion of Gr/Cu but could become significant for composites with large fiber-matrix transverse CTE and Young's modulus mismatch. The effect of nonuniform fiber distribution in the through-thickness direction of a laminate was more significant, but only approached that of the stress-free temperature for the most extreme cases that include large amounts of bending. Subsequent comparison with experimental thermal expansion data indicated the need for more accurate characterization of the graphite fiber thermomechanical properties. Correlation with cyclic data revealed the presence of a mechanism not considered in the developed models. The predicted response did, however, exhibit ratcheting behavior that has been observed experimentally in Gr/Cu. Finally, simulation of the actual fiber distribution of particular specimens had little effect on the predicted thermal expansion.

Bednarcyk, Brett A.↗

NASA NTRS1992

Numerical experiments with flows of elongated granules

Theory and numerical results are given for a program simulating two dimensional granular flow (1) between two infinite, counter-moving, parallel, roughened walls, and (2) for an infinitely wide slider. Each granule is simulated by a central repulsive force field ratcheted with force restitution factor to introduce dissipation. Transmission of angular momentum between particles occurs via Coulomb friction. The effect of granular hardness is explored. Gaps from 7 to 28 particle diameters are investigated, with solid fractions ranging from 0.2 to 0.9. Among features observed are: slip flow at boundaries, coagulation at high densities, and gross fluctuation in surface stress. A videotape has been prepared to demonstrate the foregoing effects.

Elrod, Harold G.↗

NASA NTRS1993

Establishing a relationship between maximum torque production of isolated joints to simulate EVA ratchet push-pull maneuver: A case study

As manned exploration of space continues, analytical evaluation of human strength characteristics is critical. These extraterrestrial environments will spawn issues of human performance which will impact the designs of tools, work spaces, and space vehicles. Computer modeling is an effective method of correlating human biomechanical and anthropometric data with models of space structures and human work spaces. The aim of this study is to provide biomechanical data from isolated joints to be utilized in a computer modeling system for calculating torque resulting from any upper extremity motions: in this study, the ratchet wrench push-pull operation (a typical extravehicular activity task). Established here are mathematical relationships used to calculate maximum torque production of isolated upper extremity joints. These relationships are a function of joint angle and joint velocity.

Pandya, Abhilash↗

NASA NTRS2013

Engineering Evaluation of International Low Impact Docking System Latch Hooks

The international Low Impact Docking System (iLIDS) provides a structural arrangement that allows for visiting vehicles to dock with the International Space Station (ISS) (Fig 1). The iLIDS docking units are mechanically joined together by a series of active and passive latch hooks. In order to preserve docking capability at the existing Russian docking interfaces, the iLIDS latch hooks are required to conform to the existing Russian design. The latch hooks are classified as being fail-safe. Since the latch hooks are fail-safe, the hooks are not fracture critical and a fatigue based service life assessment will satisfy the structural integrity requirements. Constant amplitude fatigue testing to failure on four sets of active/passive iLIDS latch hooks was performed at load magnitudes of 10, 11, and 12 kips. Failure analysis of the hook fatigue failures identified multi-site fatigue initiation that was effectively centered about the hook mid-plane (consistent with the 3D model results). The fatigue crack initiation distribution implies that the fatigue damage accumulation effectively results in a very low aspect ratio surface crack (which can be simulated as thru-thickness crack). Fatigue damage progression resulted in numerous close proximity fatigue crack initiation sites. It was not possible to determine if fatigue crack coalescence occurs during cyclic loading or as result of the fast fracture response. The presence of multiple fatigue crack initiation sites on different planes will result in the formation of ratchet marks as the cracks coalesce. Once the stable fatigue crack becomes unstable and the fast fracture advances across the remaining ligament and the plane stress condition at a free-surface will result in failure along a 45 deg. shear plane (slant fracture) and the resulting inclined edge is called a shear lip. The hook thickness on the plane of fatigue crack initiation is 0.787". The distance between the shear lips on this plane was on the order of 0.48" and it was effectively centered about the mid-plane of the section. The numerous ratchet marks between the shear lips on the fracture initiation plane are indicative of multiple fatigue initiation sites within this region. The distribution of the fatigue damage about the centerline of the hook is consistent with the analytical results that demonstrate peak stress/strain response at the mid-plane that decreases in the direction of the hook outer surfaces. Scanning electron microscope images of the failed sections detected fatigue crack striations in close proximity to the free surface of the hook radius. These findings were documented at three locations on the fracture surface : 1) adjacent to the left shear lip, 2) adjacent to the right shear lip, and 3) near the centerline of the section. The features of the titanium fracture surface did not allow for a determination of a critical crack size via identification of the region where the fatigue crack propagation became unstable. The fracture based service life projections where benchmarked with strain-life analyses. The strainrange response in the hook radius was defined via the correlated finite element models and the modified method of universal slopes was incorporated to define the strain-life equation for the titanium alloy. The strain-life assessment confirmed that the fracture based projections were reasonable for the loading range of interest. Based upon the analysis and component level fatigue test data a preliminary service life capability for the iLIDS active and passive hooks of 2 lifetimes is projected (includes a scatter factor of 4).

Martinez, J.↗

NASA NTRS1992

Payload retention device

A payload retention device for grappling and retaining a payload in docked position on a supporting structure in the cargo bay of a space vehicle is presented. The device comprises a two-fault tolerant electromagnetic grappling system comprising electromagnets for attracting and grappling a grapple strike plate affixed to the payload when in proximity thereto and an electromechanical latching assembly comprising a pair of independent latching subassemblies. Each subassembly comprises a set of latching pawls which are driven into latching and unlatching positions relative to a grappled payload by a pair of gearmotors, each equipped with a ratchet clutch drive mechanism which is two-fault tolerant with respect to latching such that only one gearmotor of the four needs to be operational to effect a latch of the payload but is single fault tolerant with respect to release of a latched payload. Sensors are included for automatically sensing the magnetic grappling of a payload and for automatically de-energizing the gearmotors of the latching subassemblies when a latch condition is achieved.

Monford, Leo G., Jr.↗