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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 NTRS1986

Eliminating Thermal Cracks in Flange/Duct Joints

Improved technique for attaching aluminum flange to aramid/epoxy duct prevents subsequent development of cracks in joint during thermal stress. Flange butted against cylindrical mold on which duct is fabricated. Flange has tapered neck so will nest in duct opening. Epoxy-impregnated aramid tape wrapped around mold so tape overlaps flange. While tape is wrapped, pressure applied to it and inside of flange as heated uniformly to maximum expected operating temperature. Heat and pressure maintained until aramid/epoxy laminations have cured.

Adams, J. E.↗
DOE OSTI2022

Detecting thermal crack growth on a large additive manufactured structure using acoustic emission

Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structures (reaching hundreds of pounds) develop thermal-residual stress during cool-down and can eventually crack, turning the structure into waste. Acoustic emission (AE), a passive non-intrusive global nondestructive evaluation (NDE) technique, was used to monitor crack growth and can provide the right tools that can be used for feedback loop for corrective action. This research performs thermal testing on a large AM mold with preexisting cracks, in an attempt to monitor crack growth using AE. AE was able to detect, identify and locate the crack source by means of acoustic features, waveform characteristics, spectrum analysis, and difference in arrival times.

Spencer, Ryan↗
NASA NTRS1992

Prediction of thermal cycling induced matrix cracking

Thermal fatigue has been observed to cause matrix cracking in laminated composite materials. A method is presented to predict transverse matrix cracks in composite laminates subjected to cyclic thermal load. Shear lag stress approximations and a simple energy-based fracture criteria are used to predict crack densities as a function of temperature. Prediction of crack densities as a function of thermal cycling is accomplished by assuming that fatigue degrades the material's inherent resistance to cracking. The method is implemented as a computer program. A simple experiment provides data on progressive cracking of a laminate with decreasing temperature. Existing data on thermal fatigue is also used. Correlations of the analytical predictions to the data are very good. A parametric study using the analytical method is presented which provides insight into material behavior under cyclical thermal loads.

Mcmanus, Hugh L.↗
NASA NTRS1959

Engine Operating Conditions that Cause Thermal-Fatigue Cracks in Turbojet-Engine Buckets

Five engine tests were conducted to definitely establish the failure mechanism of leading-edge cracking and to determine which conditions of engine operation cause the failures. Five groups of S-616 and M-252 buckets from master lots were run consecutively in the same J47-25 engine. The tests included a steady-state run at full-power conditions, rapid cycling between idle and rated speed, and three different start-stop tests. The first start-stop test consisted of cycles of start and stop with 5 minutes of idle speed before each stop; the second included cycles of start and stop but with 15 minutes of rated speed before each stop; the third consisted of cycles of gradual starts and normal stops with 5 minutes at idle speed before each stop. The test results demonstrated that the primary cause of leading-edge cracking was thermal fatigue produced by repeated engine starts. The leading edge of the bucket experiences plastic flow in compression during starts and consequently is subjected to a tensile stress when the remainder of the bucket becomes heated and expands. Crack initiation was accelerated when rated-speed operation was added to each normal start-stop cycle. This acceleration of crack formation was attributed to localized creep damage and perhaps to embrittlement resulting from overaging. It was demonstrated that leading-edge cracking can be prevented simply by starting the engine gradually.

Johnston, James R.↗
NASA NTRS1999

Use of Several Thermal Analysis Techniques to Study the Cracking of a Nitrile Butadiene Rubber (NBR) Insulator on the Booster Separation Motor (BSM) of the Space Shuttle

Two different vendor rubber formulations have been used to produce the silica-filled NBR insulators for the BSM of each of the two Solid Rocket Boosters (SRBs) on the Space Shuttle. Each cured insulator is bonded to the BSM aluminum aft closure with an epoxy adhesive, and some of the curved areas in the rubber may have significant residual stresses. A number of recently bonded NBR insulators have shown fine surface cracks, and stressed insulator areas may be aging at a faster rate than unstressed areas, thus hastening the surface cracking. Thermal analysis data on both vendor insulators by Dynamic Mechanical Analysis (DMA) through a temperature/frequency sweep from 24 to 74 C have shown a higher flexural storage modulus and Arrhenius activation energy for the stressed area than for the unstressed area. Other thermal analysis techniques are being used to study the insulator surface vs. bulk interior for better understanding this anomaly.

