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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

thermoplastic composites↗
NASA NTRS2022

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

laser heating↗
NASA NTRSDate not supplied

Composites From in-Situ Consolidation Automated Fiber Placement of Thermoplastics for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.

thermoplastic composites↗
NASA NTRS1993

Asymptotic behavior of modulated Taylor-Couette flows with a crystalline inner cylinder

The linear stability of a modulated Taylor-Couette system when the inner cylindrical boundary consists of a crystalline solid-liquid interface is considered. Both experimentally and in numerical calculations it is found that the two-phase system is significantly less stable than the analogous rigid-walled system for materials with moderately large Prandtl numbers. A numerical treatment based on Floquet theory is described, which gives results that are in good agreement with preliminary experimental findings. In addition, this instability is further examined by carrying out a formal asymptotic expansion of the solution in the limit of large Prandtl number. In this limit the Floquet analysis is considerably simplified, and the linear stability of the modulated system can be determined to leading order through a conventional stability analysis, without recourse to Floquet theory. The resulting simplified problem is then studied for both the narrow gap geometry and for the case of a finite gap. It is surprising that the determination of the linear stability of the two-phase system is considerably simpler than that of the rigid-walled system, despite the complications introduced by the presence of the crystal-melt interface.

Braun, R. J.↗
NASA NTRS1999

Ferroelectric and Piezoelectric Properties of Blends of Poly(Vinylidene-Trifluoroethylene) and Graft Elastomer

A piezoelectric polymeric blend system has been developed. The system contains two components: ferroelectric poly(vinylidene-trifluoroethylene) and graft elastomer. The remanent polarization, Pr, and the piezoelectric strain coefficient, d31, of the blends have been studied as a function of relative composition of the two components, temperature and frequency. Both blended copolymer and graft unit in the elastomer contribute to the total crystallinity of the blend-system, and hence to the remanent polarization and piezoelectricity. The piezoelectric strain coefficient, d31, of the blend systems shows dependence on both the remanent polarization and the mechanical stiffness, which in turn are determined by the fraction of the two components in the blends. This mechanism makes it possible for the piezoelectric strain response of the blend to be tailored by adjusting the relative composition. Although Pr of the copolymer is higher than that of the blends, the blend films containing 75 wt.% copolymer exhibit a higher d31 at room temperature, possibly due to their lower modulus. The blend films containing 50 wt.% copolymer exhibit a constant value of d31, from room temperature to 70 C.

Su, J.↗
NASA NTRS1991

Vacuum Powder Injector

Method developed to provide uniform impregnation of bundles of carbon-fiber tow with low-solubility, high-melt-flow polymer powder materials to produce composite prepregs. Vacuum powder injector expands bundle of fiber tow, applies polymer to it, then compresses bundle to hold powder. System provides for control of amount of polymer on bundle. Crystallinity of polymer maintained by controlled melt on takeup system. All powder entrapped, and most collected for reuse. Process provides inexpensive and efficient method for making composite materials. Allows for coating of any bundle of fine fibers with powders. Shows high potential for making prepregs of improved materials and for preparation of high-temperature, high-modulus, reinforced thermoplastics.

Working, Dennis C.↗
NASA NTRS1985

Brittle extension of the continental crust along a rooted system of low-angle normal faults: Colorado River extensional corridor

A transect across the 100 km wide Colorado River extensional corridor of mid-Tertiary age shows that the upper 10 to 15 km of crystalline crust extended along an imbricate system of brittle low-angle normal faults. The faults cut gently down a section in the NE-direction of tectonic transport from a headwall breakaway in the Old Woman Mountains, California. Successively higher allochthons above a basal detachment fault are futher displaced from the headwall, some as much as tens of kilometers. Allochthonous blocks are tilted toward the headwall as evidenced by the dip of the cappoing Tertiary strata and originally horizontal Proterozoic diabase sheets. On the down-dip side of the corridor in Arizona, the faults root under the unbroken Hualapai Mountains and the Colorado Plateau. Slip on faults at all exposed levels of the crust was unidirectional. Brittle thinning above these faults affected the entire upper crust, and wholly removed it locally along the central corridor or core complex region. Isostatic uplift exposed metamorphic core complexes in the domed footwall. These data support a model that the crust in California moved out from under Arizona along an asymmetric, rooted normal-slip shear system. Ductile deformation must have accompanied mid-Tertiary crustal extension at deeper structural levels in Arizona.

