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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Transverse Coefficient of Thermal Expansion Measurements of Carbon Fibers Using ESEM at High Temperatures

The transverse coefficient of thermal expansion (CTE) of single IM7, T1000, and P55 carbon fibers are measured at elevated temperatures. The specimens are prepared by press-fitting fiber tows into 0.7mm-diameter cavity in a graphite disk of 5mm in diameter and 3mm high. The specimens are placed on a crucible in an ESEM, and images of the fiber cross section are taken as the fibers are heated up to 800 C. Holding time, heating and cool down cycles are also introduced. The geometrical changes are measured using a graphics tablet. The change in area/perimeter is calculated to determine the strain and transverse CTE for each fiber. In a complimentary computational effort, displacements and stresses are calculated with finite element models.

Ochoa, O.↗
NASA NTRSDate not supplied

Developing Procedures to Implement Geometric Imperfections Beyond Right Circular Cylindrical Shells in Finite Element Method Models

Analysis of aerospace structures is frequently conducted using nominal dimensions and frequently assumes ideal conditions in loading, contact, constraints, et cetera. Off-nominal dimensions and nonideal conditions, however, are present in all structures. These are the result of widely ranging causes from coefficient of thermal expansion mismatches, manufacturing tooling anomalies, to assembly procedures that inadvertently alter the structure. Specifically, geometric imperfections can have potentially significant influence on the response of a structural test article observed in an experiment versus the response given by a numerical simulation. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS) was previously presented as a set of Python scripts to calculate and implement as-manufactured geometric midsurface and thickness imperfections into finite element method (FEM) shell models of nominally right circular cylinders. By taking advantage of the simple shape of a right circular cylinder, interpolations of the measured data points were able to be performed along directions that aligned to the cylindrical coordinate system axes of the entire structure. By taking advantage of the shell representation of the real structure as opposed to modeling using a continuum representation, the thickness variation was able to be implemented by shell section definitions instead of having to modify the position of multiple nodes in the thickness direction. Py_TIGIRS is a useful tool that established a procedural example on how to implement geometric imperfections in right circular cylindrical shell structures. Three new procedures, each expanded from concepts established in Py_TIGIRS, are proposed for various test-article designs and are intended to broaden the range of structures that can be modeled with measured geometric imperfections in the structural analysis community. Each test-article design introduces new challenges to successfully implement geometric imperfections into a FEM model. The first test-article design consists of a carbon fiber reinforced polymer square plate with a hat-shaped stiffener co-cured on one side. This test-article design was for a novel seven-point bend test that was also previously presented. Manufacturing and cure-cycle imperfections are observed using digital image correlation (DIC) techniques. As thermal expansion coefficient mismatches between the plate and stiffener materials were anticipated, a thermal analysis study with continuum shell and solid elements was conducted to capture the global shape observed prior to testing. The second test-article design is of a similar hat-stiffened plate configuration, but with a side length ratio near 3:1 with elongation in the stiffener direction. The test article was used to characterize the response to uniaxial compressive loading in the direction of the stiffener. Due to differing manufacturing steps, a thermal analysis like the one developed for the seven-point bend configuration was unable to mimic the observed geometric imperfections. Instead, a strategy based on applying deformations directly to the structure during analysis was developed for continuum shell and solid element representation of a stiffened panel.

Geometric imperfections↗
NASA NTRS2001

Autofrettage to Counteract Coefficient of Thermal Expansion Mismatch in Cryogenic Pressurized Pipes with Metallic Liners

Composite feedlines with metal liners have the potential to reduce weight/cost while providing the same level of permeation resistance and material compatibility of all-metal feedlines carrying cryogenic propellants in spacecraft. The major technical challenges are the large difference in Coefficient of Thermal Expansion between the liner and the composite, and the manufacturing method required to make a very thin liner with the required strength and dimensional tolerance. This study investigates the use of autofrettage (compressive preload) to counteract Coefficient of Thermal Expansion when pre-pressurization procedures cannot be used to solve this problem. Promising materials (aluminum 2219, Inconel 718, nickel, nickel alloy) and manufacturing techniques (chemical milling, electroplating) are evaluated to determine the best liner candidates. Robust, autofrettaged feedlines with a low Coefficient of Thermal Expansion liner (Inconel 718 or nickel alloy) are shown to successfully counteract mismatch at LOX temperature. A new concept, autofrettage by temperature, is introduced for high Coefficient of Thermal Expansion materials (aluminum and pure nickel) where pressure cannot be used to add compressive preload.

