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At least 37 records · Page 2

Electrical Properties and Manufacturability of ITO-MgF2 and Related Transparent Arcproof Spacecraft Coatings

To investigate the applicability of co-deposited indium tin oxide and magnesium fluoride as a transparent arcproof coating on the exterior of PowerSphere microsatellites. This included testing coating performance after deposition on flexible polymeric substrates, determining whether ultraviolet (UV) radiation present during deposition might affect the UV-curing resin contained in the substrate, and preparation of coated polymeric samples for radiation damage studies by the PowerSphere team.

Hambourger, Paul D.↗

Origami-based Composite Space Structures

The main objective of my internship was working on developing a new type of deployable composite for space structures and new method of deployment via use of origami, composites, UV curing resins, and shape memory polymers. My role in the project was to collect an initial literature survey on the subject including origami, the history of deployable space structures, previous issues and problems faced in the field, previous and current research being done on the structural aspect as well as the materials aspect of the subject. I presented this information to our team, where we discussed and determined our research focus and project design specs. We have been making or will make decisions on the project’s purpose, material, origami type, manufacturing method, and testing methods. I am now in charge of the protype design as we enter the design stage of our research. I am using PTC Creo software to design the structural aspects of the first protype so that we can begin small scale testing. I will perform data analysis in order to review the results with our team, so we can make the next design decisions regarding changes or iterations of the design. We hope to renew this project in the next fiscal year in order to increase the TRL of the project so that it can eventually be used in multiple functions in space such as the construction of lunar habitats. In just my brief time with NASA, I have gained so much personally and professionally. I developed my ability to search through and narrow down information when doing research. In the weekly meetings I practiced presenting information to my peers and superiors, and, just as importantly, discussing and adapting to what we were learning. I acquired experience in using technology to my advantage including remote work, new software like PTC Creo, NASA archives, and connecting with others beyond my team to gain help. I enjoyed the immense resource of knowledge that my mentors had to offer, and that they gave me a large amount of responsibility in this research. I truly felt like I was contributing to something bigger than myself and understood how directly I was involved in NASA’s work. This internship has further cemented my love for space and desire to continue in the field. I have a better understanding of the research and development process and am now considering joining a research lab with my university next year.

Composite↗

Scalability in SLA lattice through lattice orientation and hybrid frame and plate architectures

Lightweighting has been a key goal for engineers and designers, with lattice structures widely explored as the building blocks for structural components. Cellular structure-inspired lattice truss frame designs made of struts, have been extensively studied. All plate-based lattice designs have superior mechanical performance. Limits in scalability occur from formation of closed pockets limiting uv curing in processes like stereolithography (SLA). We examine hybrid frame and plate body-centered cubic-simply cubic (BCC-SC) lattices under compression. Unit cells and scaled up lattice exhibit an increase in yield stress and modulus with the addition of plates. The loading direction on the hybrid frame and plate unit cells affected the magnitude of improvement. Simulations and measurements indicated that the optimal lightweight lattice was determined to be when two plates were placed opposite each other with plates buttressing the struts, inhibiting buckling of the struts aligned with the loading direction. This lattice resulted in 63% improvement in specific modulus, a 137% improvement in specific yield point, and a 360% improvement in specific energy absorption (SEA) and the scaled up 4 × 4 × 4 scaled-up structures, showed a 107%, 148%, and 297% in specific modulus, specific yield point, and SEA, respectively A combined stretching-bending behavior was identified in optimal orientations reflecting the delayed buckling mechanism paired to a rising stress-strain curve past the elastic yield indicating bending resistance. The mass moment of inertia was found to be a key parameter correlating optimum orientation for the same number of plates added to the BCC-SC frame.

