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All sources NASA NTRS DOE OSTI

NASA NTRS1974

Carbon composites in space vehicle structures

Recent developments in the technology of carbon or graphite filaments now provide the designer with greatly improved materials offering high specific strength and modulus. Besides these advantages are properties which are distinctly useful for space applications and which provide feasibility for missions not obtainable by other means. Current applications include major and secondary structures of communications satellites. A number of R & D projects are exploring carbon-fiber application to rocket engine motor cases, advanced antenna systems, and space shuttle components. Future system studies are being made, based on the successful application of carbon fibers for orbiting space telescope assemblies, orbital transfer vehicles, and very large deployable energy generation systems. Continued technology development is needed in analysis, material standards, and advanced structural concepts to exploit the full potential of carbon filaments in composite materials.

Mayer, N. J.↗

NASA NTRS1976

Lightweight orthotic appliances

Graphite-filament reinforced polymer materials are used in applications requiring high tensile strength and modulus. Superior properties of graphite composite materials permit fabrication of supports that are considerably lighter, thinner, and stiffer than conventional components.

Baucom, R. M.↗

NASA NTRS1986

NDE reliability and process control for structural ceramics

The reliability of microfocus x-radiography and scanning laser acoustic microscopy for detecting microvoids in silicon nitride and silicon carbide was statistically evaluated. Materials- and process-related parameters that influenced the statistical findings in research samples are discussed. The use of conventional x-radiography in controlling and optimizing the processing and sintering of an Si3N4-Si02-Y203 composition designated NASA 6Y is described. Radiographic evaluation and guidance helped develop uniform high-density Si3N4 modulus-of-rupture bars with improved four-point flexural strength (857, 544, and 462 MPa at room temperature, 1200 C, and 1370 C, respectively) and reduced strength scatter.

Baaklini, G. Y.↗

NASA NTRS1987

NDE reliability and process control for structural ceramics

The reliability of microfocus X-radiography and scanning laser acoustic microscopy for detecting microvoids in silicon nitride and silicon carbide was statistically evaluated. Materials- and process-related parameters that influenced the statistical findings in research samples are discussed. The use of conventional X-radiography in controlling and optimizing the processing and sintering of an Si3N4-SiO2-Y2O3 composition designated NASA 6Y is described. Radiographic evaluation and guidance helped develop uniform high-density Si3N4 modulus-of-rupture bars with improved four-point flexural strength (857, 544, and 462 MPa at room temperature, 1200 C, and 1370 C, respectively) and reduced strength scatter.

Baaklini, G. Y.↗

NASA NTRS1991

Graphite Fiber/Copper Matrix Composites for Space Power Heat Pipe Fin Applications

High specific thermal conductivity (thermal conductivity divided by density) is a major design criterion for minimizing system mass for space power systems. For nuclear source power systems, graphite fiber reinforced copper matrix (Gr/Cu) composites offer good potential as a radiator fin material operating at service temperatures above 500 K. Specific thermal conductivity in the longitudinal direction is better than beryllium and almost twice that of copper. The high specific thermal conductivity of Gr/Cu offers the potential of reducing radiator mass by as much as 30 percent. Gr/Cu composites also offer the designer a range of available properties for various missions and applications. The properties of Gr/Cu are highly anisotropic. Longitudinal elastic modulus is comparable to beryllium and about three times that of copper. Thermal expansion in the longitudinal direction is near zero, while it exceeds that of copper in the transverse direction.

McDanels, David L.↗

NASA NTRS2014

Novel Super-Elastic Materials for Advanced Bearing Applications

Tribological surfaces of mechanical components encounter harsh conditions in terrestrial, marine and aerospace environments. Brinell denting, abrasive wear and fatigue often lead to life-limiting bearing and gear failures. Novel superelastic materials based upon Ni-Ti alloys are an emerging solution. Ni-Ti alloys are intermetallic materials that possess characteristics of both metals and ceramics. Ni-Ti alloys have intrinsically good aqueous corrosion resistance (they cannot rust), high hardness, relatively low elastic modulus, are chemically inert and readily lubricated. Ni-Ti alloys also belong to the family of superelastics and, despite high hardness, are able to withstand large strains without suffering permanent plastic deformation. In this paper, the use of hard, resilient Ni-Ti alloys for corrosion-proof, shockproof bearing and gear applications are presented. Through a series of bearing and gear development projects, it is demonstrated that Ni-Tis unique blend of materials properties lead to significantly improved load capacity, reduced weight and intrinsic corrosion resistance not found in any other bearing materials. Ni-Ti thus represents a new materials solution to demanding tribological applications.

