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Advancements in Materials Science Through Space-Based Research
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Progress in advanced high temperature turbine materials, coatings, and technology
Advanced materials, coatings, and cooling technology is assessed in terms of improved aircraft turbine engine performance. High cycle operating temperatures, lighter structural components, and adequate resistance to the various environmental factors associated with aircraft gas turbine engines are among the factors considered. Emphasis is placed on progress in development of high temperature materials for coating protection against oxidation, hot corrosion and erosion, and in turbine cooling technology. Specific topics discussed include metal matrix composites, superalloys, directionally solidified eutectics, and ceramics.
OMC Compressor Case
This report summarizes efforts expended in the development of an all-composite compressor case. Two pre-production units have been built, one utilizing V-CAP and one utilizing AFR-700B resin systems. Both units have been rig tested at elevated temperatures well above design limit loads. This report discusses the manufacturing processes, test results, and Finite Element Analysis performed. The V-CAP unit was funded by NASA-Lewis Research Center in 1994 under contract number NAS3- 27442 for Development of an All-Composite OMC Compressor Case. This contract was followed by an Air Force study in 1996 to build and identical unit using the AFR-700B resin system in place of the V-CAP system. The second compressor case was funded under U.S. Air Force contract F33615-93-D-5326, Advanced Materials for Aerospace Structures Special Studies (AMAS3), Delivery Order 0021 entitled "Advanced Polymeric Composite Materials and Structures Technology for Advanced High Temperature Gas Turbine Engines.' Initial studies using the V-CAP resin system were undertaken in 1993 under a NASA Lewis contract (NAS3-26829). A first prototype unit was developed in a joint program between Textron-Lycoming (now Allied Signal) and Brunswick (now Lincoln Composites). This unit included composite end closures using low density, high temperature molded end closures. The units was similar in size and shape to a titanium case currently used on the PT-21 0 engine and was funded as part of the integrated High Performance Turbine Engine Technology (EHPTET) initiative of DOD and NASA.
Interdisciplinary research on the nature and properties of ceramic materials
The advancement of material performance and design methodology as related to brittle materials was investigated. The processing and properties of ceramic materials as related to design requirements was also studied.
Advanced AE Techniques in Composite Materials Research
Advanced, waveform based acoustic emission (AE) techniques have been successfully used to evaluate damage mechanisms in laboratory testing of composite coupons. An example is presented in which the initiation of transverse matrix cracking was monitored. In these tests, broad band, high fidelity acoustic sensors were used to detect signals which were then digitized and stored for analysis. Analysis techniques were based on plate mode wave propagation characteristics. This approach, more recently referred to as Modal AE, provides an enhanced capability to discriminate and eliminate noise signals from those generated by damage mechanisms. This technique also allows much more precise source location than conventional, threshold crossing arrival time determination techniques. To apply Modal AE concepts to the interpretation of AE on larger composite specimens or structures, the effects of modal wave propagation over larger distances and through structural complexities must be well characterized and understood. To demonstrate these effects, measurements of the far field, peak amplitude attenuation of the extensional and flexural plate mode components of broad band simulated AE signals in large composite panels are discussed. These measurements demonstrated that the flexural mode attenuation is dominated by dispersion effects. Thus, it is significantly affected by the thickness of the composite plate. Furthermore, the flexural mode attenuation can be significantly larger than that of the extensional mode even though its peak amplitude consists of much lower frequency components.
Carbon Nanotubes: Miracle of Materials Science?
Article to be sent to Advanced Materials and Processes, journal of ASM International, as attached. This is a news-type technical journal for a large organization of scientists, engineers, salesmen, and managers. The article is quite general, meant to be an introduction to the properties of nanotubes. This is a materials science organization, therefore the article is geared toward using nanotubes for materials uses. Pictures have not been included in this version.
Systems evaluation of advanced structures and materials in future launch vehicles.
Advanced structures and materials in future launch vehicles evaluated by design synthesis technique for component weight reduction, equivalent payload gained and cost ratio
Development of processing techniques for advanced thermal protection materials
The effort, which was focused on the research and development of advanced materials for use in Thermal Protection Systems (TPS), has involved chemical and physical testing of refractory ceramic tiles, fabrics, threads and fibers. This testing has included determination of the optical properties, thermal shock resistance, high temperature dimensional stability, and tolerance to environmental stresses. Materials have also been tested in the Arc Jet 2 x 9 Turbulent Duct Facility (TDF), the 1 atmosphere Radiant Heat Cycler, and the Mini-Wind Tunnel Facility (MWTF). A significant part of the effort hitherto has gone towards modifying and upgrading the test facilities so that meaningful tests can be carried out. Another important effort during this period has been the creation of a materials database. Computer systems administration and support have also been provided. These are described in greater detail below.
