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At least 19 records

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NASA NTRS1995

Three-dimensional solutions for thermomechanical stresses in sandwich panels and shells

Analytic three-dimensional thermoelasticity solutions are presented for static problems of simply supported sandwich panels and cylindrical shells subjected to mechanical and thermal loads. The panels and shells have laminated composite face sheets of arbitrary thickness separated by a core. Each of the individual layers of the face sheets and the core is modeled as a three-dimensional continuum. Analytic first-order sensitivity coefficients are evaluated to assess the sensitivity of the responses to variations in material parameters of the face sheets and the core, as well as to variations in the curvatures and thicknesses of the sandwich and face sheets. Also, the strain energy associated with various stress components in the face sheets and core are calculated and compared. The information obtained in the present study can aid the development and assessment of two-dimensional models for sandwich structures and illuminate the role of particular material parameters in an equivalent model for the core.

Burton, W. Scott↗

NASA NTRS1990

Thermomechanical properties of polymeric materials and related stresses

The thermomechanical analysis (TMA) and dynamic mechanical analysis characterizations of a polymeric material yield useful data relating to the thermomechanical stresses of eight widely used polymeric materials. The materials encompass Lexan, Plexiglass, Epon, Conap, Uralane, Solithane, and Humiseal. A combined profile of the coefficient of thermal expansion (CTE) and the modulus change over a wide temperature range obtained by these analytical methods indicates the drastic effects of glass transition on both the CTE and the modulus of a polymer. TMA can also detect secondary transitions, and provides a convenient means for the study of a polymer's toughness.

Lee, Sheng Yen↗

NASA NTRS1976

Stress analysis, thermomechanical fatique evaluation, and root subcomponent testing of gamma/gamma prime-delta eutectic alloy

Thermomechanical fatigue (TMF) and root subcomponent tensile, creep, and low cycle fatigue (LCF) tests were conducted to determine the capability of a fully lamellar directionally solidified eutectic alloy to sustain the airfoil thermal fatigue and root attachment loads anticipated in advanced, hollow, high work turbine blades. A three dimensional finite element elastic stress analysis was performed on typical advanced hollow eutectic airfoil and root-platform designs to determine appropriate conditions for these tests. Results of TMF tests conducted on longitudinal specimens (stress axis parallel to the solidification direction) containing a simulated leading edge cooling hole pattern indicated the longitudinal TMF properties to be more than adequate for the particular advanced hollow blade analyzed, with the strain range for a 10,000 cycle life being more than 50% above the maximum strain range calculated for the advanced hollow blade.

Sheffler, K. D.↗

NASA NTRS2013

Nickel-Graphite Composite Compliant Interface and/or Hot Shoe Material

Next-generation high-temperature thermoelectric-power-generating devices will employ segmented architectures and will have to reliably withstand thermally induced mechanical stresses produced during component fabrication, device assembly, and operation. Thermoelectric materials have typically poor mechanical strength, exhibit brittle behavior, and possess a wide range of coefficient of thermal expansion (CTE) values. As a result, the direct bonding at elevated temperatures of these materials to each other to produce segmented leg components is difficult, and often results in localized microcracking at interfaces and mec hanical failure due to the stresses that arise from the CTE mismatch between the various materials. Even in the absence of full mechanical failure, degraded interfaces can lead to increased electrical and thermal resistances, which adversely impact conversion efficiency and power output. The proposed solution is the insertion of a mechanically compliant layer, with high electrical and thermal conductivity, between the low- and high-temperature segments to relieve thermomechanical stresses during device fabrication and operation. This composite material can be used as a stress-relieving layer between the thermoelectric segments and/or between a thermoelectric segment and a hot- or cold-side interconnect material. The material also can be used as a compliant hot shoe. Nickel-coated graphite powders were hot-pressed to form a nickel-graphite composite material. A freestanding thermoelectric segmented leg was fabricated by brazing the compliant pad layer between the high-temperature p- Zintl and low-temperature p-SKD TE segments using Cu-Ag braze foils. The segmented leg stack was heated in vacuum under a compressive load to achieve bonding. The novelty of the innovation is the use of composite material that re duces the thermomechanical stresses en - countered in the construction of high-efficiency, high-temperature therm - o-electric devices. The compliant pad enables the bonding of dissimilar thermoelectric materials while maintaining the desired electrical and thermal properties essential for efficient device operation. The modulus, CTE, electrical, and thermal conductances of the composite can be controlled by varying the ratio of nickel to graphite.

