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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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A nanocomposite composition having a silicone elastomer matrix having therein a filler loading of greater than 0.05 weight percentage, based on total nanocomposite weight, wherein the filler is functional graphene sheets (FGS) having a surface area of from 300 square meters per gram to 2630 square meters per gram; and a method for producing the nanocomposite and uses thereof.
Airframe noise is a growing concern in the vicinity of airports because of population growth and gains in engine noise reduction that have rendered the airframe an equal contributor during the approach and landing phases of flight for many transport aircraft. The leading-edge-slat device of a typical high-lift system for transport aircraft is a prominent source of airframe noise. Two technologies have significant potential for slat noise reduction; the slat-cove filler (SCF) and the slat-gap filler (SGF). Previous work was done on a 2D section of a transport-aircraft wing to demonstrate the implementation feasibility of these concepts. Benchtop hardware was developed in that work for qualitative parametric study. The benchtop models were mechanized for quantitative measurements of performance. Computational models of the mechanized benchtop apparatus for the SCF were developed and the performance of the system for five different SCF assemblies is demonstrated.
A nanocomposite composition having a silicone elastomer matrix having therein a filler loading of greater than 0.05 wt %, based on total nanocomposite weight, wherein the filler is functional graphene sheets (FGS) having a surface area of from 300 sq m/g to 2630 sq m2/g; and a method for producing the nanocomposite and uses thereof.
The Solid State Additive Manufacturing (AM) process referred as MELD that fabricated the samples in this study, provides a new path for repairing, coating, joining and additive manufacturing metals and metal matrix composites. This research will be the first application of a physics-based microstructure dependent internal state variable (ISV) plasticity and damage material model to capture the mechanical response of an AM Aluminum Alloy (AA) 2219 via the MELD process. In this research, a microstructure-based internal state variable (ISV) plasticity-damage model was used to capture the mechanical behavior of AFS 2219 aluminum alloy. Aeroprobe Corporation, creator and patent holder for the MELD process, fabricated the material by pushing a solid filler rod of AA2219-T861 material through a hollow rotating tool onto an AA2219 T851 plate substrate. As feedstock, solid or powder precursor metals are pushed through a nonconsumable rotating cylindrical tool. Herein, added layers are deposited and metallurgically bonded to substrate material or previously deposited layers by the heat generated from the rotating tool through plastic deformation of the filler material. Once a layer has been added, the tool height increases, and starts the deposition of the next layer. This process results in beneficial properties such as grain refinement, homogenization and reduced porosity (fully dense). This process will experience temperatures similar to those in the weld nugget zone (WNZ) in friction stir welding (FSW), ranging from 0.6-0.9 Tm, with Tm being the melting point of the material. MELD is highly scalable with AA deposition rates reaching over 1000 cm3/hr, which allows for MELD being used for repairs, coatings, and building components. A motivating factor driving the research for physics-based history dependent material modeling of MELD components is the ability to accurately capture the stress-state and strain rate dependence in the material caused by variations in material microstructure from the MELD processing of new or repaired components. The ISV model incorporates microstructural content and is consistent with continuum level kinematics, kinetics, and thermodynamics. These features allow the ISV model to capture large deformations at the structural scale using the kinematic and isotropic hardening, while microscale damage is obtained from the microstructural features. The benefits of the ISV model arise from the inclusion of structure-property relationships identified from microstructural characterization and experimentation. The Bauschinger effect (BE) is an important concept, vital in the accurate prediction of cyclic stress-strain response of ductile materials such as metals. The ISV model has been successfully used to capture the behavior and damage, and the BE of different aluminum alloys and steels. The ISV model uses kinematic and isotropic hardening to help capture deformations of the material at the macro scale. To understand this hardening relationship, calculating the kinematic and isotropic hardening relationship in the material is warranted for a high-fidelity model. Electron Backscattered Diffraction (EBSD) was used to characterize the as-fabricated microstructure, where a fully-dense equiaxed grain morphology with average grain size of 2.5 μm was observed. Microhardness mapping of the as-built structures, monotonic tension and compression experiments at both quasi-static (0.001/s) strain rates, tension-followed-by-compression and compression-followed-by-tension experiments were performed to obtain the set of plasticity and damage constants necessary to capture strain rate and stress state behavior of this additive material. To calibrate the plasticity-damage model, a single set of constants were determined to capture the different stress states the MELD AA2219. One set of the constants was determined from experimental true stress-strain curves for the tension and compression data. Additionally, microstructural information and data from the open literature were used as the other model constants. This research is a first of its kind for AFS AA2219, includes correlating the ISV model to the monotonic experimental results that capture the isotropic and kinematic plasticity mechanical response.