Mahan Ghosh↗

Compositional effects on cure kinetics, mechanical properties and printability of dual-cure epoxy/acrylate resins for DIW additive manufacturing

Interest in 3D printing of thermoset resins has increased significantly in recent years. One approach to additive manufacturing of thermoset resins is printing dual-cure resins with direct ink write (DIW). Dual-cure resins are multi-component resins which employ an in situ curable constituent to enable net-shape fabrication while a second constituent and cure mechanism contribute to the final mechanical properties of the printed materials. In this work, the cure kinetics, green strength, printability, and print fidelity of dual-cure epoxy/acrylate thermoset resins are investigated. Resin properties are evaluated as a function of acrylate concentration and in situ UV exposure conditions. The acrylate cure kinetics are probed using photo-differential scanning calorimetry and the impacts of resin composition and UV cure profile on the acrylate extent of conversion are presented. Continuous and pulsed UV cure profiles are shown to affect total conversion due to variances in radical efficiency at different UV intensities and acrylate concentrations. The effects of acrylate concentration on the kinetics of the epoxy thermal cure and the final mechanical properties are also investigated using dynamic mechanical analysis and three-point bend measurements. The glass transition temperature is dependent on formulation, with increasing acrylate content decreasing the T g . However, the room temperature shear moduli, flexural moduli, strength, strain-to-failure, and toughness values are relatively independent of resin composition. The similarity of the final properties allows for greater flexibility in resin formulation and in situ cure parameters, which can enable the printing of complex parts that require high green strength. We found that the in situ UV print intensities and exposure profiles that are necessary to achieve the best print quality are not, in most cases, the conditions that maximize conversion of the acrylate network. Lastly, this highlights the importance of developing optimized resin compositions which enable complete cure of the acrylate network by promoting acrylate dark cure or thermal cure.

36 MATERIALS SCIENCE↗

Strong Thermoset Regolith UV-Curable Composite Technology (STRUCT) Overview

Future lunar surface missions require construction materials that can be manufactured in situ using lo-cal resources while operating under extreme environmental conditions. Many Lunar material demands can be solved solely with regolith by compacting or sintering. And yet past Lunar missions rely on polymeric materials, and sustained Lunar missions must reduce Earth-supplied polymers dependence. Dual-cure (Ultraviolet (UV) and thermal) polymer-regolith composites offer a promising pathway by leveraging solar UV radiation, moderate thermal in-put, and regolith. Mission mass limits, power availability and energy constraints on the lunar surface further motivate low-energy processing and curing strategies for surface construction materials. The Strong Thermoset Regolith UV-Curable Composite Technology (STRUCT) project has successfully synthesized and demonstrated dual-cure photopolymer resins derivable from in-situ resources [3]. Morphological, thermal, and mechanical characterization show that the newly formulated UV curable resin systems integrates well with lunar regolith simulants. Processing and chemistry changes, and computational analysis advanced the composite design. X-ray CT scanned and computational analysis demonstrate that resin, regolith and additives are well incorporated. The large fraction of regolith, 95% by mass, large char yield (82% mass), low thermal conductivity (0.26 W/m/K), confirm this material as a promising high-performance thermal and structural material.

thermal conductivity↗

Differences in the Interfacial Mechanical Properties of Thiophosphate and Argyrodite Solid Electrolytes and Their Composites

Interfacial mechanics are a significant contributor to the performance and degradation of solid-state batteries. Spatially resolved measurements of interfacial properties are extremely important to effectively model and understand the electrochemical behavior. Herein, we report the interfacial properties of thiophosphate (Li 3 PS 4 )- and argyrodite (Li 6 PS 5 Cl)-type solid electrolytes. Using atomic force microscopy, we showcase the differences in the surface morphology as well as adhesion of these materials. Additionally we investigate solvent-less processing of hybrid electrolytes using UV-assisted curing. Physical, chemical, and structural characterizations of the materials highlight the differences in the surface morphology, chemical makeup, and distribution of the inorganic phases between the argyrodite and thiophosphate solid electrolytes.