Wen, Ed↗
NASA NTRS1989

Prediction of coefficients of thermal expansion for unidirectional composites

Several analyses for predicting the longitudinal, alpha(1), and transverse, alpha(2), coefficients of thermal expansion of unidirectional composites were compared with each other, and with experimental data on different graphite fiber reinforced resin, metal, and ceramic matrix composites. Analytical and numerical analyses that accurately accounted for Poisson restraining effects in the transverse direction were in consistently better agreement with experimental data for alpha(2), than the less rigorous analyses. All of the analyses predicted similar values of alpha(1), and were in good agreement with the experimental data. A sensitivity analysis was conducted to determine the relative influence of constituent properties on the predicted values of alpha(1), and alpha(2). As would be expected, the prediction of alpha(1) was most sensitive to longitudinal fiber properties and the prediction of alpha(2) was most sensitive to matrix properties.

Bowles, David E.↗
NASA NTRS1992

Effects of changes in composite lamina properties on laminate coefficient of thermal expansion

An analytical study of the effects of changes in composite lamina properties on the laminate coefficient of thermal expansion, CTE, has been made. Low modulus graphite/epoxy (T300/934) and high modulus graphite/epoxy (P75/934, P100/934, P120/934), graphite/aluminum (P100/Al), and graphite/glass (HMS/Gl) composite materials were considered in quasi-isotropic and near-zero CTE laminate configurations. The effects of changes in lamina properties on the laminate CTE strongly depend upon the type of composite material as well as the laminate configuration. A 10 percent change in the lamina transverse CTE resulted in changes as large as 0.22 ppm/C in the laminate CTE of a quasi-isotropic Gr/934 laminates. No significant differences were observed in the sensitivities of the laminate CTEs of the P100/934 and P120/934 composite materials due to identical changes in lamina properties. Large changes in laminate CTE can also result from measured temperature and radiation effects on lamina properties.

Tompkins, Stephen S.↗
NASA NTRS2012

Composite Laminate With Coefficient of Thermal Expansion Matching D263 Glass

The International X-ray Observatory project seeks to make an X-ray telescope assembly with 14,000 flexible glass segments. The glass used is commercially available SCHOTT D263 glass. Thermal expansion causes the mirror to distort out of alignment. A housing material is needed that has a matching coefficient of thermal expansion (CTE) so that when temperatures change in the X-ray mirror assembly, the glass and housing pieces expand equally, thus reducing or eliminating distortion. Desirable characteristics of this material include a high stiffness/weight ratio, and low density. Some metal alloys show promise in matching the CTE of D263 glass, but their density is high compared to aluminum, and their stiffness/weight ratio is not favorable. A laminate made from carbon fiber reinforced plastic (CFRP) should provide more favorable characteristics, but there has not been any made with the CTE matching D263 Glass. It is common to create CFRP laminates of various CTEs by stacking layers of prepreg material at various angles. However, the CTE of D263 glass is 6.3 ppm/ C at 20 C, which is quite high, and actually unachievable solely with carbon fiber and resin. A composite laminate has been developed that has a coefficient of thermal expansion identical to that of SCHOTT D263 glass. The laminate is made of a combination of T300 carbon fiber, Eglass, and RS3C resin. The laminate has 50% uni-T300 plies and 50% uni-E-glass plies, with each fiber-layer type laid up in a quasi-isotropic laminate for a total of 16 plies. The fiber volume (percent of fiber compared to the resin) controls the CTE to a great extent. Tests have confirmed that a fiber volume around 48% gives a CTE of 6.3 ppm/ C. This is a fairly simple composite laminate, following well established industry procedures. The unique feature of this laminate is a somewhat unusual combination of carbon fiber with E-glass (fiberglass). The advantage is that the resulting CTE comes out to 6.3 ppm/ C at 20 C, which matches D263 glass. The trick with this laminate is to establish the proper fiber volume to get the desired CTE. Laminates were made with several different fiber volumes and coupons were tested to establish the relationship between fiber volume and CTE. Testing proved that fiber volume should be about 48%.

Robinson, David↗
NASA NTRS1987

The effect of bromination of carbon fibers on the coefficient of thermal expansion of graphite fiber-epoxy composites

To examine the effect of bromination of carbon fibers on the coefficient of thermal expansion (CTE) of carbon fiber epoxy composites, several pristine and brominated carbon fiber-epoxy composite samples were subjected to thermomechanical analysis. The CTE's of these samples were measured in the uniaxial and transverse directions. The CTE was dominated by the fibers in the uniaxial direction, while it was dominated by the matrix in the transverse directions. Bromination had no effect on the CTE of any of the composites. In addition, the CTE of fiber tow was measured in the absence of a polymer matrix, using an extension probe. The results from this technique were inconclusive.

