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NASA NTRS1980

Coatings for Graphite Fibers

Several approaches for applying high resistance coatings continuously to graphite yarn were investigated. Two of the most promising approaches involved (1) chemically vapor depositing (CVD) SiC coatings on the surface of the fiber followed by oxidation, and (2) drawing the graphite yarn through an organo-silicone solution followed by heat treatments. In both methods, coated fibers were obtained which exhibited increased electrical resistances over untreated fibers and which were not degraded. This work was conducted in a previous program. In this program, the continuous CVD SiC coating process used on HTS fiber was extended to the coating of HMS, Celion 6000, Celion 12000 and T-300 graphite fiber. Electrical resistances three order of magnitude greater than the uncoated fiber were measured with no significant degradation of the fiber strength. Graphite fibers coated with CVD Si3N4 and BN had resistances greater than 10(exp 6) ohm/cm. Lower pyrolysis temperatures were used in preparing the silica-like coatings also resulting in resistances as high as three orders of magnitude higher than the uncoated fiber. The epoxy matrix composites prepared using these coated fibers had low shear strengths indicating that the coatings were weak.

Galasso, F. S.↗

NASA NTRS1995

Room-Temperature Fluorine-Induced Decrease in the Stability of Bromine and Iodine Intercalated Carbon Fibers

Upon exposure to room-temperature fluorine, intercalated carbon fibers (containing either bromine alone or iodine and bromine together) become heavier and less stable. For Amoco P-100 graphitized carbon fibers, which were intercalated with 18 wt percent bromine, 1 hour of fluorine exposure resulted in a large weight increase but caused only a small decrease in thermal stability. An additional 89 hours of fluorine exposure time resulted in small additional increases in fiber weight, but significant further decreases in fiber thermal stability. Such phenomena of weight increase and stability decrease do not occur if the intercalated fibers are exposed to 250 C fluorine. These observations suggest that, at room temperature, fluorine is absorbed quickly by the intercalated fibers and is intercalated slowly into the fibers. Most of the original intercalates are replaced by fluorine in the process of fluorine intercalation. In an inert environment, the bromine intercalated fibers are much more thermally stable. After 800 C vacuum heating for 2 weeks, the brominated fibers lost about 45% of their bromine, and their resistivity increased from 64 mu(Omega)-cm to a range of 95-170 mu(Omega)-cm. This is still much lower than the value of 300 mu(Omega)-cm for pristine P-100. For practical purposes, to preserve their thermal stability, brominated fibers need to be protected from exposure to fluorine at room temperature or to any intercalate at a temperature where, upon direct contact with graphite, an intercalation compound can easily be formed.

Hung, Ching-Cheh↗

NASA NTRS2000

Multimode-Optical-Fiber Imaging Probe

Currently, endoscopic surgery uses single-mode fiber-bundles to obtain in vivo image information inside orifices of the body. This limits their use to the larger natural bodily orifices and to surgical procedures where there is plenty of room for manipulation. The knee joint, for example can be easily viewed with a fiber optic viewer, but joints in the finger cannot. However, there are a host of smaller orifices where fiber endoscopy would play an important role if a cost effective fiber probe were developed with small enough dimensions (< 250 microns). Examples of beneficiaries of micro-endoscopes are the treatment of the Eustatian tube of the middle ear, the breast ducts, tear ducts, coronary arteries, fallopian tubes, as well as the treatment of salivary duct parotid disease, and the neuro endoscopy of the ventricles and spinal canal. To solve this problem, this work describes an approach for recovering images from. tightly confined spaces using multimode fibers and analytically demonstrates that the concept is sound. The proof of concept draws upon earlier works that concentrated on image recovery after two-way transmission through a multimode fiber as well as work that demonstrated the recovery of images after one-way transmission through a multimode fiber. Both relied on generating a phase conjugated wavefront which was predistorted with the characteristics of the fiber. The described approach also relies on generating a phase conjugated wavefront, but utilizes two fibers to capture the image at some intermediate point (accessible by the fibers, but which is otherwise visually unaccessible).