36 MATERIALS SCIENCE↗

Effects of Plasticizer Content and Ceramic Addition on Electrochemical Properties of Cross-Linked Polymer Electrolyte

The development of a safe electrolyte is the key to improving energy density for next generation lithium batteries. In this work, UV-crosslinked poly(ethylene oxide) (PEO) -based polymer and composite electrolytes are systematically investigated on their ionic conductivity, mechanical and electrochemical properties. The polymer electrolytes are plasticized with non-flammable linear short-chain PEO. In the composite electrolytes, a doped lithium aluminum titanium phosphate (LATP) ceramic, LICGC™, is used as the ceramic filler. It is found that the addition of the plasticizer leads to a tradeoff between ion transport and mechanical properties. In contrast, the addition of ceramic fillers improves both the ionic conductivity and mechanical properties. The sample with 20 wt% of LICGC™ shows a conductivity of ~0.6 mS cm –1 at 50 °C. This sample also demonstrates much longer cycle life than the neat polymer electrolyte in Li platting/stripping test with a capacity of 1 mAh cm –2 . Further, a full cell made with this composite electrolyte against Li metal anode and high voltage LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathode shows 94% capacity retention after 30 cycles, compared to 58% capacity retention with the neat polymer electrolyte. These results demonstrate that a hybrid of polymer/ceramic/non-flammable plasticizer is a promising path to high energy density, high voltage lithium batteries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Property changes induced by the space environment in composite materials on LDEF: Solar array materials passive LDEF experiment A0171 (SAMPLE)

Surface modifications to composite materials induced by long term exposure in low earth orbit (LEO) were dominated by atomic oxygen erosion and micrometeoroid and space debris impacts. As expected, calculated erosion rates were peculiar to material type and within the predicted order of magnitude. Generally, about one ply of the carbon fiber composites was eroded during the 70 month LDEF experiment. Matrix erosion was greater than fiber erosion and was more evident for a polysulfone matrix than for epoxy matrices. Micrometeoroid and space debris impacts resulted in small (less than 1mm) craters and splattered contaminants on all samples. Surfaces became more diffuse and darker with small increases in emissivity and absorption. Tensile strength decreased roughly with thickness loss, and epoxy matrices apparently became slightly embrittled, probably as a result of continued curing under UV and/or electron bombardment. However, changes in the ultimate yield stress of the carbon reinforced epoxy composites correlate neither with weave direction nor fiber type. Unexpected developments were the discovery of new synergistic effects of the space environment in the interaction of atomic oxygen and copious amounts of contamination and in the induced luminescence of many materials.

Source record↗

Photoinitiator Selection and Concentration in Photopolymer Formulations towards Large-Format Additive Manufacturing

Photopolymers are an attractive option for large-format additive manufacturing (LFAM), because they can be formulated from structural thermosets and cure rapidly in ambient conditions under low-energy ultraviolet light-emitting diode (UV LED) lamps. Photopolymer cure is strongly influenced by the depth penetration of UV light, which can be limited in the 2–4 mm layer thicknesses typical of LFAM. Photoinitiator (PI) systems that exhibit photobleaching have proven useful in thick-section cure applications, because they generate a photoinitiation wavefront, but this effect is time-dependent. This study investigates the light transmission and through-thickness cure behavior in (meth)acrylate photopolymer formulations with the photobleaching initiator bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide (BAPO). Utilizing an optical model developed by Kenning et al., lower concentrations (0.1 wt% to 0.5 wt%) of BAPO were predicted to yield rapid onset of photoinitiation. In situ cure measurements under continuous UV LED irradiation of 380 mW/cm2 showed that a 0.1 wt% concentration of BAPO achieved peak polymerization rate within 2.5 s at a 3-mm depth. With only 1 s of irradiation at 1.7 W/cm2 intensity, the 0.1 wt% BAPO formulation also achieved the highest level of cure of the formulas tested. For an irradiation dose of 5.5 J/cm2 at a duration of 3.7 s, cured polymer specimens achieved a flexural strength of 108 MPa and a flexural modulus of 3.1 GPa. This study demonstrates the utility of optical modeling as a potential screening tool for new photopolymer formulations, primarily in identifying an upper limit to PI concentration for the desired cure depth. The results also show that photobleaching provides only a limited benefit for LFAM applications with short (1.0 s to 3.7 s) UV irradiation times and indicate that excess PI concentration can inhibit light transmission even under extended irradiation times up to 60 s.