John, B. E.↗
NASA NTRS1993

Flow of ices in the Ammonia-Water System

We have fabricated in the laboratory and subsequently deformed crystalline hydrates and partial melts of the water-rich end of the NH3-H2O system, with the aim of improving our understanding of physical processes occurring in icy moons of the outer solar system. Deformation experiments were carried out at constant strain rate. The range of experimental variables are given. Phase relationships in the NH3-H2O system indicate that water ice and ammonia dihydrate, NH3-2H2O, are the stable phases under our experiment conditions. X-ray diffraction of our samples usually revealed these as the dominant phases, but we have also observed an amorphous phase (in unpressurized samples only) and occasionally significant ammonia monohydrate, NH3-H2O. The onset of partial melting at the peritectic temperature at about 176 K appeared as a sharp transition in strength observed in samples of x(sub NH3) = 0.05 and 0.01, the effect of melt was less pronounced. For any given water ice + dihydrate alloy in the subsolidus region, we observed one rheological law over the entire temperature range from 175 K to about 140 K. Below 140 K, a shear instability similar to that occurring in pure water ice under the same conditions limited our ability to measure ductile flow. The rheological laws for the several alloys vary systematically from that of pure ice to that of dihydrate. Pure dihydrate is about 4 orders of magnitude less viscous than water ice just below the peritectic temperature, but because of a very pronounced temperature dependence in dihydrate (100 kJ/mol versus 43 kJ/mol for water ice) the viscosity of dihydrate equals or exceeds that of water ice at T less than 140 K. The large variation in viscosity of dihydrate with relatively small changes in temperature may be helpful in explaining the rich variety of tectonic and volcanic features seen on the surfaces of icy moons in the outer solar system.

Durham, W. B.↗
NASA NTRS2001

Physical State of Ices in the Outer Solar System

Comparison of the identity and abundances of ices observed around protostars and those associated with comets clearly suggests that comets preserve the heritage of the interstellar materials that aggregated to form them. However, the ability to identify these same species on icy satellites in the outer solar system is a complex function of the composition of the original ices, their subsequent thermal histories, and their exposure to various radiation environments. Our ability to identify the ices currently present on objects in the outer solar system relies upon observational and laboratory, and theoretical efforts. To date there is ample observational evidence for crystalline water ice throughout the outer solar system. In addition, there is growing evidence that amorphous ice may be present on some bodies. More volatile ices, e.g. N2, CH4. CO, and other species, e.g. ammonia hydrate, are identified on objects lying at and beyond Uranus. Both photolysis and radiolysis play important roles in altering the original surfaces due to chemical reactions and erosion of the surface. Ultraviolet photolysis appears to dominate alteration of the upper few hundred Angstroms, although sputtering the surface can sometimes be a significantly competitative process; dominating on icy surfaces embedded in a strong planetary magnetospheric field. There is growing observational evidence that the by-products of photolysis and radiolysis, suggested on a theoretical basis, are present on icy surfaces.

Roush, Ted L.↗
NASA NTRS2020

Hardness-Strength Correlations in Zr(Cu)-Based BMG Alloys for QA Purposes

Quality assurance (QA) of bulk metallic glass (BMG) components would be expedited if hardness testing could provide a ready estimate of material strength. Consequently, a compilation of published data for Zr(Cu)-based alloys on the relationship between Vickers hardness (HV) and tensile/compressive strength (σ) is presented. An assessment reveals that the majority of data are confined within the hardness range of HV = 4.4−6.2 GPa and the strength range of σ = 1.4−2.3 GPa. Assuming a linear relationship, the statistical average of the hardness-strength correlation for BMGs (HV/σ = 2.87 ± 0.35) is very close to that established for non-austenitic steels (HV/σ = 2.86 ± 0.05). Unfortunately, the standard deviation of the BMG data is too broad for any type of correlation to be exploited for QA purposes. However, the narrow hardness range suggests that significant departures from the fully amorphous state resulting from processing variations may be detectable via indentation testing. Therefore, the relationship between hardness and volume/distribution of crystallinity for a specific alloy system warrants further investigation.