Jackson, Deborah↗

NASA NTRS2004

Measurements With a Split-Fiber Probe in Complex Unsteady Flows

A split-fiber probe was used to acquire unsteady data in a research compressor. A calibration method was devised for a split-fiber probe, and a new algorithm was developed to decompose split-fiber probe signals into velocity magnitude and direction. The algorithm is based on the minimum value of a merit function that is built over the entire range of flow velocities for which the probe was calibrated. The split-fiber probe performance and signal decomposition was first verified in a free-jet facility by comparing the data from three thermo-anemometric probes, namely a single-wire, a single-fiber, and the split-fiber probe. All three probes performed extremely well as far as the velocity magnitude was concerned. However, there are differences in the peak values of measured velocity unsteadiness in the jet shear layer. The single-wire probe indicates the highest unsteadiness level, followed closely by the split-fiber probe. The single-fiber probe indicates a noticeably lower level of velocity unsteadiness. Experiments in the NASA Low Speed Axial Compressor facility revealed similar results. The mean velocities agreed well, and differences in the velocity unsteadiness are similar to the case of a free jet. A reason for these discrepancies is in the different frequency response characteristics of probes used. It follows that the single-fiber probe has the slowest frequency response. In summary, the split-fiber probe worked reliably during the entire program. The acquired data averaged in time followed closely data acquired by conventional pneumatic probes.

Lepicovsky, Jan↗

NASA NTRS2003

Fabrication And Evaluation Of Sic/Sic Tubes With Various Fiber Architectures

SiC/SiC composites are excellent material candidates for high temperature applications where the performance requirements are high strength, high creep-rupture resistance, high environmental durability, and high thermal conductivity. In the past, the NASA UEET program has demonstrated fabrication of high-performance SiC/SiC flat panels reinforced by Sylramic-iBN SiC fibers. Currently NASA UEET is scaling up this SiC/SiC system by fabrication of more complex shaped components using the same fiber type. This paper reports the effects of various fiber architectures on the processing, mechanical, and durability behavior of small-diameter 0.5" ID SiC/SiC tubes, which are potential sub-elements for leading edges and cooling channels in turbine vanes and blades. Nine different fiber architectures were utilized for construction of seamless tube preforms, from simple 2D jelly-rolling to complex braiding, pin-weaving, filament-winding and 3D orthogonal weaving with approximately 5% fibers in the thru-thickness direction. Using the BN interphase and Sic matrix processing steps established for the flat panels, SiC/SiC tubes were fabricated with wall thicknesses of approximately 60 mils and total fiber fractions of approximately 35%. The "D" split ring tests for hoop tensile properties, micro-structural examinations for relationship between fiber architecture formation and matrix infiltration, and the low-pressure burner rig tests for the high temperature durability under thru-thickness thermal gradient were conducted. The better matrix infiltration and higher hoop strength were achieved using the tri-axial braided and the three-float pin woven SiC/SiC tubes. In general, it needs not only higher hoop direction fibers but also axial direction fibers for the higher hoop strength and the better infiltration, respectively. These results are analyzed to offer general guidelines for selecting fiber pre-form architectures and SiC/SiC processes that maximize tube hoop strength, thru-thickness thermal conductivity, and burner-rig durability under a high thermal gradient.

Yun, H. M.↗

NASA NTRS2007

Coating Carbon Fibers With Platinum

A process for coating carbon fibers with platinum has been developed. The process may also be adaptable to coating carbon fibers with other noble and refractory metals, including rhenium and iridium. The coated carbon fibers would be used as ingredients of matrix/fiber composite materials that would resist oxidation at high temperatures. The metal coats would contribute to oxidation resistance by keeping atmospheric oxygen away from fibers when cracks form in the matrices. Other processes that have been used to coat carbon fibers with metals have significant disadvantages: Metal-vapor deposition processes yield coats that are nonuniform along both the lengths and the circumferences of the fibers. The electrical resistivities of carbon fibers are too high to be compatible with electrolytic processes. Metal/organic vapor deposition entails the use of expensive starting materials, it may be necessary to use a furnace, and the starting materials and/or materials generated in the process may be hazardous. The present process does not have these disadvantages. It yields uniform, nonporous coats and is relatively inexpensive. The process can be summarized as one of pretreatment followed by electroless deposition. The process consists of the following steps: The surfaces of the fiber are activated by deposition of palladium crystallites from a solution. The surface-activated fibers are immersed in a solution that contains platinum. A reducing agent is used to supply electrons to effect a chemical reduction in situ. The chemical reduction displaces the platinum from the solution. The displaced platinum becomes deposited on the fibers. Each platinum atom that has been deposited acts as a catalytic site for the deposition of another platinum atom. Hence, the deposition process can also be characterized as autocatalytic. The thickness of the deposited metal can be tailored via the duration of immersion and the chemical activity of the solution.

