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NASA NTRS1998

Automated Fabrication Technologies for High Performance Polymer Composites

New fabrication technologies are being exploited for building high graphite-fiber-reinforced composite structure. Stitched fiber preforms and resin film infusion have been successfully demonstrated for large, composite wing structures. Other automatic processes being developed include automated placement of tacky, drapable epoxy towpreg, automated heated head placement of consolidated ribbon/tape, and vacuum-assisted resin transfer molding. These methods have the potential to yield low cost high performance structures by fabricating composite structures to net shape out-of-autoclave.

Shuart , M. J.↗

NASA NTRS1980

Fillers for improved graphite fiber retention by polymer matrix composites

This program was designed to develop technology for fabrication of graphite/epoxy composites containing selected boron and boron-containing fillers, determine the effects of the fillers on physical and mechanical properties of composites, and evaluate the effectiveness of the boron fillers for fiber retention when the composites are exposed to fire conditions followed by impact. Fillers evaluated were crystalline and amorphous boron, boron carbide, and aluminum boride. The fillers were evaluated by mixing with Narmco 5208 resin matrix at quantities up to 5%. Graphite composites were fabricated and evaluated with respect to their mechanical properties, resistance to humidity, and burning characteristics. Also, the mechanism by which the fillers prevented fiber release was studied.

Sheppard, C. H.↗

NASA NTRS1978

Large antenna structure technologies required for 1985-2000

Topics discussed include: (1) material degradation as related to graphite composites and thermal control coatings; (2) thermal distortions considering postulated end-of-life conditions for extended lifetime (over 10 years); (3) examination of built-in shape versus actively controlled surfaces; (4) testing philosophy of super large antenna structures; and (5) examination of some possibilities which may require new or different technology.

Wannlund, W. R.↗

NASA NTRS1986

Interleaved arrays antenna technology development

Phase one and two of a program to further develop and investigate advanced graphite epoxy waveguides, radiators, and components with application to space antennas are discussed. The objective of the two phases were to demonstrate mechanical integrity of a small panel of radiators and parts procured under a previous contract and to develop alternate designs and applications of the technology. Most of the emphasis was on the assembly and test of a 5 x 5 element module. This effort was supported by evaluation of adhesives and waveguide joint configurations. The evaluation and final assembly considered not only mechanical performance but also producibility in large scale.

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NASA NTRS1994

SSTO rockets. A practical possibility

Most experts agree that single-stage-to-orbit (SSTO) rockets would become feasible if more advanced technologies were available to reduce the vehicle dry weight, increase propulsion system performance, or both. However, these technologies are usually judged to be very ambitious and very far off. This notion persists despite major advances in technology and vehicle design in the past decade. There appears to be four major misperceptions about SSTOs, regarding their mass fraction, their presumed inadequate performance margin, their supposedly small payloads, and their extreme sensitivity to unanticipated vehicle weight growth. These misperceptions can be dispelled for SSTO rockets using advanced technologies that could be matured and demonstrated in the near term. These include a graphite-composite primary structure, graphite-composite and Al-Li propellant tanks with integral reusable thermal protection, long-life tripropellant or LOX-hydrogen engines, and several technologies related to operational effectiveness, including vehicle health monitoring, autonomous avionics/flight control, and operable launch and ground handling systems.

PROPELLANT MASS FRACTION↗

NASA NTRS2015

Compatibility of the Radio Frequency Mass Gauge with Graphite-Epoxy Composite Tanks

The radio frequency mass gauge (RFMG) is a low-gravity propellant quantity gauge being developed at NASA for possible use in long-duration space missions utilizing cryogenic propellants. As part of the RFMG technology development process, we evaluated the compatibility of the RFMG with a graphite-epoxy composite material used to construct propellant tanks. The key material property that can affect compatibility with the RFMG is the electrical conductivity. Using samples of 8552/IM7 graphite-epoxy composite, we characterized the resistivity and reflectivity over a range of frequencies. An RF impedance analyzer was used to characterize the out-of-plane electrical properties (along the sample thickness) in the frequency range 10 to 1800 MHZ. The resistivity value at 500 MHz was 4.8 ohm-cm. Microwave waveguide measurements of samples in the range 1.7 - 2.6 GHz, performed by inserting the samples into a WR-430 waveguide, showed reflectivity values above 98%. Together, these results suggested that a tank constructed from graphite/epoxy composite would produce good quality electromagnetic tank modes, which is needed for the RFMG. This was verified by room-temperature measurements of the electromagnetic modes of a 2.4 m diameter tank constructed by Boeing from similar graphite-epoxy composite material. The quality factor Q of the tank electromagnetic modes, measured via RF reflection measurements from an antenna mounted in the tank, was typically in the range 400 less than Q less than 3000. The good quality modes observed in the tank indicate that the RFMG is compatible with graphite-epoxy tanks, and thus the RFMG could be used as a low-gravity propellant quantity gauge in such tanks filled with cryogenic propellants.