Wingard, Charles D.↗
NASA NTRS1980

The origin of polygonal troughs on the northern plains of Mars

The morphology, distribution, geologic environment and relative age of large-scale polygonal trough systems on Mars are examined. The troughs are steep-walled, flat-floored, sinuous depressions typically 200-800 m wide, 20-120 m deep and spaced 5-10 km apart. The mechanics of formation of tension cracks is reviewed to identify the factors controlling the scale of tension crack systems; special emphasis is placed on thermal cracking in permafrost. It is shown that because of the extremely large scale of the Martian fracture systems, they could not have formed by thermal cracking in permafrost, dessication cracking in sediments or contraction cracking in cooling lava. On the basis of photogeologic evidence and analog studies, it is proposed that polygonal troughs on the northern plains of Mars are grabens.

Pechmann, J. C.↗
DOE OSTI2022

Gas generation and intramolecular isotope study in laboratory pyrolysis of the Springfield coal from the Illinois Basin

Position-specific (PS) isotopes of propane have been proposed as a potential geochemical tool to decipher various geological processes (e.g., thermal cracking, biodegradation, H exchange) in natural reservoirs. The limited studies have been conducted on the PS isotopes of propane from the pyrolysis gases from marine shales, and natural gases sourced from lacustrine and marine kerogens, but little is known on gases produced from the humic kerogen. Here, this study investigated the PS δ 13 C of propane in the closed-system pyrolysis of the Springfield coal, Illinois Basin, Indiana, at 310 to 470 °C (Easy %Ro: 0.76 to 3.07). The C kinetic isotope effect (KIE) of CH 4 produced in both this study and previous low-temperature pyrolysis of the same coal indicates the cleavage of C—O bonds is the main generation pathway at the early kerogen cracking stage, followed by the breakdown of alkyl groups. At the wet-gas cracking stage, C 3 H 8 production from thermally stable compounds has a significant influence on the bulk and position-specific C KIE in the pyrolysis of marine Woodford kerogen and Springfield coal. According to the PS δ 13 C of propane, the central site is likely more enriched in 13 C and the δ 13 C of the terminal site is relatively heterogeneous within the propyl group attached to different functional groups of the gas-prone kerogen. Our findings based on the pyrolysis experiments and natural gas samples indicate thermal cracking and biodegradation appear to alter the δ 13 C cen values more significantly than the δ 13 C ter values of propane. The larger magnitude of ΔC c-t in the kMC simulations (Peterson et al., 2018) compared with those from the marine shale and coal possibly implies the non-random distributions of 13 C of propane precursors in the kerogens. As a new dimension of intramolecular isotopic information of propane, the PS δ 13 C values can contribute to fingerprinting the gas origins and identifying the various geological processes (e.g., kerogen cracking, wet-gas cracking, microbial activities) in sedimentary basins.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Towards machine-learning a fully-coupled constitutive model for thermal-hydraulic fracture in geothermal systems: phase I (Final Report)

This project, entitled “Towards machine-learning a fully-coupled constitutive model for thermal-hydraulic fracture in geothermal systems: phase I,” addresses challenges in understanding and controlling subsurface fracture networks, which are crucial for applications like deep geothermal heat mining and deep-crustal minerals/metals/hydrogen extraction. The research focuses on advancing the understanding of coupled thermal-hydro-mechanical-chemical (THMC) processes in geologic materials, particularly under the high temperature and pressure conditions found in the deep crust. This seed grant focused specifically on thermal cracking and the development of new constitutive models. Significant progress was made in both experimental and theoretical domains. To study micro-scale fracture formation, the project demonstrated the ability to create thermal cracking under stress in granite samples using a Paterson Gas-medium Deformation Apparatus.