Effinger, Michael R.↗

NASA NTRS2014

Method and Apparatus of Multiplexing and Acquiring Data from Multiple Optical Fibers Using a Single Data Channel of an Optical Frequency-Domain Reflectometry (OFDR) System

A method and system for multiplexing a network of parallel fiber Bragg grating (FBG) sensor-fibers to a single acquisition channel of a closed Michelson interferometer system via a fiber splitter by distinguishing each branch of fiber sensors in the spatial domain. On each branch of the splitter, the fibers have a specific pre-determined length, effectively separating each branch of fiber sensors spatially. In the spatial domain the fiber branches are seen as part of one acquisition channel on the interrogation system. However, the FBG-reference arm beat frequency information for each fiber is retained. Since the beat frequency is generated between the reference arm, the effective fiber length of each successive branch includes the entire length of the preceding branch. The multiple branches are seen as one fiber having three segments where the segments can be resolved. This greatly simplifies optical, electronic and computational complexity, and is especially suited for use in multiplexed or branched OFS networks for SHM of large and/or distributed structures which need a lot of measurement points.

Parker, Jr., Allen R↗

NASA NTRS2017

Flame Retardant Fibers for Human Space Exploration - Past, Present, and Future

The National Aeronautics and Space Administration (NASA) has led the development of unique flame retardant fibers for the specific requirements of different space programs. Three of these fibers have greatly contributed to the safety of all the space missions since the Apollo program. Beta alumina-silica microfiber developed for the outer layer of the space suit after the Apollo 1 fire is no longer used and has been replaced by other glass fibers. Expanded polytetrafluoroethylene (e-PTFE) fiber used in the current spacesuit is mostly known today through its trade mark Gore-Tex®. Polybenzimidazole (PBI) filament fiber used in many applications from the Apollo to the Space Shuttle program is no longer available. More recently, TOR"TM" copolymer of polyimide fiber developed during the space shuttle program to resist the atomic oxygen present in Low Earth Orbit has been barely used. The high cost and narrow range of aeronautical and aerospace applications have, however, led to a limited production of these fibers. Only fibers that found niche markets survived. Yet, deep space exploration will require more of these inherently flame retardant fibers than what is available today. There is a need for new flame retardant fabrics inside the space vehicles as well as a need for logistics reduction for long term space missions. Materials like modacrylic and polyimide are good candidates for future flame retardant aerospace fabrics. New fabrics must be developed for astronauts' clothing, as well as crew quarters and habitat. Therefore, both staple and filament fibers of various linear densities are needed for a three years mission to Mars.

Orndoff, Evelyne↗

DOE OSTI2024

Characterization of Intrinsic Fiber Optic Temperature Sensors by In-core and Furnace Testing

Increased research and development in nuclear technology has raised the demand for novel sensors and instrumentation to meet data objectives, and survive in different conditions and environments, beyond conventional light water reactor (LWR) environments. Expediting the deployment of advanced nuclear technologies by developing, demonstrating, and qualifying advanced reactor fuel forms necessitates a deeper understanding of how irradiation affects fuels and materials' performance. To achieve a more comprehensive understanding of fuels and materials performance, researchers require more specialized experiments and measurements. The demand for innovative sensors to support nuclear fuel development arises from the complexity of materials' behavior under irradiation and the challenges of deploying instrumentation in Material Test Reactors (MTRs) for irradiation tests. Additionally, measurements of material properties require integrated measurement systems to characterize thermal properties, mechanical properties, chemistry, and microstructure [1]. Among the potential measurement techniques, optical fiber-based sensors have been identified as potential sensors to measure different physical phenomena such as temperature, strain, pressure, and fluid level. Optical fiber sensors have the capability to provide multi-sensing and multiplexing instrumentation, allowing the measurement of different physical parameters within a single sensor configuration, and transmitting data collected at multiple locations through a single fiber. They offer immunity to electromagnetic interference, electrical passivity, compatibility with various sensing methodologies, and cost-effectiveness. Beyond their widespread use in telecommunications, silica fiber-based instruments are utilized in industrial applications, even at temperatures reaching 300?400°C, such as distributed temperature sensing in oil and gas recovery. The Department of Energy (DOE) is interested in using fiber optics to support fuel cycle development [2]. Fiber optics are an excellent candidate for harsh environment sensing, including sensing at very high temperatures (1900oC for sapphire optical fibers). Distributed fiber optic sensing has been deployed in other harsh environments like coal gasification plants [3]. Distributed strain sensing, which operates similarly to distributed temperature sensing, has been deployed to monitor underground mines and fibers have been imbedded in soil to monitor sink-hole development [4][5]. The application of fiber optic sensors to advanced reactor development is a promising area of research.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Do woody vines use gelatinous fibers to climb?