Propellant tanks↗

NASA NTRS1986

Mechanical properties characterization of composite sandwich materials intended for space antenna applications

The composite materials proposed for use in the Advanced Communications Technology Satellite (ACTS) Program contains a new, high modulus graphite fiber as the reinforcement. A study was conducted to measure certain mechanical properties of the new fiber-reinforced material as well as of a composite-faced aluminum honeycomb sandwich structure. Properties were measured at -157, 22, and 121 C. Complete characterization of this material was not intended. Longitudinal tensile, picture-frame shear, short-beam shear, and flexural tests were performed on specimens of the composite face-sheet materials. Unidirectional, cross-plied, and quasi-isotropic fiber composite ply layup designs were fabricated and tested. These designs had been studied by using NASA's Integrated Composite Analyzer (ICAN) computer program. Flexural tests were conducted on (+/- 60/0 deg) sub s composite-faced sandwich structure material. Resistance strain gages were used to measure strains in the tensile, picture-frame, and sandwich flexural tests. The sandwich flexural strength was limited by the core strength at -157 and 22 C. The adhesive bond strength was the limiting factor at 121 C. Adhesive mechanical properties are reflected in sandwich structure flexural properties when the span-to-depth ratio is great enough to allow a significant shear effect on the load-deflection behavior of the sandwich beam. Most measured properties agreed satisfactorily with the properties predicted by ICAN.

Bowles, Kenneth J.↗

NASA NTRS1989

Mechanical properties characterization of composite sandwich materials intended for space antenna applications

The composite materials proposed for use in the Advanced Communications Technology Satellite (ACTS) program contains a new, high modulus graphite fiber as the reinforcement. A study was conducted to measure certain mechanical properties of the new fiber-reinforced material as well as of a composite-faced aluminum honeycomb sandwich structure. Properties were measured at -157, 22, and 121 C. Complete characterization of this material was not intended. Longitudinal tensile, picture-frame shear, short-beam shear, and flexural tests were performed on specimens of the composite face-sheet materials. Unidirectional, cross-plied, and quasi-isotropic fiber composite ply layup designs were fabricated and tested. These designs had been studied by using NASA's Integrated Composite Analyzer (ICAN) computer program. Flexural tests were conducted on (+/- 60/0 deg) sub s composite-faced sandwich structure material. Resistance strain gages were used to measure strains in the tensile, picture-frame, and sandwich flexural tests. The sandwich flexural strength was limited by the core strength at 157 and 22 c. The adhesive bond strength was the limiting factor at 121 C. Adhesive mechanical properties are reflected in sandwich structure flexural properties when the span-to-depth ratio is great enough to allow a significant shear effect on the load-deflection behavior of the sandwich beam. Most measured properties agreed satisfactorily with the properties predicted by ICAN.

Bowles, Kenneth J.↗

NASA NTRS2004

An Overview of the Nuclear Electric Xenon Ion System (NEXIS) Activity

The Nuclear Electric Xenon Ion System (NEXIS) research and development activity within NASA's Project Prometheus, was one of three proposals selected by NASA to develop thruster technologies for long life, high power, high specific impulse nuclear electric propulsion systems that would enable more robust and ambitious science exploration missions to the outer solar system. NEXIS technology represents a dramatic improvement in the state-of-the-art for ion propulsion and is designed to achieve propellant throughput capabilities >= 2000 kg and efficiencies >= 78% while increasing the thruster power to >= 20 kW and specific impulse to >= 6000 s. The NEXIS technology uses erosion resistant carbon-carbon grids, a graphite keeper, a new reservoir hollow cathode, a 65-cm diameter chamber masked to produce a 57-cm diameter ion beam, and a shared neutralizer architecture to achieve these goals. The accomplishments of the NEXIS activity so far include performance testing of a laboratory model thruster, successful completion of a proof of concept reservoir cathode 2000 hour wear test, structural and thermal analysis of a completed development model thruster design, fabrication of most of the development model piece parts, and the nearly complete vacuum facility modifications to allow long duration wear testing of high power ion thrusters.

ion thrusters↗

NASA NTRS2012

The Manufacture of W-UO2 Fuel Elements for NTP Using the Hot Isostatic Pressing Consolidation Process

NTP is attractive for space exploration because: (1) Higher Isp than traditional chemical rockets (2)Shorter trip times (3) Reduced propellant mass (4) Increased payload. Lack of qualified fuel material is a key risk (cost, schedule, and performance). Development of stable fuel form is a critical path, long lead activity. Goals of this project are: Mature CERMET and Graphite based fuel materials and Develop and demonstrate critical technologies and capabilities.

