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All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Ultrasonic Attenuation Results of Thermoplastic Resin Composites Undergoing Thermal and Fatigue Loading

As part of an effort to obtain the required information about new composites for aviation use, materials and NDE researchers at NASA are jointly performing mechanical and NDE measurements on new composite materials. The materials testing laboratory at NASA is equipped with environmental chambers mounted on load frames that can expose composite materials to thermal and loading cycles representative of flight protocols. Applying both temperature and load simultaneously will help to highlight temperature and load interactions during the aging of these composite materials. This report highlights our initial ultrasonic attenuation results from thermoplastic composite samples that have undergone over 4000 flight cycles to date. Ultrasonic attenuation measurements are a standard method used to assess the effects of material degradation. Recently, researchers have shown that they could obtain adequate contrast in the evaluation of thermal degradation in thermoplastic composites by using frequencies of ultrasound on the order of 24 MHz. In this study, we address the relationship of attenuation measured at lower frequencies in thermoplastic composites undergoing both thermal and mechanical loading. We also compare these thermoplastic results with some data from thermoset composites undergoing similar protocols. The composite s attenuation is reported as the slope of attenuation with respect to frequency, defined as b = Da(f)/Df. The slope of attenuation is an attractive parameter since it is quantitative, yet does not require interface corrections like conventional quantitative attenuation measurements. This latter feature is a consequence of the assumption that interface correction terms are frequency independent. Uncertainty in those correction terms can compromise the value of conventional quantitative attenuation data. Furthermore, the slope of the attenuation more directly utilizes the bandwidth information and in addition, the bandwidth can be adjusted in the post processing stage to compensate for the loss of dynamic range of the signal as the composites age.

Madaras, Eric I.↗
NASA NTRS2005

Role of Probabilistic Micromechanics Modeling in Establishing Design Allowables in Composites

One of the major challenges in designing with any new material, and particularly with advanced composite materials, is the fidelity of material design allowables. In the case of composite materials, the concern arises from the inherent nature of these materials, i.e., their heterogeneous make-up and the various factors that affect their properties in a specific design environment. Composites have various scales - micro, macro, laminate and structural, as well as numerous other fabrication related parameters. Many advanced composites in aerospace applications involve complex two- and three-dimensional fiber architectures and requires high-temperature processing. Since there are uncertainties associated with each of these, the observed behavior of composite materials shows scatter. Evaluating the effect of each of these variables on the observed scatter in composite properties solely by teSting is cost and time prohibitive. One alternative is to evaluate these effects by computational simulation. The authors have developed probabilistic composite micromechanics techniques by combining woven composite micromechanics and Fast Probability Integration (FPI) techniques to address these issues. In this paper these techniques will be described and demonstrated through selected examples. Results in the form of cumulative distribution functions (CDF) of the composite properties of a MI (melt-infiltrated) SiC/SiC (silicon carbide fiber in a silicon carbide matrix) Composite will be presented. A CDF is a relationship defined by the value of the property (the response variable) with respect to the cumulative probability of occurrence. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Sensitivity information is very valuable in quality control. How these results can be utilized to develop design allowables so that these materials may be used by structural analysts/designers will also be discussed.