materials↗

NASA NTRS2018

Ni-Ti Next Generation Bearings for Space Applications

NASA applications challenge traditional bearing materials. The rigors of launch often include heavy shock loads and exposure to corrosive environments (e.g., salt spray). Unfortunately, ball and roller bearings made from hardened steels are vulnerable to Brinell denting and rust which can limit performance and life. Ceramic materials can eliminate corrosion concerns but their high stiffness and extreme hardness actually makes denting problems worse. In this presentation, an emerging superelastic alloy, NiTi, is introduced for rolling element bearing applications. Through a decade of RD, NiTi alloy bearings have been put through a comprehensive series of life and performance tests. Hardness, corrosion, strength, stiffness, and rolling contact fatigue tests have been conducted and reported. Ball bearings ranging in size from 12 to 50mm bore have been successfully engineered and operated over a wide range of speeds and test conditions including being submerged in water. The combination of high hardness, moderate elastic modulus, low density, and intrinsic corrosion immunity provide new possibilities for mechanisms that operate under extreme conditions. Recent preliminary tests indicate that bearings can be made from NiTi alloys that are easily lubricated by conventional oils and greases and exhibit acceptable rolling contact fatigue resistance. This presentation introduces the NiTi materials systems and shows how NASA is using it to alleviate several specific problems encountered in advanced space applications.

bearings↗

NASA NTRS1988

Universality relationships in condensed matter - Bulk modulus and sound velocity

New forms for the bulk modulus and sound velocity of solids under compression, based on the universal equation of state of Vinet, Ferrante, Smith, and Rose (1987) are presented. These expressions are compared with a number of bulk modulus formulas previously utilized in high-pressure studies. It is demonstrated that this form yields a superior fit to experimental data to very high compressions, for a very wide range of solids. These solids cover the entire range of values of the pressure derivative of the bulk modulus which has been observed in high-pressure measurements.

Schlosser, Herbert↗

NASA NTRS1990

Reinforcements: The key to high performance composite materials

Better high temperature fibers are the key to high performance, light weight composite materials. However, current U.S. and Japanese fibers still have inadequate high temperature strength, creep resistance, oxidation resistance, modulus, stability, and thermal expansion match with some of the high temperature matrices being considered for future aerospace applications. In response to this clear deficiency, both countries have research and development activities underway. Once successful fibers are identified, their production will need to be taken from laboratory scale to pilot plant scale. In such efforts it can be anticipated that the Japanese decisions will be based on longer term criteria than those applied in the U.S. Since the initial markets will be small, short term financial criteria may adversely minimize the number and strength of U.S. aerospace materials suppliers to well into the 21st century. This situation can only be compounded by the Japanese interests in learning to make commercial products with existing materials so that when the required advanced fibers eventually do arrive, their manufacturing skills will be developed.

Grisaffe, Salvatore J.↗

DOE OSTI2022

High-Entropy Borides under Extreme Environment of Pressures and Temperatures

The high-entropy transition metal borides containing a random distribution of five or more constituent metallic elements offer novel opportunities in designing materials that show crystalline phase stability, high strength, and thermal oxidation resistance under extreme conditions. We present a comprehensive theoretical and experimental investigation of prototypical high-entropy boride (HEB) materials such as (Hf, Mo, Nb, Ta, Ti)B2 and (Hf, Mo, Nb, Ta, Zr)B2 under extreme environments of pressures and temperatures. The theoretical tools include modeling elastic properties by special quasi-random structures that predict a bulk modulus of 288 GPa and a shear modulus of 215 GPa at ambient conditions. HEB samples were synthesized under high pressures and high temperatures and studied to 9.5 GPa and 2273 K in a large-volume pressure cell. The thermal equation of state measurement yielded a bulk modulus of 276 GPa, in excellent agreement with theory. The measured compressive yield strength by radial X-ray diffraction technique in a diamond anvil cell was 28 GPa at a pressure of 65 GPa, which is a significant fraction of the shear modulus at high pressures. The high compressive strength and phase stability of this material under high pressures and high temperatures make it an ideal candidate for application as a structural material in nuclear and aerospace fields.

36 MATERIALS SCIENCE↗

NASA NTRS1980

Degradation of tensile and shear properties of composites exposed to fire or high temperature

The decrease in ultimate tensile strength, shear strength, tensile modulus, and shear modulus of fiber reinforced composites exposed to fire or to high temperature was investigated. A simple model was developed for calculating the mass loss of the material and the thickness of the char layer. The mass loss as well as the degradation in tensile and shear properties of Fiberite T300/1034 and Hercules AS/3501-6 graphite epoxy composites exposed to fire were measured. A correlation between the degradation in properties and the calculated mass loss and the char layer thickness was developed. A technique was proposed for predicting material damage through the use of such correlations.