NASA technology program for future civil air transports
An assessment is undertaken of the development status of technology, applicable to future civil air transport design, which is currently undergoing conceptual study or testing at NASA facilities. The NASA civil air transport effort emphasizes advanced aerodynamic computational capabilities, fuel-efficient engines, advanced turboprops, composite primary structure materials, advanced aerodynamic concepts in boundary layer laminarization and aircraft configuration, refined control, guidance and flight management systems, and the integration of all these design elements into optimal systems. Attention is given to such novel transport aircraft design concepts as forward swept wings, twin fuselages, sandwich composite structures, and swept blade propfans.
NASA N+3 Subsonic Fixed Wing Silent Efficient Low-Emissions Commercial Transport (SELECT) Vehicle Study
A conceptual commercial passenger transport study was performed to define a single vehicle for entry into service in the 2030 to 2035 timeframe, meeting customer demands as well as NASA goals for improved fuel economy, NOx emissions, noise, and operability into smaller airports. A study of future market and operational scenarios was used to guide the design of an advanced tube-and-wing configuration that utilized advanced material and structural concepts, an advanced three-shaft high-bypass turbofan engine, natural laminar flow technology, and a suite of other advanced technologies. This configuration was found to meet the goals for NOx emissions, noise, and field length. A 64 percent improvement in fuel economy compared to a current state-of-the-art airliner was achieved, which fell slightly short of the desired 70 percent goal. Technology maturation plans for the technologies used in the design were developed to help guide future research and development activities.
Comparison Testing and Analysis of Braided Cords Constructed from Varying Kevlar Fiber Types
Material advancements move quickly, resulting in material obsolescence issues that require parachute engineers to understand how the material properties change with a material upgrade and if there are expected impacts to overall performance of the parachute. The objective of this test was to measure the elongation of different Kevlar types at both the cord-level and at the yarn-level to determine if a change in Kevlar type impacted parachute performance. An Instron machine with a pin-to-pin connection was used to measure load and displacement time histories for various Kevlar cord and yarn samples in a cyclic load profile. Twenty-four cord samples and twenty-four yarn samples were tested; each sample was cycled five times to the relevant maximum load (either to breaking strength or to the 30% peak load expected in flight). In addition to the Instron measurements, a photogrammetric technique was also implemented to measure elongation of the samples using button targets. Modulus test data shows approximately a 10% difference in elongation between Kevlar 29AP and Kevlar 129, and another 10% difference in elongation between Kevlar 29 and Kevlar 29AP. Although this is a measurable change in modulus, the effect on parachute performance is likely small, particularly for non-primary structure elements of relatively small length. This test campaign provides an example of the type of testing and analysis that parachute engineers could do to understand how material upgrades affect performance of their systems.
Comparison Testing and Analysis of Braided Cords Constructed from Varying Kevlar Fiber Types
Material advancements move quickly, resulting in material obsolescence issues that require parachute engineers to understand how the material properties change with a material upgrade and if there are expected impacts to overall performance of the parachute. The objective of this test was to measure the elongation of different Kevlar types at both the cord-level and at the yarn-level to determine if a change in Kevlar type impacted parachute performance. An Instron machine with a pin-to-pin connection was used to measure load and displacement time histories for various Kevlar cord and yarn samples in a cyclic load profile. Twenty-four cord samples and twenty-four yarn samples were tested; each sample was cycled five times to the relevant maximum load (either to breaking strength or to the 30% peak load expected in flight). In addition to the Instron measurements, a photogrammetric technique was also implemented to measure elongation of the samples using button targets. Modulus test data shows approximately a 10% difference in elongation between Kevlar 29AP and Kevlar 129, and another 10% difference in elongation between Kevlar 29 and Kevlar 29AP. Although this is a measurable change in modulus, the effect on parachute performance is likely small, particularly for non-primary structure elements of relatively small length. This test campaign provides an example of the type of testing and analysis that parachute engineers could do to understand how material upgrades affect performance of their systems.