Mital, Subodh K.↗
NASA NTRS2000

Constituent-Based Life Models Being Developed for SiC/SiC Composites

For the successful utilization of ceramic matrix composites (CMC) as hot-section components in advanced aeropropulsion engines, the CMC constituents will need to be tailored and optimized to meet all the critical property demands of each component. Under the High-Speed Research (HSR) and Advanced High-Temperature Engine Materials Technology (HITEMP) Programs, the NASA Glenn Research Center at Lewis Field initiated research to develop mechanistic models for key CMC thermostructural properties. These models would describe the effects of different constituent factors (composition, geometry, and volume fraction) and of potential application conditions (stress, time, temperature, and environment) on these properties. Particular focus was placed on both analytical and numerical modeling of state-of-the-art SiC/SiC composites where the primary load-bearing constituents are stoichiometric SiC fibers in a complex multiphase SiC matrix produced by chemical vapor infiltration and melt infiltration. Recent studies have resulted in computer-based numerical models for the elastic modulus, thermal expansion, and thermal conductivity properties of the SiC/SiC system. Additional studies have generated analytical and empirical models for the time dependence of composite rupture strength at temperatures above 2200 F (1200 C), where CMC's have an important thermostructural advantage over current nickel-based superalloys. These life models utilize thermal activation theory and fiber stress-rupture results measured at Glenn to generate Larson-Miller (L M) plots of fiber rupture strength versus q, a single time- and temperature-dependent parameter. Assuming a worse case in which the SiC matrix is cracked, rupture is then controlled by the time-dependent fracture characteristics of the fiber bundles bridging the matrix cracks. With this as the controlling mechanism, one can then use simple composite theory and the fiber L M plots to predict CMC rupture strength versus the q parameter. The dashed line shows the predicted rupture strength of a SiC/SiC composite that is reinforced by a state-of-the-art stoichiometric SiC fiber. For the q parameter, time is in hours and temperature in degrees kelvin. To generate these predictions, a two-dimensional 0 /90 composite with approximately 16 percent fiber in the applied stress direction and an air test environment were assumed. As such, it is possible to compare the model predictions against limited stress-rupture data for this CMC as shown by the data points. The good agreement confirms the rupture model at least for the selected CMC and test conditions. Thus for this particular SiC/SiC composite, one can estimate a 1000-hr rupture strength of approximately 12 ksi at 2400 F (T = 1588 K and q = 39 700 K). At lower CMC application stresses, the SiC matrix is typically uncracked, so both the fiber and matrix constituents share the composite load. In this case, CMC rupture is controlled by the constituent with the longest rupture time based on the creep rate of the composite. Measured Monkman-Grant plots of rupture time versus creep rate for the two SiC constituents have been used to develop CMC life models for this important application condition. NASA and DOD are currently using this information to establish application and material goals for more advanced CMC's that can be used at even higher temperatures.

DiCarlo, James A.↗
NASA NTRS2004

Method Developed for Improving the Thermomechanical Properties of Silicon Carbide Matrix Composites

Today, a major thrust for achieving engine components with improved thermal capability is the development of fiber-reinforced silicon-carbide (SiC) matrix composites. These materials are not only lighter and capable of higher use temperatures than state-of-the-art metallic alloys and oxide matrix composites (approx. 1100 C), but they can provide significantly better static and dynamic toughness than unreinforced silicon-based monolithic ceramics. However, for successful application in advanced engine systems, the SiC matrix composites should be able to withstand component service stresses and temperatures for the desired component lifetime. Since the high-temperature structural life of ceramic materials is typically controlled by creep-induced flaw growth, a key composite property requirement is the ability to display high creep resistance under these conditions. Also, because of the possibility of severe thermal gradients in the components, the composites should provide maximum thermal conductivity to minimize the development of thermal stresses. State-of-the-art SiC matrix composites are typically fabricated via a three-step process: (1) fabrication of a component-shaped architectural preform reinforced by high-performance fibers, (2) chemical vapor infiltration of a fiber coating material such as boron nitride (BN) into the preform, and (3) infiltration of a SiC matrix into the remaining porous areas in the preform. Generally, the highest performing composites have matrices fabricated by the CVI process, which produces a SiC matrix typically more thermally stable and denser than matrices formed by other approaches. As such, the CVI SiC matrix is able to provide better environmental protection to the coated fibers, plus provide the composite with better resistance to crack propagation. Also, the denser CVI SiC matrix should provide optimal creep resistance and thermal conductivity to the composite. However, for adequate preform infiltration, the CVI SiC matrix process typically has to be conducted at temperatures below 1100 C, which results in a SiC matrix that is fairly dense, but contains metastable atomic defects and is nonstoichiometric because of a small amount of excess silicon. Because these defects typically exist at the matrix grain boundaries, they can scatter thermal phonons and degrade matrix creep resistance by enhancing grain-boundary sliding. To eliminate these defects and improve the thermomechanical properties of ceramic composites with CVI SiC matrices, researchers at the NASA Glenn Research Center developed a high-temperature treatment process that can be used after the CVI SiC matrix is deposited into the fiber preform.