Pering, G. A.↗

DOE OSTI2022

Direct Ink Writing of 3D Zn Structures as High‐Capacity Anodes for Rechargeable Alkaline Batteries

The relationship between structure and performance in alkaline Zn batteries is undeniable, where anode utilization, dendrite formation, shape change, and passivation issues are all addressable through anode morphology. While tailoring 3D hosts can improve the electrode performance, these practices are inherently limited by scaffolds that increase the mass or volume. Herein, a direct write strategy for producing template‐free metallic 3D Zn electrode architectures is discussed. Concentrated inks are customized to build designs with low electrical resistivity (5 × 10 −4 Ω cm), submillimeter sizes (200 μm filaments), and high mechanical stability (Young's modulus of 0.1–0.5 GPa at relative densities of 0.28–0.46). A printed Zn lattice anode versus NiOOH cathode with an alkaline polymer gel electrolyte is then demonstrated. This Zn||NiOOH cell operates for over 650 cycles at high rates of 25 mA cm −2 with an average areal capacity of 11.89 mAh cm −2 , a cumulative capacity of 7.8 Ah cm −2 , and a volumetric capacity of 23.78 mAh cm −3 . A thicker Zn anode achieves an ultrahigh areal capacity of 85.45 mAh cm −2 and a volumetric capacity of 81.45 mAh cm −3 without significant microstructural changes after 50 cycles.

25 ENERGY STORAGE↗

NASA NTRS2012

Static Indentation Load Capacity of the Superelastic 60NiTi for Rolling Element Bearings

The nickel-rich, binary nickel-titanium alloys, such as 60NiTi (60Ni-40Ti by wt%), are emerging as viable materials for use in mechanical components like rolling element bearings and gears. 60NiTi is a superelastic material that simultaneously exhibits high hardness and a relatively low elastic modulus (approx.100 GPa). These properties result in the potential to endure extremely high indentation loads such as those encountered in bearings, gears and other mechanical components. In such applications, quantifying the load that results in permanent deformation that can affect component performance and life is important. In this paper, the static load capacity is measured by conducting indentation experiments in which 12.7 mm diameter balls made from the ceramic Si3N4 are pressed into highly polished, hardened 60NiTi flat plates. Hertz stress calculations are used to estimate contact stress. The results show that the 60NiTi surface can withstand an approximately 3400 kN load before significant denting (>0.6 microns deep) occurs. This load capacity is approximately twice that of high performance bearing steels suggesting that the potential exists to make highly resilient bearings and components from such materials.

DellaCorte, Christopher↗

DOE OSTI2022

Ultrahigh strength, modulus, and conductivity of graphitic fibers by macromolecular coalescence

Theoretical considerations suggest that the strength of carbon nanotube (CNT) fibers be exceptional; however, their mechanical performance values are much lower than the theoretical values. To achieve macroscopic fibers with ultrahigh performance, we developed a method to form multidimensional nanostructures by coalescence of individual nanotubes. The highly aligned wet-spun fibers of single- or double-walled nanotube bundles were graphitized to induce nanotube collapse and multi-inner walled structures. These advanced nanostructures formed a network of interconnected, close-packed graphitic domains. Their near-perfect alignment and high longitudinal crystallinity that increased the shear strength between CNTs while retaining notable flexibility. The resulting fibers have an exceptional combination of high tensile strength (6.57 GPa), modulus (629 GPa), thermal conductivity (482 W/m·K), and electrical conductivity (2.2 MS/m), thereby overcoming the limits associated with conventional synthetic fibers.

36 MATERIALS SCIENCE↗

NASA NTRS2005

Toughened Matrix SiC Fiber Reinforced Composites

First matrix cracking stress is a critical parameter for application of Sic fiber reinforced composites in highly stressed, environmentally demanding applications such as turbine blades. High matrix fracture toughness is a key property that contributes to high composite fracture stress. Silicon nitride offers reduced matrix elastic modulus, lower coefficient of thermal expansion, and potentially high fracture toughness compared to Sic matrices. All of these factors can be used to advantage to increase matrix fracture stress. As a first model system we are pursuing toughened silicon nitride matrix composites reinforced with SCS-9 fibers. Fabrication is by tape casting the matrix plies and tape lay-up with fiber plies followed by hot pressing at 1800 C. Progress toward this end will be reported.

