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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

Correlation between microstructure and residual stress formation in friction stir welded armor steels characterized by neutron diffraction

Friction stir welding (FSW) is a solid-state joining process that minimizes the heat-affected zone (HAZ) compared with fusion-based arc welding, making it well suited for joining martensitic armor steels where hardness and ballistic resistance are critical. This study investigates residual stress formation in three defect-free FSW butt-joint configurations relevant to armored-vehicle fabrication: similar rolled homogeneous armor (RHA–RHA, Case 1), similar high-hardness armor (HHA–HHA, Case 2), and dissimilar HHA–RHA (Case 3) joints produced under temperature-controlled conditions (770 °C). Neutron diffraction was employed to quantify the magnitude and spatial distribution of residual stresses in the longitudinal, transverse, and normal directions and to correlate them with weld microstructure and hardness. Tensile residual stresses were concentrated in the softened HAZ, reaching approximately 300 MPa for Case 2 and 400 MPa for Case 1 (≈50–70 % of the base-metal yield strength; ∼581 MPa for RHA and ∼566 MPa for HHA), while compressive residual stresses dominated the stir zone. The spatial extent of tensile stresses scaled with the width of the softened HAZ, which was largest in the dissimilar HHA–RHA joint and smallest in the HHA–HHA joint. Full-width-at-half-maximum (FWHM) analysis revealed low microstrain in overtempered HAZ regions and high microstrain in the stir zone associated with severe plastic deformation and fresh martensite formation. This work demonstrates that residual stress evolution in FSW of martensitic armor steels is governed not primarily by peak temperature or thermal contraction, as inferred from fusion-welding analogies, but by the competition between transformation-induced volumetric expansion and tempering-induced stress relaxation. The relative dominance of these mechanisms is shown to depend on alloy hardenability and local thermal history, leading to more extensive HAZ softening and broader tensile stress regions in the lower-hardenability RHA steel. These findings establish a transferable mechanistic framework for optimizing solid-state joining strategies in high-strength steels and other transformation-hardening alloys beyond armor applications.

Friction stir welding↗
NASA NTRS1990

Composite structural armor for combat vehicle applications

Several projects that have demonstrated the advantages of using thick composite armor technology for structural applications in armored combat vehicles are discussed. The first involved composite cargo doors for the Marine Corps LVTP-7 amphibious landing vehicle. Another was a demonstration composite turret that offered a weight reduction of 15.5 percent. The advantages of this composite armor compared to metallic armors used for combat vehicle hull and turret applications are reduced weight at equal ballistic protection; reduced back armor spall; excellent corrosion resistance; reduced production costs by parts consolidation; and inherent thermal and acoustic insulative properties. Based on the encouraging results of these past programs, the Demonstration Composite Hull Program was started in September 1986. To demonstrate this composite armor technology, the Army's newest infantry fighting vehicle, the Bradley Fighting Vehicle (BFV), was selected as a model. A composite infantry fighting vehicle, designated the CIFV for this program, has been designed and fabricated and is currently undergoing a 6000 mile field endurance test. The CIFV demonstration vehicle uses the BFV engine, transmission, suspension, track and other equipment.

Haskell, William E., III↗
NASA NTRS1992

Optimization of armored spherical tanks for storage on the lunar surface

A redundancy strategy for reducing micrometeroid armoring mass is investigated, with application to cryogenic reactant storage for a regenerative fuel cell (RFC) on the lunar surface. In that micrometeoroid environment, the cryogenic fuel must be protected from loss due to tank puncture. The tankage must have a sufficiently high probability of survival over the length of the mission so that the probability of system failure due to tank puncture is low compared to the other mission risk factors. Assuming that a single meteoroid penetration can cause a storage tank to lose its contents, two means are available to raise the probability of surviving micrometeoroid attack to the desired level. One can armor the tanks to a thickness sufficient to reduce probability of penetration of any tank to the desired level or add extra capacity in the form of spare tanks that results in survival of a given number out of the ensemble at the desired level. A combination of these strategies (armoring and redundancy) is investigated. The objective is to find the optimum combination which yields the lowest shielding mass per cubic meter of surviving fuel out of the original ensemble. The investigation found that, for the volumes of fuel associated with multikilowatt class cryo storage RFC's, and the armoring methodology and meteoroid models used, storage should be fragmented into small individual tanks. Larger installations (more fuel) pay less of a shielding penalty than small installations. For the same survival probability over the same time period, larger volumes will require less armoring mass per unit volume protected.