36 MATERIALS SCIENCE↗

Rapid Prototyping of Composite Structures

This progress report for the project Rapid Production of Composite Structures covers the period from July 14, 1997 to June 30, 1998. It will present a short overview of the project, followed by the results to date and plans for the future. The goal of this research is to provide a minimum 100x reduction in the time required to produce arbitrary, laminated products without the need for a separate mold or an autoclave. It will accomplish this by developing the science underlying the rapid production of composite structures, specifically those of carbon fiber-epoxy materials. This scientific understanding will be reduced to practice in a demonstration device that will produce a part on the order of 12" by 12" by 6". Work in the past year has focussed on developing an understanding of the materials issues and of the machine design issues. Our initial goal was to use UV cureable resins to accomplish full cure on the machine. Therefore, we have centered our materials work around whether or not UV cureable resins will work. Currently, the answer seems to be that they will not work, because UV light cannot penetrate the carbon fibers, and because no "shadow" curing seems to occur. As a result, non-UV cureable resins are being investigated. This has resulted in a change in the machine design focus. We are now looking into a "dip and place" machine design, whereby a prepreg layer would have one side coated with a curing agent, and then would be placed onto the previous layer. This would lead to cure at the interface, but not to the top of the layer. The formulation of the resins to accomplish this task at room or slightly elevated temperatures is being investigated, as is the machine design needed to apply the curing agent and then cure or partially cure the part. A final, out-of-autoclave, post-cure may be needed with this strategy, as final cure on the machine may not be possible, as it was for the initial UV cure strategy. The remainder of this report details the progress in the materials and machine design areas. Materials Development The material system must be designed to fulfill the following requirements: to reduce the time and labor requirements of typical cure cycles; to reduce the thermal stresses developed during conventional heat curing; and to develop a structure that the build sequence requires. In order to accomplish these goals, there have been parallel tracks of investigation. One area has tested photopolymerizable (ultraviolet (UV) curable) materials and combinations of these materials with standard heat curing resins. The second area has investigated resins that cure rapidly at room or low heat temperatures. The main goal of these investigations has been to identify a system that will rapidly set or cure at room temperature during a tape lay-up process and hold its structure during a post-cure cycle.

Colton, Jonathan S.↗

Rapid Prototyping of Composite Structures

This final report for the project Rapid Production of Composite Structures covers the period from July 14, 1997 to September 30, 1998. It will present a short overview of the project, followed by the results to date and plans for the future. The goal of this research is to provide a minimum 100x reduction in the time required to produce arbitrary, laminated products without the need for a separate mold or an autoclave. It will accomplish this by developing the science underlying the rapid production of composite structures, specifically those of carbon fiber-epoxy materials. This scientific understanding will be reduced to practice in a demonstration device that will produce a part on the order of 12in. by 12in. by 6in. Work in the past year has focussed on developing an understanding of the materials issues and of the machine design issues. Our initial goal was to use UV cureable resins to accomplish full cure on the machine. Therefore, we have centered our materials work around whether or not UV cureable resins will work. Currently, the answer seems to be that they will not work, because UV light cannot penetrate the carbon fibers, and because no "shadow" curing seems to occur. As a result, non-UV cureable resins are being investigated. This has resulted in a change in the machine design focus. We are now looking into a "dip and place" machine design, whereby a prepreg layer would have one side coated with a curing agent, and then would be placed onto the previous layer. This would lead to cure at the interface, but not to the top of the layer. The formulation of the resins to accomplish this task at room or slightly elevated temperatures is being investigated, as is the machine design needed to apply the curing agent and then cure or partially cure the part. A final, out-of-autoclave, post-cure may be needed with this strategy, as final cure on the machine may not be possible, as it was for the initial UV cure strategy. The remainder of this report details the progress in the materials and machine design areas.

Colton, Jonathan S.↗

Photo-Curing 3D Printing of Thermosetting Sacrificial Tooling for Fabricating Fiber-Reinforced Hollow Composites

Carbon fiber-reinforced hollow composites play a vital role in lightweighting modern cars and aircrafts. Fabrication of such hollow composites with seamless internal finish requires sacrificial tooling that can be used under pressure and high temperature. For the very first time, high performance sacrificial tooling that can be used to fabricate fiber-reinforced hollow composites is produced using photocuring 3D printing technology. This is achieved by developing UV-curable resins containing highly soluble yet hydrolysable acetal acrylate cross-linker and hydrophilic 4-acryloylmorpholine monomer. It is found that the cross-linker content greatly affects the printing speed. Further, the widely adopted UV post-curing method is found to have negligible impact on improving the thermal-mechanical properties of printed structures. Additionally, after thermal post-treatment, printed sacrificial tooling exhibits a heat deflection temperature of 112 °C at 0.455 MPa and an average coefficient of linear thermal expansion of 59 ppm °C -1 between 30 and 100 °C. As a result, printed tooling enables fabrication of carbon fiber-reinforced hollow composites with complex geometry, which shows a tensile strength of 802 MPa and an elastic modulus of 50.2 GPa.