Levine, Stanley R.↗

DOE OSTI2022

The cosmological moduli problem and naturalness

Nowadays, the cosmological moduli problem (CMP) comes in three parts: 1. potential violation of Big-Bang nucleosynthesis (BBN) constraints from late decaying moduli fields, 2. the moduli-induced gravitino problem wherein gravitinos are overproduced and their decays violate BBN or dark matter overproduction bounds and 3. the moduli-induced lightest SUSY particle (LSP) overproduction problem. Also, the CMP may be regarded as either a problem or else a solution to scenarios with dark matter over- or under-production. We examine the cosmological moduli problem and its connection to electroweak naturalness. We calculate the various two-body decay widths of a light modulus field into MSSM particles and gravitinos within general supersymmetric models. We include both phase space and mixing effects. We examine cases without and with helicity suppression of modulus decays to gravitinos (cases 1 & 2) and/or gauginos (cases A & B). For case B1, we evaluate regions of gravitino mass m 3/2 vs. modulus mass mΦ parameter space constrained by BBN, by overproduction of gravitinos and by overproduction of neutralino dark matter, along with connections to naturalness. For this case, essentially all of parameter space is excluded unless mΦ ≳ 2.5 × 10 3 TeV with mΦ< 2m 3/2 For a potentially most propitious case B2 with Φ decay to Higgs and matter turned off, then modulus branching fractions to SUSY and to gravitinos become highly suppressed at large m Φ . But since the modulus number density increases faster than the branching fractions decrease, there is still gross overproduction of neutralino dark matter. We also show that in this scenario the thermally produced gravitino problem is fixed by huge entropy dilution, but non-thermal gravitino production from moduli decay remains a huge problem unless it is kinematically suppressed with m Φ < 2m 3/2 . In a pedagogical appendix, we present detailed calculations of modulus field two-body decay widths.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

High-pressure high-temperature synthesis and thermal equation of state of high-entropy transition metal boride

High-entropy transition metal boride (Hf 0.2 Ti 0.2 Zr 0.2 Ta 0.2 Mo 0.2 )B 2 sample was synthesized under high-pressure and high-temperature starting from ball-milled oxide precursors (HfO 2 , TiO 2 , ZrO 2 , Ta 2 O 5 , MoO 3 ) mixed with graphite and boron-carbide. Experiments were conducted in a large-volume Paris Edinburgh press combined with an in-situ Energy Dispersive X-ray Diffraction. The hexagonal AlB 2 phase with an ambient pressure volume V 0 = 27.93 ± 0.03 Å 3 was synthesized at a pressure of 0.9 GPa and temperatures above 1373K. High-pressure high-temperature studies on the synthesized high-entropy transition metal boride sample were performed to 7.6 GPa and 1873 K. The thermal equation of state fitted to the experimental data resulted in an ambient pressure bulk-modulus K 0 = 344 ± 39 GPa, dK/dT = –0.108 ± 0.027 GPa/K, and a temperature dependent volumetric thermal expansion coefficient α = α 0 + α 1 T + α 2 T –2 . The thermal stability combined with a high bulk-modulus establishes this high-entropy transition metal boride as an ultrahard high-temperature ceramic material.

36 MATERIALS SCIENCE↗

NASA NTRS2014

The Effect of Indenter Ball Radius on the Static Load Capacity of the Superelastic 60NiTi for Rolling Element Bearings

Static load capacity is a critical design parameter for rolling element bearings used in space mechanisms because of the potential for Brinell (surface dent) damage due to shock and vibration loading events during rocket launch. Brinell damage to bearing raceways can lead to torque variations (noise) and reduced bearing life. The growing use of ceramic rolling elements with high stiffness in hybrid bearings exacerbates the situation. A new family of hard yet resilient materials based upon nickel-titanium is emerging to address such bearing challenges. 60NiTi is a superelastic material that simultaneously exhibits high hardness and a relatively low elastic modulus (~100GPa) and has been shown to endure higher indentation loads than conventional and high performance steel. Indentation load capacity has been reported for relatively large (12.7mm diameter) ceramic (Si3N4) indenter balls pressed against flat plates of 60NiTi. In order to develop damage load threshold criteria applicable to a wide range of bearing designs and sizes, the effects of indenter ball radius and the accuracy of interpolation of the Hertz contact stress relations for 60NiTi must be ascertained. In this paper, results of indentation tests involving ceramic balls ranging from 6.4 to 12.7mm in diameter and highly polished 60NiTi flat plates are presented. When the resulting dent depth data for all the indenter ball sizes are normalized using the Hertz equations, the data (dent depth vs. stress) are comparable. Thus when designing bearings made from 60NiTi, the Hertz stress relations can be applied with relative confidence over a range of rolling element sizes and internal geometries.

bearings↗