Firdosy, Samad A.↗

NASA NTRS1998

Mechanical Characterization of Thermomechanical Matrix Residual Stresses Incurred During MMC Processing

In recent years, much effort has been spent examining the residual stress-strain states of advanced composites. Such examinations are motivated by a number of significant concerns that affect composite development, processing, and analysis. The room-temperature residual stress states incurred in many advanced composite systems are often quite large and can introduce damage even prior to the first external mechanical loading of the material. These stresses, which are induced during the cooldown following high-temperature consolidation, result from the coefficient of thermal expansion mismatch between the fiber and matrix. Experimental techniques commonly used to evaluate composite internal residual stress states are non-mechanical in nature and generally include forms of x-ray and neutron diffraction. Such approaches are usually complex, involving a number of assumptions and limitations associated with a wide range of issues, including the depth of penetration, the volume of material being assessed, and erroneous effects associated with oriented grains. Furthermore, and more important to the present research, these techniques can assess only "single time" stress in the composite. That is, little, if any, information is obtained that addresses the time-dependent point at which internal stresses begin to accumulate, the manner in which the accumulation occurs, and the presiding relationships between thermoelastic, thermoplastic, and thermoviscous behaviors. To address these critical issues, researchers at the NASA Lewis Research Center developed and implemented an innovative mechanical test technique to examine in real time, the time-dependent thermomechanical stress behavior of a matrix alloy as it went through a consolidation cycle.

Castelli, Michael G.↗

NASA NTRS1990

Thermomechanical properties of polymeric materials and related stresses

The thermomechanical properties of a number of widely used polymeric materials were determined by thermomechanical analysis and dynamic mechanical analysis. A combined profile of the coefficient of thermal expansion and the modulus change over a wide temperature range obtained by the analyses shows clearly the drastic effect of the glass transition on both the CTE and the modulus of a polymer, and the damaging potential due to such effect.

Lee, Sheng Yen↗

NASA NTRS1984

Thermal and thermomechanical effects in dry sliding

Developments in the study of interrelated thermal and mechanical phenomena in sliding systems are reviewed. The topics reviewed include mechanisms of frictional heating and the distribution of heat during sliding friction, the experimental measurement and analysis of surface and near-surface temperatures resulting from frictional heating, thermal deformation around sliding contacts and the changes in contact geometry caused by thermal deformation and thermoelastic instability, and the thermomechanical stress distribution around the frictionally heated and thermally deformed contact spots. The influence of the thermal and thermomechanical contact phenomena on friction and wear, surface melting, softening, chemical deterioration, and thermocracking are discussed. The phenomena have important implications in the design and application of sliding or sliding-rolling mechanical components such as dynamic seals, brakes, clutches, plastic bearings, solid or boundary-lubricated bearings, and gears.

Kennedy, F. E., Jr.↗

NASA NTRS2011

Material Characterization and Geometric Segmentation of a Composite Structure Using Microfocus X-Ray Computed Tomography Image-Based Finite Element Modeling

This study utilizes microfocus x-ray computed tomography (CT) slice sets to model and characterize the damage locations and sizes in thermal protection system materials that underwent impact testing. ScanIP/FE software is used to visualize and process the slice sets, followed by mesh generation on the segmented volumetric rendering. Then, the local stress fields around several of the damaged regions are calculated for realistic mission profiles that subject the sample to extreme temperature and other severe environmental conditions. The resulting stress fields are used to quantify damage severity and make an assessment as to whether damage that did not penetrate to the base material can still result in catastrophic failure of the structure. It is expected that this study will demonstrate that finite element modeling based on an accurate three-dimensional rendered model from a series of CT slices is an essential tool to quantify the internal macroscopic defects and damage of a complex system made out of thermal protection material. Results obtained showing details of segmented images; three-dimensional volume-rendered models, finite element meshes generated, and the resulting thermomechanical stress state due to impact loading for the material are presented and discussed. Further, this study is conducted to exhibit certain high-caliber capabilities that the nondestructive evaluation (NDE) group at NASA Glenn Research Center can offer to assist in assessing the structural durability of such highly specialized materials so improvements in their performance and capacities to handle harsh operating conditions can be made.