Jaworske, D. A.↗
NASA NTRS1985

Optimal design of a thermally stable composite optical bench

The Lidar Atmospheric Sensing Experiment will be performed aboard an ER-2 aircraft; the lidar system used will be mounted on a lightweight, thermally stable graphite/epoxy optical bench whose design is presently subjected to analytical study and experimental validation. Attention is given to analytical methods for the selection of such expected laminate properties as the thermal expansion coefficient, the apparent in-plane moduli, and ultimate strength. For a symmetric laminate in which one of the lamina angles remains variable, an optimal lamina angle is selected to produce a design laminate with a near-zero coefficient of thermal expansion. Finite elements are used to model the structural concept of the design, with a view to the optical bench's thermal structural response as well as the determination of the degree of success in meeting the experiment's alignment tolerances.

Gray, C. E., Jr.↗
NASA NTRS1992

Sensitivity of the coefficients of thermal expansion of selected graphite reinforced composite laminates to lamina thermoelastic properties

An analytical study of the sensitivity of the laminate coefficient of thermal expansion, CTE, to changes in lamina elastic properties has been made. High modulus graphite/epoxy (P75/934, P100/934, P120/934), graphite/aluminum (P100/Al), and graphite/glass (HMS/Gl) composite materials were considered in quasi-isotropic, low thermal stress, and 'near-zero' thermal expansion laminate configurations. The effects of a positive or negative 10 percent change in lamina properties on laminate CTE is strongly dependent upon both the composite material and the laminate configuration. A 10 percent change in all of the lamina properties had very little effect on the laminate CTE of the HMS/Gl composite laminates investigated. The sensitivity and direction of change in the laminate CTE of Gr/934 depended very strongly on the fiber properties. A 10 percent change in the lamina transverse CTE resulted in changes as large as 0.216 ppm/C in the laminate CTE of a quasi-isotropic Gr/934 laminate. No significant difference was observed in the sensitivity of the laminate CTE of the P100/934 and P120/934 composite materials due to changes in lamina properties. Large changes in laminate CTE can result from measured temperature and radiation effects on lamina properties.

Tompkins, S. S.↗
NASA NTRS1981

Heat storage in alloy transformations

The feasibility of using metal alloys as thermal energy storage media was determined. The following major elements were studied: (1) identification of congruently transforming alloys and thermochemical property measurements; (2) development of a precise and convenient method for measuring volume change during phase transformation and thermal expansion coefficients; (3) development of a numerical modeling routine for calculating heat flow in cylindrical heat exchangers containing phase change materials; and (4) identification of materials that could be used to contain the metal alloys. Several eutectic alloys and ternary intermetallic phases were determined. A method employing X-ray absorption techniques was developed to determine the coefficients of thermal expansion of both the solid and liquid phases and the volume change during phase transformation from data obtained during one continuous experimental test. The method and apparatus are discussed and the experimental results are presented. The development of the numerical modeling method is presented and results are discussed for both salt and metal alloy phase change media.

Birchenall, C. E.↗
NASA NTRS1982

Moire interferometry for thermal expansion of composites

Moire interferometry by reflection is described and demonstrated for the case of a real reference grating of 1200 lines/mm. Extraneous beams can be displaced and stopped by using a wedge-shaped air gap between reference and specimen gratings. Double-order dominance, the use of diffraction sequences for reflection, the isolation of preferred sequences, and the use of two-beam interference are discussed. Experimental accuracy is enhanced significantly by using several data points to establish displacements along a line, and random errors characterized by one standard deviation can be as small as one microstrain. The method is well adapted to thermal environments, coefficients of thermal expansion of selected graphite-epoxy laminates being determined in the temperature range of 297-422 K. Very good precision was achieved for a wide range of thermal expansion coefficients, from approximately zero to 27 microstrains/K.