Materials Science
The Materials Science Program is structured so that NASA s headquarters is responsible for the program content and selection, through the Enterprise Scientist, and MSFC provides for implementation of ground and flight programs with a Discipline Scientist and Discipline Manager. The Discipline Working Group of eminent scientists from outside of NASA acts in an advisory capacity and writes the Discipline Document from which the NRA content is derived. The program is reviewed approximately every three years by groups such as the Committee on Microgravity Research, the National Materials Advisory Board, and the OBPR Maximization and Prioritization (ReMaP) Task Force. The flight program has had as many as twenty-six principal investigators (PIs) in flight or flight definition stage, with the numbers of PIs in the future dependent on the results of the ReMaP Task Force and internal reviews. Each project has a NASA-appointed Project Scientist, considered a half-time job, who assists the PI in understanding and preparing for internal reviews such as the Science Concept Review and Requirements Definition Review. The Project Scientist also insures that the PI gets the maximum science support from MSFC, represents the PI to the MSFC community, and collaborates with the Project Manager to insure the project is well-supported and remains vital. Currently available flight equipment includes the Materials Science Research Rack (MSRR-1) and Microgravity Science Glovebox. Ground based projects fall into one or more of several categories. Intellectual Underpinning of Flight Program projects include theoretical studies backed by modeling and computer simulations; bring to maturity new research, often by young researchers, and may include preliminary short duration low gravity experiments in the KC-135 aircraft or drop tube; enable characterization of data sets from previous flights; and provide thermophysical property determinations to aid PIs. Radiation Shielding and preliminary In Situ Resource Utilization (ISRU) studies work towards future long duration missions. Biomaterials support materials issues affecting crew health. Nanostructured Materials are currently considered to be maturing new research, and Advanced Materials for Space Transportation has as yet no PIs. PIs are assigned a NASA Technical Monitor to maintain contact, a position considered to be a 5 percent per PI effort. Currently 33 PIs are supported on the 1996 NRA, which is about to expire, and 59 on the 1998 NRA. Two new NRAs, one for Radiation Shielding and one for Materials Science for Advanced Space Propulsion are due to be announced by the 2003 fiscal year. MSFC has a number of facilities supporting materials science. These include the Microgravity Development Laboratory/SD43; Electrostatic Levitator Facility; SCN Purification Facility; Electron Microscope/Microprobe Facility; Static and Rotating Magnetic Field Facility; X-Ray Diffraction Facility; and the Furnace Development Laboratory.
Overview of Lightweight Structures for Rotorcraft Engines and Drivetrains
This is an overview presentation of research being performed in the Advanced Materials Task within the NASA Subsonic Rotary Wing Project. This research is focused on technology areas that address both national goals and project goals for advanced rotorcraft. Specific technology areas discussed are: (1) high temperature materials for advanced turbines in turboshaft engines; (2) polymer matrix composites for lightweight drive system components; (3) lightweight structure approaches for noise and vibration control; and (4) an advanced metal alloy for lighter weight bearings and more reliable mechanical components. An overview of the technology in each area is discussed, and recent accomplishments are presented.
SiC Recession Due to SiO2 Scale Volatility Under Combustor Conditions
One of today's most important and challenging technological problems is the development of advanced materials and processes required to design and build a fleet of supersonic High Speed Civil Transport (HSCT) airliners, a follow-up to the Concorde SST. The innovative combustor designs required for HSCT engines will need high-temperature materials with long-term environmental stability. Higher combustor liner temperatures than today's engines and the need for lightweight materials will require the use of advanced ceramic-matrix composites (CMC's) in hot-section components. The HSCT is just one example being used to demonstrate the need for such materials. This thesis evaluates silicon carbide (SiC) as a potential base material for HSCT and other similar applications. Key issues are the environmental durability for the materials of interest. One of the leading combustor design schemes leads to an environment which will contain both oxidizing and reducing gas mixtures. The concern is that these environments may affect the stability of the silica (SiO2) scale on which SiC depends for environmental protection. A unique High Pressure Burner Rig (HPBR) was developed to simulate the combustor conditions of future gas turbine engines, and a series of tests were conducted on commercially available SiC material. These tests are intended as a feasibility study for the use of these materials in applications such as the HSCT. Linear weight loss and surface recession of the SiC is observed as a result of SiO2 volatility for both fuel-lean and fuel-rich gas mixtures. These observations are compared and agree well with thermogravimetric analysis (TGA) experiments. A strong Arrhenius-type temperature dependence exists. In addition, the secondary dependencies of pressure and gas velocity are defined. As a result, a model is developed to enable extrapolation to points outside the experimental space of the burner rig, and in particular, to potential gas turbine engine conditions.
Advanced organic composite materials for aircraft structures: Future program
Revolutionary advances in structural materials have been responsible for revolutionary changes in all fields of engineering. These advances have had and are still having a significant impact on aircraft design and performance. Composites are engineered materials. Their properties are tailored through the use of a mix or blend of different constituents to maximize selected properties of strength and/or stiffness at reduced weights. More than 20 years have passed since the potentials of filamentary composite materials were identified. During the 1970s much lower cost carbon filaments became a reality and gradually designers turned from boron to carbon composites. Despite progress in this field, filamentary composites still have significant unfulfilled potential for increasing aircraft productivity; the rendering of advanced organic composite materials into production aircraft structures was disappointingly slow. Why this is and research and technology development actions that will assist in accelerating the application of advanced organic composites to production aircraft is discussed.