Abdul-Aziz, Ali↗

NASA NTRS1981

Design and development of integral heat pipe/thermal energy storage devices

The major design and performance test subtasks in the development of small (200 to 1,000 whr) integral heat pipe/thermal energy storage devices for use with thermally driven spacecraft cryo-coolers are described. The design of the integral heat pipe/thermal energy storage device was based on a quasi steady resistance heat transfer, lumped capacitance model. Design considerations for the heat pipe and thermal storage annuli are presented. The thermomechanical stress and insulation system design for the device are reviewed. Experimental correlations are described, as are the plans for the further development of the concept.

Mahefkey, E. T.↗

NASA NTRS1983

Improved performance thermal barrier coatings

Thermal barrier coatings offer an attractive approach to improving the durability and efficiency of the hot section of heat engines. The coatings typically consist of an inner alloy bond coating about 0.01 cm thick resistant to oxidation and hot corrosion and an outer ceramic layer, usually a stabilized zirconia, 0.01-0.05 cm thick. Here, the materials, thermomechanical stress, and hot corrosion problems associated with thermal barrier coatings are reviewed along with the capabilities and limitations of current technology. The coatings discussed include ZrO2-Y2O3/NiCrAlY, ZrO2-Y2O3/NiCoCrAlY, ZrO2-MgO/NiCoCrAlY, CaO-SiO2/Co-Cr-Al-Y, and CaO-SiO2/NiCrAlY systems. It is emphasized that the performance of thermal barrier coatings is governed by many complex and interrelated factors, so that optimization of these coatings always involves certain tradeoffs.

Levine, S. R.↗

NASA NTRS1987

Thermomechanical behavior of plasma-sprayed ZrO2-Y2O3 coatings influenced by plasticity, creep and oxidation

Thermocycling of ceramic-coated turbomachine components produces high thermomechanical stresses that are mitigated by plasticity and creep but aggravated by oxidation, with residual stresses exacerbated by all three. These residual stresses, coupled with the thermocyclic loading, lead to high compressive stresses that cause the coating to spall. A ceramic-coated gas path seal is modeled with consideration given to creep, plasticity, and oxidation. The resulting stresses and possible failure modes are discussed.

Padovan, J.↗

NASA NTRS1987

Thermomechanical behavior of plasma-sprayed ZrO2-Y2O3 coatings influenced by plasticity, creep, and oxidation

Padovan, J.↗

NASA NTRS2001

Silicon Nitride Plates for Turbine Blade Application: FEA and NDE Assessment

Engine manufacturers are continually attempting to improve the performance and the overall efficiency of internal combustion engines. The thermal efficiency is typically improved by raising the operating temperature of essential engine components in the combustion area. This reduces the heat loss to a cooling system and allows a greater portion of the heat to be used for propulsion. Further improvements can be achieved by diverting part of the air from the compressor, which would have been used in the combustor for combustion purposes, into the turbine components. Such a process is called active cooling. Increasing the operating temperature, decreasing the cooling air, or both can improve the efficiency of the engine. Furthermore, lightweight, strong, tough hightemperature materials are required to complement efficiency improvement for nextgeneration gas turbine engines that can operate with minimum cooling. Because of their low-density, high-temperature strength, and thermal conductivity, ceramics are being investigated as potential materials for replacing ordinary metals that are currently used for engine hot section components. Ceramic structures can withstand higher operating temperatures and other harsh environmental factors. In addition, their low densities relative to metals helps condense component mass (ref. 1). The objectives of this program at the NASA Glenn Research Center are to develop manufacturing technology, a thermal barrier coating/environmental barrier coating (TBC/EBC), and an analytical modeling capability to predict thermomechanical stresses, and to do minimal burner rig tests of silicon nitride (Si3N4) and SiC/SiC turbine nozzle vanes under simulated engine conditions. Furthermore, and in support of the latter objectives, an optimization exercise using finite element analysis and nondestructive evaluation (NDE) was carried out to characterize and evaluate silicon nitride plates with cooling channels.

Abdul-Aziz, Ali↗

NASA NTRS2002

Influence of Cooling Channel Geometry on the Thermal Response in Silicon Nitride Plates Studied