Bhatt, Ramakrishna T.↗
NASA NTRS2004

Associative Flow Rule Used to Include Hydrostatic Stress Effects in Analysis of Strain-Rate-Dependent Deformation of Polymer Matrix Composites

designing reliable composite engine cases that are lighter than the metal cases in current use. The types of polymer matrix composites that are likely to be used in such an application have a deformation response that is nonlinear and that varies with strain rate. The nonlinearity and the strain-rate dependence of the composite response are due primarily to the matrix constituent. Therefore, in developing material models to be used in the design of impact-resistant composite engine cases, the deformation of the polymer matrix must be correctly analyzed. However, unlike in metals, the nonlinear response of polymers depends on the hydrostatic stresses, which must be accounted for within an analytical model. By applying micromechanics techniques along with given fiber properties, one can also determine the effects of the hydrostatic stresses in the polymer on the overall composite deformation response. First efforts to account for the hydrostatic stress effects in the composite deformation applied purely empirical methods that relied on composite-level data. In later efforts, to allow polymer properties to be characterized solely on the basis of polymer data, researchers at the NASA Glenn Research Center developed equations to model the polymers that were based on a non-associative flow rule, and efforts to use these equations to simulate the deformation of representative polymer materials were reasonably successful. However, these equations were found to have difficulty in correctly analyzing the multiaxial stress states found in the polymer matrix constituent of a composite material. To correct these difficulties, and to allow for the accurate simulation of the nonlinear strain-rate-dependent deformation analysis of polymer matrix composites, in the efforts reported here Glenn researchers reformulated the polymer constitutive equations from basic principles using the concept of an associative flow rule. These revised equations were characterized and validated in an experimental program carried out through a university grant with the Ohio State University, wherein tensile and shear deformation data were obtained for a representative polymer for strain rates ranging from quasi-static to high rates of several hundred per second. Tensile deformation data also were obtained over a variety of strain rates and fiber orientation angles for a representative polymer matrix composite composed using the polymer.

Goldberg, Robert K.↗
NASA NTRS2008

Composite Materials for Low-Temperature Applications

Composite materials with improved thermal conductivity and good mechanical strength properties should allow for the design and construction of more thermally efficient components (such as pipes and valves) for use in fluid-processing systems. These materials should have wide application in any number of systems, including ground support equipment (GSE), lunar systems, and flight hardware that need reduced heat transfer. Researchers from the Polymer Science and Technology Laboratory and the Cryogenics Laboratory at Kennedy Space Center were able to develop a new series of composite materials that can meet NASA's needs for lightweight materials/composites for use in fluid systems and also expand the plastic-additive markets. With respect to thermal conductivity and physical properties, these materials are excellent alternatives to prior composite materials and can be used in the aerospace, automotive, military, electronics, food-packaging, and textile markets. One specific application of the polymeric composition is for use in tanks, pipes, valves, structural supports, and components for hot or cold fluid-processing systems where heat flow through materials is a problem to be avoided. These materials can also substitute for metals in cryogenic and other low-temperature applications. These organic/inorganic polymeric composite materials were invented with significant reduction in heat transfer properties. Decreases of 20 to 50 percent in thermal conductivity versus that of the unmodified polymer matrix were measured. These novel composite materials also maintain mechanical properties of the unmodified polymer matrix. These composite materials consist of an inorganic additive combined with a thermoplastic polymer material. The intrinsic, low thermal conductivity of the additive is imparted into the thermoplastic, resulting in a significant reduction in heat transfer over that of the base polymer itself, yet maintaining most of the polymer's original properties. Normal polymer processing techniques can turn these composite materials into unique, custom parts for ground support, Shuttle, and Constellation needs. We fabricated test specimens of the composite and base materials for thermal and mechanical characterization and found that the strength of the composite material at nominal-percentage loading remained relatively unchanged from the base material.

Source record↗
NASA NTRS2012

Probabilistic Simulation of Multi-Scale Composite Behavior

A methodology is developed to computationally assess the non-deterministic composite response at all composite scales (from micro to structural) due to the uncertainties in the constituent (fiber and matrix) properties, in the fabrication process and in structural variables (primitive variables). The methodology is computationally efficient for simulating the probability distributions of composite behavior, such as material properties, laminate and structural responses. Bi-products of the methodology are probabilistic sensitivities of the composite primitive variables. The methodology has been implemented into the computer codes PICAN (Probabilistic Integrated Composite ANalyzer) and IPACS (Integrated Probabilistic Assessment of Composite Structures). The accuracy and efficiency of this methodology are demonstrated by simulating the uncertainties in composite typical laminates and comparing the results with the Monte Carlo simulation method. Available experimental data of composite laminate behavior at all scales fall within the scatters predicted by PICAN. Multi-scaling is extended to simulate probabilistic thermo-mechanical fatigue and to simulate the probabilistic design of a composite redome in order to illustrate its versatility. Results show that probabilistic fatigue can be simulated for different temperature amplitudes and for different cyclic stress magnitudes. Results also show that laminate configurations can be selected to increase the redome reliability by several orders of magnitude without increasing the laminate thickness--a unique feature of structural composites. The old reference denotes that nothing fundamental has been done since that time.