Polyphenylsulfone (PPSU) is a high-temperature, chemically resistant thermoplastic with high impact resistance that is often used in interior aircraft cabin components, medical devices, and membranes. The aforementioned properties have led to interest investigating PPSU’s compatibility with hexagonal boron nitride (hBN) platelets as a thermally conductive, electrical composite insulator for high power-density electric machines. Preliminary trials extruding PPSU-hBN composite tapes showed promising dielectric properties and higher thermal conductivity as a function of hBN concentration compared to their neat analog. On the other hand, only few studies have reported on the extrusion process and resulting thermo-mechanical properties for PPSU and its composites made with chopped fiber reinforcement or fillers, none of which containing boron nitride filler. Prospects may exist for this type of material to be incorporated into extrusion-based additive manufacturing techniques to print other composites bearing unique properties useful for aerospace. Loading levels with up to approximately 23 wt% were achieved using micro-size BN platelets without observing any significant affects to PPSU’s glass-transition temperature. This work includes a description of the rheological properties of PPSU, the extrusion parameters for mixing and compounding the PPSU-hBN composite tapes, and the thermal and thermo-mechanical properties of PPSU-hBN composites.
Polyphenylsulfone (PPSU) is a high-temperature, chemically resistant thermoplastic with high impact resistance that is often used in interior aircraft cabin components, medical devices, and membranes. The aforementioned properties have led to interest investigating PPSU’s compatibility with hexagonal boron nitride (hBN) platelets as a thermally conductive, electrical composite insulator for high power-density electric machines. Preliminary trials extruding PPSU-hBN composite tapes showed promising dielectric properties and higher thermal conductivity as a function of hBN concentration compared to their neat analog. On the other hand, only few studies have reported on the extrusion process and resulting thermo-mechanical properties for PPSU and its composites made with chopped fiber reinforcement or fillers, none of which contained boron nitride filler. Prospects may exist for this type of material to be incorporated into extrusion-based additive manufacturing techniques to print other composites bearing unique properties useful for aerospace. Loading levels with up to approximately 23 wt% were achieved using micro-size BN platelets without observing any significant affects to PPSU’s glass-transition temperature. This work includes a description of the rheological properties of PPSU, the extrusion parameters for mixing and compounding the PPSU-hBN composite tapes, and the thermal and thermo-mechanical properties of PPSU-hBN composites.
Improving matrix-filler interactions is critical for optimizing dielectric performance in composite insulation; however, the technique used to an introduce inorganic filler into organic matrices varies in its ability to satisfactorily reduce the size of cavities and interfaces. This study reports how sample rheology influenced the dielectric performance and thermal conductivity of extruded polyphenylsulfone (PPSU) – hexagonal boron nitride (BN) composite insulation through changing the BN incorporation strategy. Depending on the technique used to introduce BN into the host matrix, the low melt viscosity, torque, and melt viscosity temperature of the polymer were reduced, enabling better mixing, heat transfer, and smaller voids. This corresponded to an increase in dielectric strength compared to other formulations; however, the thermal conductivity shifted further away from the thermal conductivity target of 1 W/m·K target, which was an indication of a larger separation distance between the particles in samples with smaller interfaces. A trade-off between dielectric strength and thermal conductivity may exist when maximizing thermal conduction without sacrificing dielectric strength.
A test campaign was conducted in the open-jet test section of the NASA Langley 14- by 22-Foot Subsonic Tunnel on a 10%-scale, semispan version of a High-Lift Common Research Model (CRM-HL) incorporating a leading-edge slat, trailing-edge flap and removable high-fidelity main landing gear. Far field acoustic measurements were obtained on baseline and acoustically treated model configurations using a traversing 97-microphone phased array that viewed the pressure side of the airframe. A modified version of the DAMAS deconvolution method incorporating corrections for shear layer acoustic wave decorrelation was employed to determine the locations and strengths of relevant noise sources along the span of the slat and in the vicinity of the flap edges and landing gear. The main goal of the test campaign was to use the array data to evaluate the effectiveness of various slat noise reduction concepts. It was found that slat-gap fillers produced significant broadband noise reduction for all Mach numbers and airfoil angles of attack that were investigated. Mach number scaling revealed an approximate velocity to the sixth power relationship for the slat noise at higher frequencies. Directivity measurements obtained from integration of DAMAS pressure-squared values over defined geometric zones around the model showed that baseline slat noise radiation approximated a dipole as a function of polar emission angle, becoming approximately omnidirectional with the introduction of the slat-gap filler. The test campaign clearly demonstrated the noise reduction benefits that can be obtained by applying appropriate treatments to leading edge slats on commercial transport-class aircraft.