Engine manufacturers are continually attempting to improve the performance and efficiency of internal combustion engines. Usually they raise the operating temperature or reduce the cooling air requirement for the hot section turbine components. However, the success of these attempts depends on finding materials that are lightweight, are strong, and can withstand high temperatures. Ceramics are among the top candidate materials considered for such harsh applications. They hold low-density, high-temperature strength, and thermal conductivity, and they are undergoing investigation as potential materials for replacing nickel-base alloys and superalloys that are currently used for engine hot-section components. Ceramic structures can withstand higher operating temperatures and a harsh combustion environment. In addition, their low densities relative to metals help reduce component mass. The long-term objectives of the High Temperature Propulsion Components (HOTPC) Project are to develop manufacturing technology, thermal and environmental barrier coatings (TBC/EBC), and the analytical modeling capability to predict thermomechanical stresses in minimally cooled silicon nitride turbine nozzle vanes under simulated engine conditions. Two- and three-dimensional finite element analyses with TBC were conducted at the NASA Glenn Research Center. Nondestructive evaluation was used to determine processing defects. The study included conducting preliminary parametric analytical runs of heat transfer and stress analyses under steady-state conditions to demonstrate the feasibility of using cooled Si3N4 parts for turbine applications. The influence of cooling-channel shapes (such as circular, square, and ascending-order cooling channels) on cooling efficiency and thermal stresses was investigated. Temperature distributions were generated for all cases considered under both cooling and no-cooling conditions, with air being the cooling medium. The table shows the magnitude of the maximum and minimum temperature obtained for the plates under air cooling. Each channel's cross-sectional shape delivered a different temperature; however, the two-dimensional analyses for circular and square or equal-side rectangular holes produced close results. Moreover, the model of the panel with ascending order cooling channels experienced the lowest temperature. A difference of near 260 C was found among the three cooling-hole configurations investigated. The ascending-order cooling channels arrangement showed superior performance by attaining the lowest temperature (1077 C) in comparison to the circular (1379 C) and square (1343 C) channels for the same cooling-hole size. This indicates that the panel with ascending-order cooling channels is the most suitable configuration regardless of the complexity involved in its manufacture. More details pertaining to this study are reported.

Abdul-Aziz, Ali↗

NASA NTRS2003

Thermal Response of Cooled Silicon Nitride Plate Due to Thermal Conductivity Effects Analyzed

Lightweight, strong, tough high-temperature materials are required to complement efficiency improvements for next-generation gas turbine engines that can operate with minimum cooling. Because of their low density, high-temperature strength, and high thermal conductivity, ceramics are being investigated as materials to replace the nickelbase superalloys that are currently used for engine hot-section components. Ceramic structures can withstand higher operating temperatures and a harsh combustion environment. In addition, their low densities relative to metals help reduce component mass (ref. 1). To complement the effectiveness of the ceramics and their applicability for turbine engine applications, a parametric study using the finite element method is being carried out. The NASA Glenn Research Center remains very active in conducting and supporting a variety of research activities related to ceramic matrix composites through both experimental and analytical efforts (ref. 1). The objectives of this work are to develop manufacturing technology, develop a thermal and environmental barrier coating (TBC/EBC), develop an analytical modeling capability to predict thermomechanical stresses, and perform a minimal burner rig test on silicon nitride (Si3N4) and SiC/SiC turbine nozzle vanes under simulated engine conditions. Moreover, we intend to generate a detailed database of the material s property characteristics and their effects on structural response. We expect to offer a wide range of data since the modeling will account for other variables, such as cooling channel geometry and spacing. Comprehensive analyses have begun on a plate specimen with Si3N4 cooling holes.

Baaklini, George Y.↗

NASA NTRS2005

Quick Access Rocket Exhaust Rig Testing of Coated GRCop-84 Sheets Used to Aid Coating Selection for Reusable Launch Vehicles

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition1 invented at the NASA Glenn Research Center: Cu-8(at.%)Cr-4%Nb. Many of the properties of this alloy have been shown to be far superior to those of other conventional copper alloys, such as NARloy-Z. Despite this considerable advantage, it is expected that GRCop-84 will suffer from some type of environmental degradation depending on the type of rocket fuel utilized. In a liquid hydrogen (LH2), liquid oxygen (LO2) booster engine, copper alloys undergo repeated cycles of oxidation of the copper matrix and subsequent reduction of the copper oxide, a process termed "blanching". Blanching results in increased surface roughness and poor heat-transfer capabilities, local hot spots, decreased engine performance, and premature failure of the liner material. This environmental degradation coupled with the effects of thermomechanical stresses, creep, and high thermal gradients can distort the cooling channel severely, ultimately leading to its failure.