Bents, D. J.↗
DOE OSTI2024

Data-Driven Assessment of the Impact of Hurricanes Ian and Nicole: Natural and Armored Dunes in the Aftermath of Hurricanes on Florida’s Central East Coast

Hurricanes Ian and Nicole caused devastating destruction across Florida in September and November 2022, leaving widespread damage in their wakes. This study focuses on the assessment of barrier islands’ shorelines, encompassing natural sand dunes and dune vegetation as well as armored dunes with man-made infrastructure such as seawalls. High-resolution satellite imagery from Planet was used to assess the impacts of these hurricanes on the beach shorelines of Volusia, Flagler, and St. Johns Counties on the Florida Central East Coast. Shorefront vegetation was classified into two classes. Normalized Difference Vegetation Index (NDVI) values were calculated before the hurricanes, one month after Hurricane Ian, one month after Hurricane Nicole, and one-year post landfall. LiDAR (Light Detection and Ranging) was incorporated to calculate vertical changes in the shorelines before and after the hurricanes. The results suggest that natural sand dunes were more resilient as they experienced less impact to vegetation and elevation and more substantial recovery than armored dunes. Moreover, the close timeframe of the storm events suggests a compound effect on the weakened dune systems. This study highlights the importance of understanding natural dune resilience to facilitate future adaptive management efforts because armored dunes may have long-term detrimental effects on hurricane-prone barrier islands.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1992

Optimization of armored spherical tanks for storage on the lunar surface

A redundancy strategy for reducing micrometeroid armoring mass is investigated, with application to cryogenic reactant storage for a regenerative fuel cell (RFC) on the lunar surface. In that micrometeoroid environment, the cryogenic fuel must be protected from loss due to tank puncture. The tankage must have a sufficiently high probability of survival over the length of the mission so that the probability of system failure due to tank puncture is low compared to the other mission risk factors. Assuming that a single meteoroid penetration can cause a storage tank to lose its contents, two means are available to raise the probability of surviving micrometeoroid attack to the desired level. One can armor the tanks to a thickness sufficient to reduce probability of penetration of any tank to the desired level or add extra capacity in the form of space tanks that results in survival of a given number out of the ensemble at the desired level. A combination of these strategies (armor and redundancy) is investigated.

Bents, D. J.↗
NASA NTRS1998

Analysis of Tile-Reinforced Composite Armor: Advanced Modeling and Strength Analyses - Part 1

The results of an analytical and experimental study of the structural response and strength of tile-reinforced components of the Composite Armored Vehicle are presented. The analyses are based on specialized finite element techniques that properly account for the effects of the interaction between the armor tiles, the surrounding elastomers, and the glass-epoxy sublaminates. To validate the analytical predictions, tests were conducted with panels subjected to three-point bending loads. The sequence of progressive failure events for the laminates is described. This paper describes the results of Part 1 of a study of the response and strength of tile-reinforced composite armor.

Davila, C. G.↗
NASA NTRS2009

The UAH/NSSTC Advanced Radar for Meteorological and Operational Research (ARMOR)