Bowles, D. E.↗
DOE OSTI2024

Convergent laser beam shapes: Unveiling the dynamics of Laser-induced elastic waves in composite materials

Overcoming the low signal-to-noise ratio (SNR) in laser ultrasonic testing of composite materials remains a significant challenge. Current efforts focus on enhancing SNR by inserting more energy into the material through temporal and/or spatial modulation of the laser beam. However, potential SNR improvements through wave convergence and wave energy manipulation have been overlooked. This paper addresses this gap by demonstrating the convergence of different wave types to a designated point and by showing the feasibility of directing absorbed laser energy into a specific wave type through spatial modulation of the laser beam. To achieve this, mathematical expressions for the convergent laser beams are derived. Various laser beam profiles are then introduced to the thermoelastic equations and solved using the finite element method. The sample under investigation is a transversely isotropic unidirectional carbon fiber reinforced plastic, characterized by anisotropic thermal expansion coefficients and thermal conductivities. Results reveal pronounced convergence of the intended wave type at the center due to laser beam shaping. This study showcases the ability to direct absorbed laser energy toward a specific wave type through spatial modulation of the laser beam and highlights the role of material anisotropy in energy focusing.

composite materials↗
NASA NTRS2000

Solid Freeform Fabrication of Continuous Fiber Reinforced Composites for Propulsion Applications

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500'C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible- manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. This is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths With carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites-, they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP process.

Vaidyanathan, R.↗
NASA NTRS2001

Solid Free-Form Fabrication of Continuous Fiber Reinforced Composites for Propulsion Application

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500 C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible-manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. M is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths with carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites; they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP processes.

Vaidyanathan, R.↗
NASA NTRS2001

Solid Freeform Fabrication of Continuous Fiber Reinforced Composites for Propulsion Applications

Monolithic ceramics lack the fracture toughness necessary to be considered for propulsion related applications. To be used for such applications, materials must possess low density, high elastic modulus, a low thermal expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. They will in many cases also be required to possess the ability to be joined, to survive thermal cycling and multi-axial stress states, and for reusable applications the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attributes for these materials are the need to be of low cost and readily available in large quantities.

Vaidyanathan, R.↗
NASA NTRS2002

Strength and Fracture Toughness of Solid Oxide Fuel Cell Electrolyte Material Improved

Solid oxide fuel cells (SOFC) are being developed for various applications in the automobile, power-generation, and aeronautics industries. Recently, the NASA Glenn Research Center has been exploring the possibility of using SOFC's for aeropropulsion under its Zero Carbon Dioxide Emission Technology (ZCET) Program. 10-mol% yttriastabilized zirconia (10YSZ) is a very good anionic conductor at high temperatures and is, therefore, used as an oxygen solid electrolyte in SOFC. However, it has a high thermal expansion coefficient, low thermal shock resistance, low fracture toughness, and poor mechanical strength. For aeronautic applications, the thin ceramic electrolyte membrane of the SOFC needs to be strong and tough. Therefore, we have been investigating the possibility of enhancing the strength and fracture toughness of the 10YSZ electrolyte without degrading its electrical conductivity to an appreciable extent. We recently demonstrated that the addition of alumina to zirconia electrolyte increases its strength as well as its fracture toughness. Zirconia-alumina composites containing 0 to 30 mol% of alumina were fabricated by hot pressing. The hot pressing procedure was developed and various hot pressing parameters were optimized, resulting in dense, crackfree panels of composite materials. Cubic zirconia and a-alumina were the only phases detected, indicating that there was no chemical reaction between the constituents during hot pressing at elevated temperatures. Flexure strength sf and fracture toughness K(sub IC) of the various zirconia-alumina composites were measured at room temperature as well as at 1000 C in air. Both properties showed systematic improvement with increased alumina addition at room temperature and at 1000 C. Use of these modified electrolytes with improved strength and fracture toughness should prolong the life and enhance the performance of SOFC in aeronautics and other applications.

Bansal, Narottam P.↗
NASA NTRS1989

Optimum interface properties for metal matrix composites

Due to the thermal expansion coefficient mismatch (CTE) between the fiber and the matrix, high residual sresses exist in metal matrix composite systems upon cool down from processing temperature to room temperature. An interface material can be placed between the fiber and the matrix to reduce the high tensile residual stresses in the matrix. A computer program was written to minimize the residual stress in the matrix subject to the interface material properties. The decision variables are the interface modulus, thickness and thermal expansion coefficient. The properties of the interface material are optimized such that the average distortion energy in the matrix and the interface is minimized. As a result, the only active variable is the thermal expansion coefficient. The optimum modulus of the interface is always the minimum allowable value and the interface thickness is always the maximum allowable value, independent of the fiber/matrix system. The optimum interface thermal expansion coefficient is always between the values of the fiber and the matrix. Using this analysis, a survey of materials was conducted for use as fiber coatings in some specific composite systems.

Ghosn, Louis J.↗