Many plant movements are facilitated by contractile cells called gelatinous fibers (G-fibers), but how G-fibers function in the climbing movements of woody vines remains underexplored. In this report, we compare the presence and distribution of G-fibers in the stems of stem-twiners, which wrap around supports, with non-stem-twiners, which attach to supports via tendrils or adventitious roots. An examination of 164 species spanning the vascular plant phylogeny reveals that G-fibers are common in stem-twiners but scarce in non-stem-twiners, suggesting that G-fibers are preferentially formed in the organ responsible for movement. When present, G-fibers are in the xylem, phloem, pericycle, and/or cortex. We discuss the hypothesis that G-fibers are foundational to plant movement and highlight research opportunities concerning G-fiber development and function.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Active Irradiation Testing of Temperature Sensing Capability of Clad Sapphire Optical Fibers with Type 2 Bragg Gratings using Optical Backscatter Reflectometry

This work investigated the temperature-sensing capabilities of Type II fiber Bragg gratings (FBGs) inscribed in sapphire optical fiber in the Ohio State University Research Reactor (OSURR). A Luna Innovations 4600 optical backscatter reflectometer (OBR) was used to interrogate FBGs in three sapphire optical fibers with an internal cladding that was developed by Ohio State. The sapphire fibers were fusion-spliced to silica lead fibers. In addition to the sapphire fibers, two silica fibers with the same Type II FBGs were included in the experiment as a reference. The fiber-based sensors were irradiated in the Central Irradiation Facility (CIF) of the OSURR for a total of 40 hours over 5 days at a reactor power of 450 kW, resulting in a total neutron fluence of approximately 2.5 × 10 18 n/cm 2 and a gamma dose of approximately 3.48 Grad. Two K-type thermocouples were included within the rig: one at the core centerline and the other 12 inches above the top of the core. The temperature was not actively controlled, but the thermocouples were used to provide a reference to which the fiber-based temperature measurements could be compared.

36 MATERIALS SCIENCE↗

DOE OSTI2022

SMC Reinforced by Recycled or Textile Carbon Fiber

There is a significant need to expand material options for SMC that has traditionally used glass fibers for decades. There are several integral issues related to chopping and conveying a range of materials including glass, carbon, basalt, thermoplastic tapes, and recycled fibers. These are in a variety of forms including continuous tows, discontinuous agglomerates such as pyrolyzed carbon fibers that could be used to produce a range of SMC intermediates. Standard/conventional SMC processing is limited to cutting rotors specifically for glass and compounding with thermoset polyesters and some epoxies. The multi-material, multi-format line developed in this project is flexible to enable custom conveying and uses an interchangeable rotor dedicated for specific material types. The overall tasks undertaken in this project included: evaluation of the fiber feed mechanism, effect of textile grade carbon, evaluating servo motor controlling of conveyor, evaluate doctor box resin feed, evaluate compaction unit, evaluation of different formulations, and develop automation such as PLC programming. The new multi-material SMC line Version 2 (SCM-V2) incorporated servo motors over induction motors which gave the overall cutter system precision control and made it quiet. The addition of a 14-roll compaction unit at the end of the line in SMC-V2 enabled higher material wet out which was a limitation in the SMC Version 1 (SMC-V1). The cutters were further updated to reduce the cantilever overhang of the fiber which enabled more uniform cut lengths for glass, carbon, and basalt fibers. The overall instrumentation and system control including a remote control operation was enabled in the SMC-V2. The line speed is capable of 10-20 ft/minute. The cutting modules were designed and engineered for cutting glass, basalt and textile grade carbon in 300k and 450-600k format widths. The cutting trials were established for a range of fiber types. The study also demonstrated the utility of the line to cut and produce basalt fiber SMC. Initial trials were conducted on the properties from recycled carbon fiber (rCF) mats in epoxy resin. Overall, the Covid19 situation constrained the team from accessing the SMC line for over 18 months. Despite this challenge major advancements were made.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Influence of Fiber Orientation on Deformation of Additive Manufactured Composites

Anisotropy caused by flow-induced fiber orientation of discontinuous fibers within the extrudate in the Extrusion Deposition Additive Manufacturing (EDAM) process gives rise to anisotropic shrinkage in printed parts and thereby, final part deformations. Three fiber orientation states, described by the second-order orientation tensor, were investigated to determine their influence upon final geometry. Two material systems were investigated including a short glass fiber-reinforced polyamide and a short carbon fiber-reinforced polyamide. A curvilinear geometry was modeled and printed virtually in the thermo-mechanical simulation, ADDITIVE3D©. The scale of the printed geometry was in the range of 300–400 mm and contained three semicircular geometry regions connected to linear regions, thereby inducing significant magnification of the spring-in deformation. The predicted deformation of the printed geometry for the three fiber orientation states and two material systems were compared. The deformation predicted for glass fiber-filled polyamide and carbon fiber-filled polyamide of the same fiber orientation states showed comparable deformations. In conclusion, the largest residual deformation was shown to correspond to the orientation tensor with the greatest degree of anisotropy.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Direct observation on supersonic microprojectile penetration of carbon fiber composites with ultrafast synchrotron X-ray phase contrast imaging