The past four years have seen a marked enhancement in meteorological-radar infrastructure and radar-research capability at the University of Alabama-Huntsville (UAH) and National Space Science and Technology Center (NSSTC; a collaborative center supported by UAH, NASA-MSFC and USRA). This enhancement is due in part to the development of the ARMOR C-band dual-polarimetric radar facility (amongst other mobile radar facilities also discussed in this conference). The ARMOR radar, located at Huntsville International Airport, originated as a unique collaboration between university, government and broadcast meteorologists (the very first of its kind relative to concurrent operational, research and broadcast applications of dual-polarimetry). Contributions from each of these entities resulted in the upgrade of a surplus National Weather Service WSR-74C radar to a research-grade C-band polarimetric radar. The initial upgrade of the radar took place in late 2004 with WHNT-TV purchase and installation of a SIGMET (now Vaisala) Antenna Mounted Receiver (AMR), RVP8/RCP8 radar processor/antenna controller, new radome, and a new dual-polarimetric antenna feed. The AMR enabled simultaneous transmit and receive (STSR) capability and hence collection of dual-polarimetric moments. During the initial part of the AMR upgrade the original WSR74C antenna reflector and 250 kW magnetron-transmitter were used. In early 2005, a new 350 kW magnetron transmitter was purchased from Baron Services and installed. In October of 2006 a new high performance parabolic antenna and dual-pol feed (Seavey) were installed together with a new Orbit pedestal. ARMOR Radar control and data delivery are facilitated through the use of T-1 lines that run from the airport to both NSSTC and WHNT-TV in Huntsville. Under current operating protocols radar scanning and product development are completed at NSSTC, though meteorologists at WHNT-TV can also control the radar if desired. In its default scanning configuration the radar is operated 24/7 in an STSR polarimetric rain scan mode alternating with a surveillance scan on a 5-minute cycle; scans separated by 2.5 minutes. Every 2.5 minutes the raw data arrive at NSSTC where they are corrected in real time for attenuation and differential attenuation (using a constrained ZDR/Z-PHI approach) and new products are generated (e.g., rain maps, hydrometeor identification etc.). The raw and derived products are archived at NSSTC and also redistributed locally in real time over the network within NSSTC to the National Weather Service Forecast Office in Huntsville (collocated with NSSTC) for operational use. During periods of interesting weather the radar is often operated in full, sector, or RHI volume modes from NSSTC and coincident with UAH mobile radar or NWS NEXRAD radar platforms as needed.

Petersen, Walter A.↗
NASA NTRS1999

Advanced Modeling Strategies for the Analysis of Tile-Reinforced Composite Armor

A detailed investigation of the deformation mechanisms in tile-reinforced armored components was conducted to develop the most efficient modeling strategies for the structural analysis of large components of the Composite Armored Vehicle. The limitations of conventional finite elements with respect to the analysis of tile-reinforced structures were examined, and two complementary optimal modeling strategies were developed. These strategies are element layering and the use of a tile-adhesive superelement. Element layering is a technique that uses stacks of shear deformable shell elements to obtain the proper transverse shear distributions through the thickness of the laminate. The tile-adhesive superelement consists of a statically condensed substructure model designed to take advantage of periodicity in tile placement patterns to eliminate numerical redundancies in the analysis. Both approaches can be used simultaneously to create unusually efficient models that accurately predict the global response by incorporating the correct local deformation mechanisms.

Davila, Carlos G.↗
NASA NTRS1998

Superelement Analysis of Tile-Reinforced Composite Armor

Super-elements can greatly improve the computational efficiency of analyses of tile-reinforced structures such as the hull of the Composite Armored Vehicle. By taking advantage of the periodicity in this type of construction, super-elements can be used to simplify the task of modeling, to virtually eliminate the time required to assemble the stiffness matrices, and to reduce significantly the analysis solution time. Furthermore, super-elements are fully transferable between analyses and analysts, so that they provide a consistent method to share information and reduce duplication. This paper describes a methodology that was developed to model and analyze large upper hull components of the Composite Armored Vehicle. The analyses are based on two types of superelement models. The first type is based on element-layering, which consists of modeling a laminate by using several layers of shell elements constrained together with compatibility equations. Element layering is used to ensure the proper transverse shear deformation in the laminate rubber layer. The second type of model uses three-dimensional elements. Since no graphical pre-processor currently supports super-elements, a special technique based on master-elements was developed. Master-elements are representations of super-elements that are used in conjunction with a custom translator to write the superelement connectivities as input decks for ABAQUS.

Davila, Carlos G.↗
NASA NTRS2008

ARMOR Dual-Polarimetric Radar Observations of Tornadic Debris Signatures

During the Super-Tuesday tornado outbreak of 5-6 February 2008, two EF-4 tornadoes occurred in Northern Alabama within 75 km range of the University of Alabama in Huntsville (UAH) Advanced Radar for Meteorological and Operational Research (ARMOR, C-band dual-polarimetric). This study will present an analysis of ARMOR radar-indicated dual-polarimetric tornadic debris signatures. The debris signatures were associated with spatially-confined large decreases in the copolar correlation coefficient (rho(hv)hv) that were embedded within broader mesocyclone "hook" signatures. These debris signatures were most obviously manifest during the F-3 to F-4 intensity stages of the tornado(s) and extended to altitudes of approximately 3 km. The rho(hv) signatures of the tornadic debris were the most easily distinguished relative to other polarimetric and radial velocity parameters (e.g., associated with large hail and/or the incipient mesocyclone). Based on our analysis, and consistent with the small number of studies found in the literature, we conclude that dual-polarimetric radar data offer at least the possibility for enhancing specificity and confidence in the process of issuing tornado warnings based only on radar detection of threatening circulation features.