Raj, Sai V.↗

NASA NTRS2007

Mo/Ti Diffusion Bonding for Making Thermoelectric Devices

An all-solid-state diffusion bonding process that exploits the eutectoid reaction between molybdenum and titanium has been developed for use in fabricating thermoelectric devices based on skutterudite compounds. In essence, the process is one of heating a flat piece of pure titanium in contact with a flat piece of pure molybdenum to a temperature of about 700 C while pushing the pieces together with a slight pressure [a few psi (of the order of 10 kPa)]. The process exploits the energy of mixing of these two metals to form a strong bond between them. These two metals were selected partly because the bonds formed between them are free of brittle intermetallic phases and are mechanically and chemically stable at high temperatures. The process is a solution of the problem of bonding hot-side metallic interconnections (denoted hot shoes in thermoelectric jargon) to titanium-terminated skutterudite n and p legs during the course of fabrication of a unicouple, which is the basic unit cell of a thermoelectric device (see figure). The hot-side operating temperature required for a skutterudite thermoelectric device is 700 C. This temperature precludes the use of brazing to attach the hot shoe; because brazing compounds melt at lower temperatures, the hot shoe would become detached during operation. Moreover, the decomposition temperature of one of the skutterudite compounds is 762 C; this places an upper limit on the temperature used in bonding the hot shoe. Molybdenum was selected as the interconnection metal because the eutectoid reaction between it and the titanium at the ends of the p and n legs has characteristics that are well suited for this application. In addition to being suitable for use in the present bonding process, molybdenum has high electrical and thermal conductivity and excellent thermal stability - characteristics that are desired for hot shoes of thermoelectric devices. The process takes advantage of the chemical potential energy of mixing between molybdenum and titanium. These metals have a strong affinity for each other. They are almost completely soluble in each other and remain in the solid state at temperatures above the eutectoid temperature of 695 C. As a result, bonds formed by interdiffusion of molybdenum and titanium are mechanically stable at and well above the original bonding temperature of about 700 C. Inasmuch as the bonds are made at approximately the operating temperature, thermomechanical stresses associated with differences in thermal expansion are minimized.

Sakamoto, Jeffrey↗

NASA NTRS2004

SiC-Based Miniature High-Temperature Cantilever Anemometer

The figure depicts a miniature cantilever-type anemometer that has been developed as a prototype of compact, relatively nonintrusive anemometers that can function at temperatures up to 600 C and that can be expected to be commercially mass-producible at low cost. The design of this anemometer, and especially the packaging aspect of the design, is intended to enable measurement of turbulence in the high-temperature, high-vibration environment of a turbine engine or in any similar environment. The main structural components of the anemometer include a single-crystal SiC cantilever and two polycrystalline SiC clamping plates, all made from chemical-vapor-deposited silicon carbide. Fabrication of these components from the same basic material eliminates thermal-expansion mismatch, which has introduced spurious thermomechanical stresses in cantilever-type anemometers of prior design. The clamping plates are heavily oxidized to improve electrical insulation at high temperature. A cavity that serves as a receptacle for the clamped end of the cantilever is etched into one end of one clamping plate. Trenches that collectively constitute a socket for a multipin electrical plug (for connection to external electronic circuitry) are etched into the opposite end of this clamping plate. Metal strips for electrical contact are deposited on one face of the other clamping plate. Piezoresistive single-crystal SiC thin-film strain gauges are etched in the n-type SiC epilayer in a Wheatstone-bridge configuration. Metal contact pads on the cantilever that extend into the clamping-receptacle area, are obtained by deposition and patterning using standard semiconductor photolithography and etching methods. The cantilever and the two clamping plates are assembled into a sandwich structure that is then clamped in a stainless-steel housing. The Wheatstone- bridge carrying SiC cantilever with the metal contact pads on the piezoresistors is slid into the receptacle in the bottom clamping plate. The top clamping plate is brought into contact with the bottom plate so that the narrow section of the metal strips on the top clamp plate aligns with the metal contact pads on the cantilever. When the parts are clamped together, the metal strips provide electrical connections between the Wheatstone-bridge contact points and the sides the trenches that constitute the socket for the multipin electrical plug. Hence, to connect the Wheatstone bridge to external circuitry for processing of the anemometer readout, one need only insert the plug in the socket. In operation, the cantilever end of the stainless-steel housing is mounted flush with an engine wall and the unclamped portion of the cantilever is exposed into the flow. The cantilever is deflected in direct proportion to the force induced by component of flow parallel to the engine wall and perpendicular to the broad exposed face of the cantilever. The maximum strain on the cantilever occurs at the clamped edge and is measured by the piezoresistors, which are located there. The corresponding changes in resistance manifest themselves in the output of the Wheatstone bridge.

Okojie, Robert S.↗