15 GEOTHERMAL ENERGY↗
NASA NTRS1979

Seismic Q and velocity at depth

Measurements of the p-wave and s-wave internal friction quality factors (Q) and velocities of samples of a moderately outgassed terrestrial analog of lunar basalt exposed simultaneously to temperatures and hydrostatic confining pressures in accordance with the best available estimates of the lunar selenotherm are presented. Q values and velocities are found to increase with simulated depth, and an extrapolation of the Q value to a thoroughly outgassed states provides a Q value in reasonable agreement with those derived from lunar seismic data, suggesting a very dry lunar crust. Results also imply that similar seismic determinations for Mars would be able to distinguish between a dry crust and a crust containing water trapped beneath a layer of ice. Results of thermal cracking tests which demonstrate that high degrees of cracking associated with thermal cycling, as during the lunar day, are not inconsistent with high Q in a dry environment are presented, and it is shown that volatiles with diple moments comparable to H2O can greatly affect Q. Possible attenuation mechanisms are then considered, and velocity measurements on a synthetic anorthosite are presented.

Tittmann, B. R.↗
NASA NTRS1994

Penetration of carbon-fabric-reinforced composites by edge cracks during thermal aging

Thermo-oxidative stability (TOS) test results are significantly influenced by the formation and growth or presence of interlaminar and interlaminar cracks in the cut edges of all carbon-fiber-crosslinked high-temperature polymer matrix composites(exp 1-5) (i.e., unidirectional, crossplied, angle-plied, and fabric composites). The thermo-oxidative degradation of these composites is heavily dependent on the surface area that is exposed to the harmful environment and on the surface-to-volume ratio of the structure under study. Since the growth of cracks and voids on the composite surfaces significantly increases the exposed surface areas, it is imperative that the interaction between the aging process and the formation of new surface area as the aging time progresses be understood.

Bowles, Kenneth J.↗
DOE OSTI2022

Multiscale characterization and comparison of historical and modern nuclear graphite grades

Beginning with Chicago Pile I, graphite has been used as a moderator material in nuclear power stations and is considered a potential material for use in future Generation IV advanced reactors. The microstructure of graphite is responsible for much of its mechanical and thermo-physical properties, and how it responds to irradiation. To understand graphite microstructure, it is necessary to understand its porosity at the macro- and micro-scales; and to understand its porosity, it is necessary to characterize the morphological connectivity of the void content and the two main phases of graphite: filler and binder. Here, using several microscopy and analytical techniques, a detailed examination of the heterogeneity, microstructure and pore structure of different graphite grades and their binder and filler phases is presented. Significant differences were found between coarser and finer nuclear grades. Coarse grades have a more diverse range of filler particles, pores and thermal cracks. Finer grades have a more well-defined pore size distribution, fewer variations of filler particles sizes and do not contain as many large thermal cracks. Fine grades tend to have a well-connected network of pores whereas coarser grades contain a larger content of closed porosity. The framework developed within this work can be applied and used to assess the various graphite grades that would down-select materials for specific use in graphite moderated reactor designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Thermally induced cracking on the massive concrete structure of the NSLS II synchrotron and its engineering remediation

Synchrotron accelerator facilities such as the NSLS II require extreme stability, both transient (short-term) and quasi-static (long-term) to achieve the desired resolution performance. Consequently, even μm-level movements, particularly differential movements between locations in the concrete structure supporting the accelerator electron beam lattice (storage ring) or high sensitivity experiments (experimental floor) will lead to serious degradation of its performance. Differential settlement in the overall structure or structural movement exceeding anticipated levels will inevitably degrade the performance and will require intervention. Presented in this paper are the design philosophy of the NSLS II ring structure favoring a monolithic ring, the observed cracking behavior of the young NSLS II concrete following casting and in combination with extreme ambient temperature fluctuation, the results of a non-linear, high-fidelity numerical analysis used to emulate the observed cracking and establish the driving mechanism, the numerical analysis-based identification of the crack-arresting solution and finally the implementation of the remediation solution and the long-term performance of the adopted engineering solution. The multi-stage process revealed that computational methods such as non-linear finite element methods have the potential of providing engineering guidance even when complex structures and in combination with non-linear materials, such as steel reinforcement and concrete are involved.

42 ENGINEERING↗