Chamis, Christos C.↗
NASA NTRS2018

Undirectional Carbon Nanotube Yarn/Polymer Composites

Carbon nanotubes (CNTs) are one-dimensional nanomaterials with outstanding electrical and thermal conductivities and mechanical properties at the nanoscale. With these superior physical properties, CNTs are very attractive materials for future light weight structural aerospace applications. Recent manufacturing advances have led to the availability of bulk formats of CNTs such as yarns, tapes, and sheets in commercial quantities, thus enabling the development of macroscale composite processing methods for aerospace applications. The fabrication of unidirectional CNT yarn/polymer composites and the effect of processing parameters such as resin type, number of CNT yarn layers, CNT yarn/resin ratio, consolidation method, and tension applied during CNT yarn winding on the mechanical properties of unidirectional CNT yarn composites are reported herein. Structural morphologies, electrical and thermal conductivities, and mechanical performance of unidirectional CNT yarn/polymer composites under tensile and short beam shear loads are presented and discussed. The application of higher tension during the winding process and elevated cure pressure during the press molding step afforded a compact structural morphology and reduced void content in the composite. However, the composite tensile strength was negligibly impacted by the fabrication parameters, such as cure pressure, winding tension, and resin chemistry, excepting resin content and number of CNT yarn layers. The tension winding method produced better quality and lower resin content CNT yarn composites compared to conventional prepregging methods, resulting in higher specific strength and modulus of the composites. The specific tensile strength of the CNT composite was approximately 69 % of the starting CNT yarn. Electrical and thermal conductivities of unidirectional CNT yarn/polymer composites were in the range of 1000 to 12000 S/cm and 22 to 45 W/mK, respectively.

Kim, Jae-Woo↗
NASA NTRS2017

Development and Validation of NDE Standards for NASA’s Advanced Composites Project

The adoption of composite materials in aircraft manufacturing for use in structural applications continues to increase but is still relatively new to the industry. Composite components have large development and certification costs in comparison to metallic structures. Traditional methods of nondestructive evaluation (NDE) used for isotropic materials such as metals may not be adequate for composite applications and therefore is a contributing factor to the cost and complexity of developing new structural composites. Additionally, the defects of interest in composite materials are significantly different from metals. Thus, good quality composite reference standards are essential to obtaining reliable and quantifiable NDE results. Ideally, reference standards contain flaws or damage whose NDE indications most closely represent those created by actual flaws/damage. They should also be easy to duplicate and inexpensive to manufacture. NASA’s Advanced Composites Project, working with industry partners, developed a set of composite standards that contain a range of validated defects representing those typically found in aerospace composite materials. This paper will provide an overview of the standards fabricated, the manufacturing plans used to fabricate them, the types of defects included, and validation testing that has performed. Also discussed is an inter-laboratory “round-robin” test that is being performed on these standards. The paper will describe a guidance document being compiled to outline relevant inspection procedures for challenging and critical defects unique to composites where conventional techniques may not be appropriate.

Cramer, K. Elliott↗
DOE OSTI2026

Effects of cleavable comonomer structure and crosslinker chemistry on the performance and deconstructability of frontally cured pDCPD composites

Reclaiming undamaged carbon fiber from thermoset composites requires chemical recycling methods that leverage complete deconstruction of the polymer matrix. Cleavable comonomers enable chemical recycling of poly(dicyclopentadiene) (pDCPD) composites, but current systems suffer from reduced glass transition temperature (T g ), limiting application. Here, we investigate the effect of cleavable comonomer loading and cleavable crosslinker chemistry on network formation, thermomechanical properties, and fiber recovery in frontally cured pDCPD composites. All formulations fully deconstructed in acid and recovered fibers ranged from pristine to variably contaminated depending on crosslinker chemistry. Reducing backbone-cleaving comonomer content and introducing cleavable crosslinkers raised composite T g to 126–138 °C compared to 105 °C previously reported in deconstructable pDCPD composites. Although the cleavable crosslinkers increased T g in unreinforced polymers to 150–160 °C, the fiber-reinforced composite T g remained lower due to under-curing and interactions between the crosslinkers and the fiber surface. Increasing polymerization initiator loading improved comonomer conversion and yielded a deconstructable composite with T g = 151 °C, approaching the performance of non-deconstructable pDCPD composites (T g = 161 °C). This work clarifies how cleavable comonomer and crosslinker chemistry governs curing, thermomechanical performance, and reclaimed reinforcement quality, and the results highlight the need for more robust cleavable comonomers to realize multigenerational composite materials without sacrificing thermomechanical performance.