High-speed penetration into carbon fiber composites is of fundamental importance to materials science and impact engineering, but research along this line suffers considerably from the lack of direct experimental observations. Here we investigate such penetration dynamics of a unidirectional carbon fiber reinforced epoxy (UCFRE) composite, with a combination of in situ, ultrafast, synchrotron phase contrast imaging and finite element (FE) analysis. The experiments yield the first direct observation on projectile trajectories and fiber-scale deformation and damage in the UCFRE composites during supersonic microprojectile penetration, for different fiber orientations (0 degrees - 90 degrees from the impact direction) and projectile velocities (600 - 850 m.s -1 ), at unprecedented temporal (~ 100 ps) and spatial (5 μm) resolutions. The maximum penetration depth decreases with increasing fiber orientation angles, as a result of anisotropic damage evolution in the composite sample. Strain localizations are prone to develop along a direction perpendicular to the fiber orientation, while the damage or cavity region, along the fiber direction. FE modeling with a three-dimensional Hashin criterion yields consistent projectile trajectory and cavity morphology with the experimental results. Finally, with increasing fiber orientation angles, damage analyses show a transition in the damage mode from fiber compression to matrix compression damage, in line with the increasing maximum penetration depth.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Effect of spatial distribution of polymer fibers on preventing spalling of UHPC at high temperatures

Polypropylene (PP) fibers are commonly used for the prevention of thermal spalling of ultra-high performance concrete (UHPC). In this work, the effect of fiber distribution on permeability and spalling resistance is investigated and an analytical model for permeability at 150 °C is proposed. This model, considering the parameters like fiber dimensions, dosage, and percolation, is based on Kozeny-Carman equation. It was found that the percolation of the interconnecting fiber network resulted in a significant increase in permeability of UHPC. X-ray tomography data on the three-dimensional spatial distribution of fibers reiterated that fiber aspect ratio and dosage (and fiber number density) were critical in increasing the fiber connectivity (percolation). It was also found that a vapor permeability of larger than 0.6 × 10{sup −16} m{sup 2} at 150 °C could eliminate spalling. Further, based on a semi-empirical approach, aspect ratio between 300 and 600 was recommended for spalling prevention with a fiber dosage of 0.3–0.4 vol%.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Fiber orientation effects on ultra-high performance concrete formed by 3D printing

Despite the growing interest in 3D concrete printing, its current progress is limited by reinforcing methods. Inclusion of steel fibers is a potential reinforcing solution; however, the effect of printing process on orientation of the fibers is still unknown. This study aims to quantitatively investigate the orientation distribution of steel fibers in 3D printed ultra-high performance concrete. The effects of extrusion nozzle size, Cartesian print speed, and fiber volume fraction on the orientation of fibers were evaluated using digital image analysis. The consequent effects of the fiber orientation on the mechanical properties of the 3D-printed specimens were also determined. The results were compared with those of the conventionally mold-cast specimens. The results revealed that the smaller nozzle size and higher fiber volume fraction significantly enhanced the fiber alignment parallel to the printing direction. This preferential fiber alignment led to superior mechanical performance of the printed specimens to the mold-cast specimens.

36 MATERIALS SCIENCE↗

DOE OSTI2018

X-ray computed tomography of microstructure evolution during matrix impregnation and curing in unidirectional fiber beds

Microstructural evolution during axial impregnation and subsequent curing of a preceramic polymer in unidirectional ceramic fiber beds is studied using X-ray computed tomography. The principal goal is to identify connections between void locations, void sizes, local fiber bed porosity, fiber movement, and impregnation conditions. The degree of saturation after impregnation is found to increase with instantaneous capillary number. But, because of the need to create pathways for gas escape during curing, fiber beds with high saturation after impregnation show the largest reductions in saturation during curing. Notwithstanding, saturation after curing increases with instantaneous capillary number. Voids tend to form in the largest channels between fibers, where the local fiber bed porosity is high, during both impregnation and curing. Here, void formation is typically accompanied by fiber movement that increases both the local fiber bed porosity near voids and the overall non-uniformity in the fiber bed, as measured by local porosity entropy.

(A - Material) fibers↗

DOE OSTI2025

Fiber orientation and porosity in large-format extrusion process: The role of processing parameters

Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. In conclusion, these findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.

Design of experiments↗