Bulk metallic glass↗
NASA NTRS2019

Preparation, Identification, and Low-Temperature Infrared Spectra of Two Elusive Crystalline Nitrile Ices

Infrared (IR) spectra of the alkyl nitrile ices CH3CN and CH3CH2CN are relevant to the study of the low- temperature chemistry of objects within and beyond the Solar System, but the thermodynamically favored low-temperature crystalline phases of these compounds have not been presented and identified in the planetary- sciences literature. Moreover, there is a large variation in the published IR spectra of these two icy solids, including spectra that are used for the analyses of spacecraft data from the Voyager and Cassini missions. Here the IR spectra of the low-temperature crystalline forms of CH3CN and CH3CH2CN, which are the thermodynamically stable phases at Titan temperatures, are presented for the first time with all samples being made by vapor-phase deposition. Conditions are described for producing these ice phases for both compounds, and new measurements are reported of ice density and refractive index, quantities needed to compute IR absorption coefficients, band strengths, optical constants, and, ultimately, nitrile abundances in extraterrestrial environments. Comparisons are drawn between CH3CN and CH3CH2CN, an earlier prediction on their similar crystallization behaviors is verified, and previous work is examined in light of these new results, including a counterintuitive observation in which the low-temperature phase of an ice is made by heating a high-temperature phase. Applications and extensions are described.

Hudson, Reggie L.↗
NASA NTRS2019

Preparation, Identification, and Low-Temperature Infrared Spectra of Two Elusive Crystalline Nitrile Ices

Infrared (IR) spectra of the alkyl nitrile ices CH3CN and CH3CH2CN are relevant to the study of the low- temperature chemistry of objects within and beyond the Solar System, but the thermodynamically favored low-temperature crystalline phases of these compounds have not been presented and identified in the planetary- sciences literature. Moreover, there is a large variation in the published IR spectra of these two icy solids, including spectra that are used for the analyses of spacecraft data from the Voyager and Cassini missions. Here the IR spectra of the low-temperature crystalline forms of CH3CN and CH3CH2CN, which are the thermody-namically stable phases at Titan temperatures, are presented for the first time with all samples being made by vapor-phase deposition. Conditions are described for producing these ice phases for both compounds, and new measurements are reported of ice density and refractive index, quantities needed to compute IR absorption coefficients, band strengths, optical constants, and, ultimately, nitrile abundances in extraterrestrial environments. Comparisons are drawn between CH3CN and CH3CH2CN, an earlier prediction on their similar crystallization behaviors is verified, and previous work is examined in light of these new results, including a counter- intuitive observation in which the low-temperature phase of an ice is made by heating a high-temperature phase. Applications and extensions are described.

Hudson, Reggie L.↗
NASA NTRS2003

CO2 Acquisition Membrane (CAM)