Broadway, Jeramie↗

NASA NTRS2015

SiLix-C Nanocomposites

For this Phase II project, Superior Graphite Co., in collaboration with the Georgia Institute of Technology and Streamline Nanotechnologies, Inc., developed, explored the properties of, and demonstrated the enhanced capabilities of novel nanostructured SiLix-C anodes. These anodes can retain high capacity at a rapid 2-hour discharge rate and at 0 C when used in Li-ion batteries. In Phase I, these advanced anode materials had specific capacity in excess of 1,000 mAh/g, minimal irreversible capacity losses, and stable performance for 20 cycles at C/1. The goals in Phase II were to develop and apply a variety of novel nanomaterials, fine-tune the properties of composite particles at the nanoscale, optimize the composition of the anodes, and select appropriate binder and electrolytes. In order to achieve a breakthrough in power characteristics of Li-ion batteries, the team developed new nanostructured SiLix-C anode materials to offer up to 1,200 mAh/g at C/2 at 0 C.

Henry, Francois↗

NASA NTRS2007

Deicing System Protects General Aviation Aircraft

Kelly Aerospace Thermal Systems LLC worked with researchers at Glenn Research Center on deicing technology with assistance from the Small Business Innovation Research (SBIR) program. Kelly Aerospace acquired Northcoast Technologies Ltd., a firm that had conducted work on a graphite foil heating element under a NASA SBIR contract and developed a lightweight, easy-to-install, reliable wing and tail deicing system. Kelly Aerospace engineers combined their experiences with those of the Northcoast engineers, leading to the certification and integration of a thermoelectric deicing system called Thermawing, a DC-powered air conditioner for single-engine aircraft called Thermacool, and high-output alternators to run them both. Thermawing, a reliable anti-icing and deicing system, allows pilots to safely fly through ice encounters and provides pilots of single-engine aircraft the heated wing technology usually reserved for larger, jet-powered craft. Thermacool, an innovative electric air conditioning system, uses a new compressor whose rotary pump design runs off an energy-efficient, brushless DC motor and allows pilots to use the air conditioner before the engine even starts

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NASA NTRS1988

Status of Gr/glass composites technology at UTOS

The TSC (Thermally Stable Composite) refers to a family of graphite reinforced glass matrix composite materials developed by UTOS. This fiber matrix combination exhibits low coefficients of thermal expansion (CTE), exceptional dimensional stability, high specific strength and stiffness, adequate fracture toughness, and space environment compatibility. The dimensional stability of a TSC mirror structure was experimentally characterized at the Steward Observatory. Preliminary results indicate that TSC is significantly more thermally stable than most current structural composite materials. In addition, the use of lower CTE glass matrix materials, such as 96 percent silica glass, have the potential for producing graphite/glass panels with expansion rates and stability comparable to that of fused silica.

Mayor, Ramon A.↗

NASA NTRS1980

Development of assembly and joint concepts for erectable space structures

The technology associated with the on-orbit assembly of tetrahedral truss platforms erected of graphite epoxy tapered columns is examined. Associated with the assembly process is the design and fabrication of nine member node joints. Two such joints demonstrating somewhat different technology were designed and fabricated. Two methods of automatic assembly using the node designs were investigated, and the time of assembly of tetrahedral truss structures up to 1 square km in size was estimated. The effect of column and node joint packaging on the Space Shuttle cargo bay is examined. A brief discussion is included of operating cost considerations and the selection of energy sources. Consideration was given to the design assembly machines from 5 m to 20 m. The smaller machines, mounted on the Space Shuttle, are deployable and restowable. They provide a means of demonstrating the capabilities of the concept and of erecting small specialized platforms on relatively short notice.