Carbon fibers↗
DOE OSTI2025

LABQ3: Bayesian method for quantification of mineral compositions and nano-scale elemental mapping of 3D synchrotron XCT data

Quantitative analysis of mineral compositions is essential in understanding geochemical, mineralogical and environmental processes. Fine-resolution 3D imaging is widely done using synchrotron X-ray computed tomography (XCT), but existing analyses are limited to visualization and segmentation. This paper presents a new method, Linear Attenuation Bayesian Quantitative 3D-mapper (LABQ3), based on the linearity of X-ray attenuation with respect to elemental concentrations. To address the random variability in attenuation measurements, LABQ3 employs Bayesian decision theory to minimize classification error, using reference attenuation distributions from scans of pure mineral standards. To demonstrate LABQ3 and test its performance, we studied precipitated carbonate samples. XCT scans were done at multiple energies using the transmission X-ray microscope (TXM) at beamline 32-ID-C of the Advanced Photon Source at Argonne National Laboratory. The reconstructed 3D images have a voxel size of 20 nm. Analyses revealed rich nano-scale compositional heterogeneity within individual particles. A mixture of calcium and cadmium produced an overall stoichiometric composition of (Ca 0.78 ,Cd 0.22 )CO 3 , with some voxels containing nearly pure CdCO 3 . The addition of zinc led to an overall stoichiometric composition of 33% Ca, 28% Cd, 39% Zn, with a nearly pure CaCO 3 core and compositional zonation through the rim. These compositional gradients are related to temporal sequences of carbonate mineral formation where Cd precipitated at the beginning in (Ca,Cd)CO 3 , while Cd and Zn precipitated at the end in (Ca, Cd,Zn)CO 3 . Results differ from bulk analyses using Inductively Coupled Plasma-Mass Spectrometry (ICP-MS), showing that LABQ3 provides particle-specific insights. LABQ3 distinguishes itself by quantifying chemical compositions along a continuum, making it different from XCT analyses based on segmentation. LABQ3 allows simultaneous acquisition of morphology and chemical composition in 3D, facilitating the interpretation of chemical gradients of trace elements, quantification of solid solution compositions, inferences about temporal sequences of mineral precipitation, and addressing other concerns about solid-phase chemistry.

58 GEOSCIENCES↗
DOE OSTI2025

Technical Considerations on MURR Control Blade Design Change and Testing using a New Metal Matrix Composite

The University of Missouri Research Reactor (MURR) is one of six research reactors, including a critical facility, that are pursuing conversion as part of a collaboration with the U.S. Department of Energy National Nuclear Security Administration Material Management and Minimization Office of Reactor Conversion and Uranium Supply, under the U.S. High Performance Research Reactors (USHPRR) conversion project. Five of the six USHPRR are planned to convert from highly enriched uranium (HEU) fuel using a low-enriched uranium (LEU) high assay monolithic alloy of uranium-10 wt% molybdenum (U-10Mo). As part of the conversion safety analysis, it is necessary to demonstrate the safety performance of the proposed core fueled with LEU as compared to the current HEU cores. The MURR reactor is planning to switch to a new control blade design that uses a metal matrix composite of boron carbide (B 4 C) and aluminum as the absorber in place of Boral®. Since MURR is expected to adopt the new metal matrix composite control blade design prior to conversion, the impact of the new blade design on the neutronics characteristics of the MURR cores for conversion are analyzed in this work through updates to incorporate the changes to the blade design in conversion models as they directly impact the LEU conversion safety analysis. The quantitative comparison shows that the neutronics and thermal hydraulic behavior of one metal matrix composite blade replacing a Boral blade is comparable for the two example MURR LEU and HEU cores states considered. Geometrical changes in the metal matrix composite blade design, combined with a 4% increase in areal boron density, showed local heating effects up to 20% higher than the Boral design. As expected, the metal matrix composite showed slightly lower heat depositions and absorber region temperatures for the LEU cases compared to HEU. Although this analysis was comparative for a single blade, maximum control blade temperatures for both Boral, metal matrix composite, and HEU/LEU remained below 100 °C, though additional analysis at a core level could differ. A qualitative irradiation behavior assessment concludes that the mechanisms that may drive swelling and blistering in the current Boral design are eased by the adoption of the metal matrix composite design. The work concludes that the two blade designs are essentially equivalent with regards to neutronics, thermal hydraulics, and expected material behavior under irradiation. However, due to the geometrical changes to the blades including redesigned and thinner cladding, new testing and increased surveillance for distortion and swelling are recommended to confirm the performance of the metal matrix composite control blade design. Where testing is completed prior to conversion, the only anticipated impacts on conversion to LEU U-10Mo fuel would be the need for models and safety analysis incorporating the metal matrix composite control blades.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1974