The objective of CAM is to develop, test, and analyze thin film membrane materials for separation and purification of carbon dioxide (CO2) from mixtures of gases, such as those found in the Martian atmosphere. The membranes are targeted toward In Situ Resource Utilization (ISRU) applications that will operate in extraterrestrial environments and support future unmanned and human space missions. A primary application is the Sabatier Electrolysis process that uses Mars atmosphere CO2 as raw material for producing water, oxygen, and methane for rocket fuel and habitat support. Other applications include use as an inlet filter to collect and concentrate Mars atmospheric argon and nitrogen gases for habitat pressurization, and to remove CO2 from breathing gases in Closed Environment Life Support Systems (CELSS). CAM membrane materials include crystalline faujasite (FAU) zeolite and rubbery polymers such as silicone rubber (PDMS) that have been shown in the literature and via molecular simulation to favor adsorption and permeation of CO2 over nitrogen and argon. Pure gas permeation tests using commercial PDMS membranes have shown that both CO2 permeance and the separation factor relative to other gases increase as the temperature decreases, and low (Delta)P(Sub CO2) favors higher separation factors. The ideal CO2/N2 separation factor increases from 7.5 to 17.5 as temperature decreases from 22 C to -30 C. For gas mixtures containing CO2, N2, and Ar, plasticization decreased the separation factors from 4.5 to 6 over the same temperature range. We currently synthesize and test our own Na(+) FAU zeolite membranes using standard formulations and secondary growth methods on porous alumina. Preliminary tests with a Na(+) FAU membrane at 22 C show a He/SF6 ideal separation factor of 62, exceeding the Knudsen diffusion selectivity by an order of magnitude. This shows that the membrane is relatively free from large defects and associated non-selective (viscous flow) transport mechanisms. The Membrane Test Facility (MTF) has been developed to measure membrane permeance over a wide range of temperature and pressure. The facility uses two volume compartments separated by the membrane that are instrumented to measure temperature, delta pressure across the membrane, and gas composition. A thermal shroud supports and encloses the membrane, and provides temperature control. Methods were developed to determine membrane permeance using the first order decay of the pressure difference between the sealed compartments, using the total pressure for pure gases, and partial pressure of each species in gas mixtures. The technique provides an end-to-end measurement of gas permeance that includes concentration polarization effects. Experiments have shown that in addition to membrane permeance properties, the geometry and design of associated structures play an important role in how membrane systems will function on Mars.

Mason, Larry W.↗
NASA NTRS2019

Preparation, Identification, and Low-Temperature Infrared Spectra of Two Elusive Crystalline Nitrile Ices

Infrared (IR) spectra of the alkyl nitrile ices CH3CN and CH3CH2CN are relevant to the study of the low-temperature chemistry of objects within and beyond the Solar System, but the thermodynamically favored low-temperature crystalline phases of these compounds have not been presented and identified in the planetary-sciences literature. Moreover, there is a large variation in the published IR spectra of these two icy solids, including spectra that are used for the analyses of spacecraft data from the Voyager and Cassini missions. Here the IR spectra of the low-temperature crystalline forms of CH3CN and CH3CH2CN, which are the thermodynamically stable phases at Titan temperatures, are presented for the first time with all samples being made by vapor-phase deposition. Conditions are described for producing these ice phases for both compounds, and new measurements are reported of ice density and refractive index, quantities needed to compute IR absorption coefficients, band strengths, optical constants, and, ultimately, nitrile abundances in extraterrestrial environments. Comparisons are drawn between CH3CN and CH3CH2CN, an earlier prediction on their similar crystallization behaviors is verified, and previous work is examined in light of these new results, including a counter-intuitive observation in which the low-temperature phase of an ice is made by heating a high-temperature phase. Applications and extensions are described.

Reggie L Hudson↗
NASA NTRS2019

Preparation, Identification, and Low-Temperature Infrared Spectra of Two Elusive Crystalline Nitrile Ices

Infrared (IR) spectra of the alkyl nitrile ices CH3CN and CH3CH2CN are relevant to the study of the low-temperature chemistry of objects within and beyond the Solar System, but the thermodynamically favored low-temperature crystalline phases of these compounds have not been presented and identified in the planetary-sciences literature. Moreover, there is a large variation in the published IR spectra of these two icy solids, including spectra that are used for the analyses of spacecraft data from the Voyager and Cassini missions. Here the IR spectra of the low-temperature crystalline forms of CH3CN and CH3CH2CN, which are the thermodynamically stable phases at Titan temperatures, are presented for the first time with all samples being made by vapor-phase deposition. Conditions are described for producing these ice phases for both compounds, and new measurements are reported of ice density and refractive index, quantities needed to compute IR absorption coefficients, band strengths, optical constants, and, ultimately, nitrile abundances in extraterrestrial environments. Comparisons are drawn between CH3CN and CH3CH2CN, an earlier prediction on their similar crystallization behaviors is verified, and previous work is examined in light of these new results, including a counter-intuitive observation in which the low-temperature phase of an ice is made by heating a high-temperature phase. Applications and extensions are described.

Ices, IR spectroscopy, Titan, organic chemistry, i↗
NASA NTRSDate not supplied

Innovations in Continuous Ultrasonic Welding of Thermoplastic Composites and Evaluation for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗
NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