Petersen, W. A,↗
DOE OSTI2025

Welding investigation of a wrought FeMnAl steel for armor application

A new wrought FeMnAl steel contains high Mn content and high Al content. This steel has high strength. When it is compared to conventional steels with the similar strength, its density is lower. FeMnAl steels can be used in armor vehicle manufacturing, in which welding is a common practice to join the steel plates together. The welding of FeMnAl steels has not been sufficiently studied before. Here, this work studied the weldability and weld microstructure of an FeMnAl steel and provided useful data for the welding practice of FeMnAl steels. The influences of weld filler metals and shielding gases were studied, using single-pass bead-on-plate gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) two processes. The optimal filler metals and shielding gases have been determined to achieve the better weldability. Autogenous GTAW and electron beam welding were also conducted. Cracks were found in the HAZ in the GMAW welds and electron beam welds. Fewer or no cracks were found in the HAZ of GTAW welds. SEM, SEM/EDX, TEM, TEM/EDX, and EBSD were used to analyze the grain boundaries in the HAZ and the cracks. The grain boundaries of FeMnAl base metal are mostly high angle grain boundaries (HAGBs), which attract impurity and solute atoms and cause intergranular cracking. The proposed cracking mechanisms are liquation cracking and ductility-dip cracking. It was found that GTAW provides much better weldability for the FeMnAl steel than GMAW and EBW.

FeMnAl steel↗
NASA NTRS1990

The weight optimization of an armored crashworthy crewseat through the use of advanced composites and design

The development of composite-related technology applicable to armored crashworthy helicopter crewseats is discussed. The main objective was to achieve a significant weight reduction relative to the first-generation seats exemplified by the UH-60A and the AH-64A designs. This weight reduction was achieved while maintaining full compliance with the most recent version of the military crashworthy crewseat specification, MIL-S-58095A. The technology developed during this effort is intended to apply to the next generation of Army helicopters, such as LHX.

Lindsay, Howard A.↗
DOE OSTI2022

Multi-layer wearable body armor

A multi-layer body armor plate includes a strike plate; a mesh layer positioned over the strike plate, the mesh layer having a number of open cells; and an outer skin layer positioned over the mesh layer so as to encapsulate the open cells of the mesh layer between the strike plate and the outer skin layer. The open cells of the mesh layer may entrap air or may be filled with expandable, buoyant foam.

Barr, Christian G.↗
DOE OSTI2023

Multi-layer wearable body armor

A multi-layer body armor plate includes a strike plate; a mesh layer positioned over the strike plate, the mesh layer having a number of open cells; and an outer skin layer positioned over the mesh layer so as to encapsulate the open cells of the mesh layer between the strike plate and the outer skin layer. The open cells of the mesh layer may entrap air or may be filled with expandable, buoyant foam.

Barr, Christian↗
DOE OSTI2023

Armor for Steel: Facile Synthesis of Hexagonal Boron Nitride Films on Various Substrates

Abstract While hexagonal boron nitride (hBN) has been widely used as a buffer or encapsulation layer for emerging electronic devices, interest in utilizing it for large‐area chemical barrier coating has somewhat faded. A chemical vapor deposition process is reported here for the conformal growth of hBN on large surfaces of various alloys and steels, regardless of their complex shapes. In contrast to the previously reported very limited protection by hBN against corrosion and oxidation, protection of steels against 10% HCl and oxidation resistance at 850 °C in air is demonstrated. Furthermore, an order of magnitude reduction in the friction coefficient of the hBN coated steels is shown. The growth mechanism is revealed in experiments on thin metal films, where the tunable growth of single‐crystal hBN with a selected number of layers is demonstrated. The key distinction of the process is the use of N 2 gas, which gets activated exclusively on the catalyst's surface and eliminates adverse gas‐phase reactions. This rate‐limiting step allowed independent control of activated nitrogen along with boron coming from a solid source (like elemental boron). Using abundant and benign precursors, this approach can be readily adopted for large‐scale hBN synthesis in applications where cost, production volume, and process safety are essential.

2D materials↗