36 MATERIALS SCIENCE↗

Waveguides for neurostimulation in the cochlea

Introduction Optical stimulation has been suggested for neural stimulation to improve cochlear implants. Light allows for more spatially selective activation of neuron populations than electrical current, offering more independent frequency bands along the spiral ganglion. These bands are available to encode acoustic information with anticipated better frequency resolution, improving cochlear implant user performance in noisy listening environments, tonal languages, and music perception. Methods Optical cochlear implants (oCIs) can deliver light either directly via small emitters within the cochlea or via waveguides from external optical sources. We investigated three waveguide designs made from OrmoComp ® , a polymer that cures through ultraviolet (UV) radiation. Waveguides were fabricated via injection molding and coated using dip-coating or thermal reflow, or through aspiration of OrmoComp ® into polyimide tubing that served as the cladding of the waveguide. The choice of fabrication technique directly determined the waveguides' total diameter: thermal reflow yielded ≈940 μm, dip-coating produced ≈306 μm, and aspiration resulted in ≈132 μm core diameter waveguides. Given the human cochlea's small size, we focused on analyzing the 306-μm and 132-μm waveguides, evaluating their optical performance (propagation and bending losses) and mechanical properties (bending stiffness and insertion forces). Furthermore, we evaluated some of these designs in in-vivo guinea pigs experiments. Results For the 100-μm core diameter waveguides, the propagation losses were 12.34 ± 1.26, 1.18 ± 0.88, 1.49 ± 0.58, and 3.43 ± 0.68 dB/cm at 534, 1,375, 1,460, and 1,550 nm, respectively. The respective bending losses at a 2 mm radius of curvature were 5.50 ± 1.32, 0.56 ± 0.26, 0.79 ± 0.18, and 0.64 ± 0.23 dB, and at 1 mm 8.54 ± 1.30, 2.05 ± 0.84, 2.11 ± 0.50, and 1.44 ± 0.37 dB. The bending stiffness of a 1 mm segment of the 100-μm-diameter waveguides was 18.9 ± 2.2 N/m. Insertion forces for the 100-μm-diameter waveguides into an acrylic human-size scala tympani model were < 25 mN. For the waveguides with 306 and 940 μm total diameter, the propagation losses ranged between 0.43 and 2.40 dB/cm at 534, 680, 1,375, and 1,550 nm, between 2.19 and 3.78 dB/cm at 450 and 1,460 nm. Bending losses for 360 degrees at 1,375 nm were 5.0, 2.4, and 0.46 for a bending radius of 2.5-, 3-, and 4-mm. Discussion Our study demonstrated that the polymer OrmoComp ® is suitable for fabricating waveguides to transmit near-infrared radiation. In-vivo experiments showed optically evoked auditory responses originating from optical stimulation in the guinea pigs' first cochlear turn while radiation was delivered. Incoming experiments will focus on evaluating long-term performance of these waveguides in guinea pigs and cats. This study will be designed to provide insights into the waveguides' performance and biocompatibility over extended periods, essential for their potential clinical application in future oCIs.