Some metal-graphite and metal-ceramic composites for use as high energy brake lining materials

Materials were studied as candidates for development as potential new aircraft brake lining materials. These families were (1) copper-graphite composites; (2) nickel-graphite composites; (3) copper - rare-earth-oxide (gadolinium oxide (Gd2O3) or lanthanum oxide (La2O3)) composites and copper - rare-earth-oxide (La2O3) - rare-earth-fluoride (lanthanum fluoride (LaF3)) composites; (4) nickel - rare-earth-oxide composites and nickel - rare-earth-oxide - rare-earth-fluoride composites. For comparison purposes, a currently used metal-ceramic composite was also studied. Results showed that the nickel-Gd2O3 and nickel-La2O3-LaF3 composites were comparable or superior in friction and wear performance to the currently used composite and therefore deserve to be considered for further development.

Bill, R. C.↗
NASA NTRS1986

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimeter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, C. C.↗
NASA NTRS1987

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimenter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, Ching-Cheh↗
NASA NTRS1986

SiC fiber reinforced reaction-bonded Si3N4 composites

A technique for fabricating strong and tough SiC fiber reinforced reaction bonded Si3N4 matrix composites (SiC/RBSN) was developed. Using this technique, composites containing approximately 23, 30, and 40 volume fractions of aligned 140 micron diameter, chemically vapor deposited SiC fibers were fabricated. The room temperature physical and mechanical properties were evaluated. The results for composite tensile strength, bend strength, and fracture strain indicate that the composite displays excellent properties when compared with the unreinforced matrix of comparable porosity. The composite stress at which the matrix first cracks and the ultimate composite fracture strength increase with increasing volume fraction of fibers, and the composite fails gracefully. The mechanical property data of this ceramic composite are compared with similar data for unreinforced commercially available Si3N4 materials and for SEP SiC/SiC composites.

Bhatt, Ramakrishna T.↗
NASA NTRS1989

The role of rapid solidification processing in the fabrication of fiber reinforced metal matrix composites

Advanced composite processing techniques for fiber reinforced metal matrix composites require the flexibility to meet several widespread objectives. The development of uniquely desired matrix microstructures and uniformly arrayed fiber spacing with sufficient bonding between fiber and matrix to transmit load between them without degradation to the fiber or matrix are the minimum requirements necessary of any fabrication process. For most applications these criteria can be met by fabricating composite monotapes which are then consolidated into composite panels or more complicated components such as fiber reinforced turbine blades. Regardless of the end component, composite monotapes are the building blocks from which near net shape composite structures can be formed. The most common methods for forming composite monotapes are the powder cloth, foil/fiber, plasma spray, and arc spray processes. These practices, however, employ rapid solidification techniques in processing of the composite matrix phase. Consequently, rapid solidification processes play a vital and yet generally overlooked role in composite fabrication. The future potential of rapid solidification processing is discussed.

Locci, Ivan E.↗
NASA NTRS1990

Open hole and post-impact compression fatigue of stitched and unstitched carbon/epoxy composites

The performance is studied of a stitched uniweave fabric composite and that of a toughened tape composite. The effects of stitching on compression fatigue life are addressed. Post impact compression fatigue and open hole fatigue tests were run on an AS4/3501-6 uniweave with stitching and a toughened IM7/8551-7 tape without stitching. Stitching was found to increase the thickness and consequently the weight of the composite material. The two materials were compared on an equal carbon content basis as well as on an equal weight basis. The excess thickness in the stitched uniweave composite was responsible for the lower fatigue life, on an equal carbon basis, compared to the toughened resin tape composite. Comparison of fatigue lives on an equal carbon content basis indicated that puncture or crimp type damage from stitching has very little effect on compression failure. Post impact fatigue test showed that although the damage area in the stitched uniweave composite was twice that of the toughened tape composite, the fatigue lives of the stitched composite were significantly longer than those of the toughened composite. Thus, it appears that the increase in thickness from stitching is much more of a penalty than crimped fibers or puncture type damage from stitching.

Portanova, M. A.↗