In this welding test campaign, electron beam welding (EBW) and manual gas tungsten arc welding (GTAW) processes were utilized to join an additively manufactured aluminum alloy nozzle to a wrought aluminum flange. Both aluminum alloys were 6061, which in their conventional form are susceptible to solidification cracking issues. The AM nozzle utilized a novel high-performance modified version of 6061 which exhibits crack resistant properties during the AM process and during welding. When manually conducting GTAWs a filler wire with the same modified version of 6061 was utilized to weld different combinations of 6061 coupons (either modified or unmodified). Due to the grain refinement technology in the modified 6061, either as filler material or base material, there was complete elimination of weld solidification cracking. During EBW development a combination of wrought 6061 with a modified and additively manufactured 6061 was investigated. The EBWs developed exhibited no crack like defects. Each weld development program utilized non-destructive evaluation, metallography, and mechanical testing to determine the final weld acceptance. Mechanical testing involved hardness evaluation and tension testing on welded coupons. Both welding techniques were successfully developed and exhibited adequate properties for the final test articles and met all requirements of the development campaign. These welds were ultimately developed to be utilized on a set of all-aluminum liquid rocket nozzles to demonstrate additively manufactured aluminum alloys for propulsion applications. These aluminum nozzles were tested at NASA Marshall Space Flight Center’s hot fire test facility and subsequently underwent a test campaign involving a variety of chamber pressures and liquid propellant combinations. Following the hot fire test campaign each weldment was investigated for post operation performance and any defects that may have evolved during testing.
In this study, we apply the electromagnetic (EM) melt processing of thermoplastics on an innovative EM field-driven powder bed fusion additive manufacturing (AM) concept for high-performance functional parts: Selective Microwave Melting/Sintering (SMM/SMS). This technique leverages the EM susceptibility of carbon nanotube-coated polymer micro-pellets to achieve rapid, localized heating and powder fusion. Thus, selective microwave melting (SMM) was used to fabricate multilayer specimens made of recycled polyphenylene sulfide (rPPS) and carbon nanotubes (CNTs). The resulting SMM specimens exhibited very good interlayer integrity, localized fusion at pellet boundaries, and tolerable residual porosity, indicating effective fusion and acceptable consolidation. CNT-rich interphases were retained after irradiation, generating anisotropic electrically active network pathways and enabling conductivity enhancement at low filler content. At only 1.0 wt% CNT, the specimens exhibited electrical conductivity approximately three orders of magnitude higher than neat rPPS. Dynamic mechanical analysis showed improved viscoelastic response relative to neat rPPS, while tensile testing confirmed that the SMM-processed specimens retained practical mechanical integrity despite localized voids. These results demonstrate that SMM can effectively consolidate EM susceptible thermoplastic powder beds while preserving their segregated conductive networks. This may become a scalable route for producing multifunctional thermoplastic parts with low filler loadings, tunable anisotropy, and structured materials and parts. Overall, the findings suggest that EM field-based AM can help overcome key limitations of conventional thermoplastic processing by enabling scalable, energy-efficient fabrication of nanostructured composites and expanding AM to a broader range of resins, including high-performance thermoplastics with customized functional properties.
Effects of factors associated with aluminum base plate and filler wire on occurrence of weld defects
Dynamic, viscoelastic properties of molten polyethylene with fillers
Bending and buckling calculations for sandwich panels filled with glass particles, and optimal compression of sandwich plate having foam filler
This presentation provides the background information on NASA-GRC high voltage (HV) materials team research efforts towards electrified propulsion systems since 2016 . Additionally, it covers polymer and ceramic filler materials development for HV electrical insulation composites, copper/ carbon nanotube hybrid conductors, modeling efforts, HV test capabilities, and future material processing capabilities.
To facilitate welding of closed vessels, a metal backup strip is used at the junction inside the vessel. After welding from the outside, this strip is dissolved by a chemically reactive solvent poured through a filler hole into the vessel.
Adhesive cured at room temperature provides an effective adhesive bond over the range from room temperature down to the temperature of liquid hydrogen. The adhesive consists of one part of 200-mesh powdered nylon filler to two parts of an epoxy-polyamine resin.
Thermoplastic rubberlike material is prepared by blending a copolymer of ethylene and vinyl acetate with asphalt and a petroleum distillate. This low cost material is easily molded or extruded and is compatible with a variety of fillers.
Treating organic polymers with iodine improves the electrical conductivity. Diffusion enables products of desired properties to be custom formulated. This eliminates a buildup of static electricity and the need for fillers or bound metal salts.