Kim, Matthew↗

Atomic Oxygen Durability Evaluation of a UV Curable Ceramer Protective Coating

The exposure of most silicones to atomic oxygen in low Earth orbit (LEO) results in the oxidative loss of methyl groups with a gradual conversion to oxides of silicon. Typically there is surface shrinkage of oxidized silicone protective coatings which leads to cracking of the partially oxidized brittle surface. Such cracks widen and branch crack with continued atomic oxygen exposure ultimately allowing atomic oxygen to reach any hydrocarbon polymers under the silicone coating. A need exists for a paintable silicone coating that is free from such surface cracking and can be effectively used for protection of polymers and composites in LEO. A new type of silicone based protective coating holding such potential was evaluated for atomic oxygen durability in an RF atomic oxygen plasma exposure facility. The coating consisted of a UV curable inorganic/organic hybrid coating, known as a ceramer, which was fabricated using a methyl substituted polysiloxane binder and nanophase silicon-oxo-clusters derived from sol-gel precursors. The polysiloxane was functionalized with a cycloaliphatic epoxide in order to be cured at ambient temperature via a cationic UV induced curing mechanism. Alkoxy silane groups were also grafted onto the polysiloxane chain, through hydrosilation, in order to form a network with the incorporated silicon-oxo-clusters. The prepared polymer was characterized by H-1 and Si-29 NMR, FT-IR, and electrospray ionization mass spectroscopy. The paper will present the results of atomic oxygen protection ability of thin ceramer coatings on Kapton H as evaluated over a range of atomic oxygen fluence levels.

Banks, Bruce A.↗

Self-Assembly Driven Microlithography via Near-Infrared Light Activation

Current vat photopolymerization (VP) relies on UV or visible light to start the rapid crosslinking of liquid photocurable resins into 3D-printed structures. Here, we develop a self-assembly-driven photopatterning approach to photothermally generate polymeric solids by combining thermoplasmonic nanoparticles and thermoresponsive polymers, in which near-infrared (NIR) light activates thermoplasmonic heating of nanoparticles, triggering the irreversible self-assembly of thermoresponsive polymers into insoluble mesoglobules. A small amount of thermal initiator and crosslinker leads to irreversible self-assembly of polymer nanocomposites. NIR light offers deeper penetration and reduced scattering compared to UV, enabling more uniform curing of thicker or filled materials and expanded process control for composites or opaque systems. Thermoplasmonic heat generation is achieved using surface-modified gold nanorods (AuNRs) with a longitudinal localized surface plasmon resonance peak in the NIR region. Key variables such as polymer composition, molecular weight, physical interactions at the nanoparticle–polymer interface, which can be tuned by surface functionalization, AuNR concentration, and pH can be used to tailor the assembly behavior of these systems, including photothermal effect, flocculation, and cloud point temperature, and the mechanical properties of the final structures. Collectively, these results highlight a platform for photothermally-driven microlithography of polymer solids with diverse, tunable macroscopic properties, enabled by low-energy NIR light-activated self-assembly.

36 MATERIALS SCIENCE↗

Cross-linkable nanocomposite anticorrosion coating

Nanocomposite anticorrosion coating can be achieved by depositing alternating, multilayers of a cross-linkable polymer and dispersed and aligned inorganic platelets followed by cross-linking of the cross-linkable polymer. The cross-linkable polymer can be an externally cross-linkable polymer that is cross-linked by diffusing a cross-linking agent into the deposited multilayer coating. Alternately, the cross-linkable polymer can be a functionalized cross-linkable polymer that is cross-linked by self-curing, thermal heat curing, or light (e.g., UV) following deposition of the multilayer coating.

Percival, Stephen John↗

Hybrid AlGaN-SiC Avalanche Photodiode for Deep-UV Photon Detection

The proposed device is capable of counting ultraviolet (UV) photons, is compatible for inclusion into space instruments, and has applications as deep- UV detectors for calibration systems, curing systems, and crack detection. The device is based on a Separate Absorption and Charge Multiplication (SACM) structure. It is based on aluminum gallium nitride (AlGaN) absorber on a silicon carbide APD (avalanche photodiode). The AlGaN layer absorbs incident UV photons and injects photogenerated carriers into an underlying SiC APD that is operated in Geiger mode and provides current multiplication via avalanche breakdown. The solid-state detector is capable of sensing 100-to-365-nanometer wavelength radiation at a flux level as low as 6 photons/pixel/s. Advantages include, visible-light blindness, operation in harsh environments (e.g., high temperatures), deep-UV detection response, high gain, and Geiger mode operation at low voltage. Furthermore, the device can also be designed in array formats, e.g., linear arrays or 2D arrays (micropixels inside a superpixel).

Aslam, Shahid↗