Jacquemin, G. G.↗

NASA NTRS2012

Electrochemical Ultracapacitors Using Graphitic Nanostacks

Electrochemical ultracapacitors (ECs) have been developed using graphitic nanostacks as the electrode material. The advantages of this technology will be the reduction of device size due to superior power densities and relative powers compared to traditional activated carbon electrodes. External testing showed that these materials display reduced discharge response times compared to state-of-the-art materials. Such applications are advantageous for pulsed power applications such as burst communications (satellites, cell phones), electromechanical actuators, and battery load leveling in electric vehicles. These carbon nanostructures are highly conductive and offer an ordered mesopore network. These attributes will provide more complete electrolyte wetting, and faster release of stored charge compared to activated carbon. Electrochemical capacitor (EC) electrode materials were developed using commercially available nanomaterials and modifying them to exploit their energy storage properties. These materials would be an improvement over current ECs that employ activated carbon as the electrode material. Commercially available graphite nanofibers (GNFs) are used as precursor materials for the synthesis of graphitic nanostacks (GNSs). These materials offer much greater surface area than graphite flakes. Additionally, these materials offer a superior electrical conductivity and a greater average pore size compared to activated carbon electrodes. The state of the art in EC development uses activated carbon (AC) as the electrode material. AC has a high surface area, but its small average pore size inhibits electrolyte ingress/egress. Additionally, AC has a higher resistivity, which generates parasitic heating in high-power applications. This work focuses on fabricating EC from carbon that has a very different structure by increasing the surface area of the GNF by intercalation or exfoliation of the graphitic basal planes. Additionally, various functionalities to the GNS surface will be added that can exhibit pseudocapacitance. This pseudocapacitance exhibits faradaic (charge transfer) properties that can further increase the overall relative and volumetric capacitance of the material. A process is also proposed to use GNF as a precursor material to fabricate GNS that will be used as EC electrodes. This results in much better electrical conductivity than activated carbon. This is advantageous for high-pulsed-power applications to reduce parasitic heating. Larger average pore size allows more complete electrolyte wetting (faster charge transfer kinetics). These properties contribute to a lowered equivalent series resistance (ESR), increased specific power, shorter charging times, and decreased parasitic heating. The high density of basal plane edges provides nucleation sites for activation (addition of hydrophilic functional groups) that facilitate electrolyte wetting, and will contribute to pseudocapacitance.

Marotta, Christopher↗

NASA NTRS2000

Shelf Life of PMR Polyimide Monomer Solutions and Prepregs Extended

PMR (Polymerization of Monomeric Reactants) technology was developed in the mid-1970's at the NASA Glenn Research Center at Lewis Field for fabricating high-temperature stable polyimide composites. This technology allowed a solution of polyimide monomers or prepreg (a fiber, such as glass or graphite, impregnated with PMR polyimide monomers) to be thermally cured without the release of volatiles that cause the formation of voids unlike the non-PMR technology used for polyimide condensation type resins. The initial PMR resin introduced as PMR 15 is still commercially available and is used worldwide by aerospace industries as the state-of-the-art resin for high-temperature polyimide composite applications. PMR 15 offers easy composite processing, excellent composite mechanical property retention, a long lifetime at use temperatures of 500 to 550 F, and relatively low cost. Later, second-generation PMR resin versions, such as PMR II 50 and VCAP 75, offer improvements in the upper-use temperature (to 700 F) and in the useful life at temperature without major compromises in processing and property retention but with significant increases in resin cost. Newer versions of nontoxic (non-methylene dianiline) PMR resins, such as BAX PMR 15, offer similar advantages as originally found for PMR 15 but also with significant increases in resin cost. Thus, the current scope of the entire PMR technology available meets a wide range of aeronautical requirements for polymer composite applications.

Alston, William B.↗

NASA NTRS1966

Nuclear Rocket Technology Conference

The Lewis Research Center has a strong interest in nuclear rocket propulsion and provides active support of the graphite reactor program in such nonnuclear areas as cryogenics, two-phase flow, propellant heating, fluid systems, heat transfer, nozzle cooling, nozzle design, pumps, turbines, and startup and control problems. A parallel effort has also been expended to evaluate the engineering feasibility of a nuclear rocket reactor using tungsten-matrix fuel elements and water as the moderator. Both of these efforts have resulted in significant contributions to nuclear rocket technology. Many successful static firings of nuclear rockets have been made with graphite-core reactors. Sufficient information has also been accumulated to permit a reasonable Judgment as to the feasibility of the tungsten water-moderated reactor concept. We therefore consider that this technoIogy conference on the nuclear rocket work that has been sponsored by the Lewis Research Center is timely. The conference has been prepared by NASA personnel, but the information presented includes substantial contributions from both NASA and AEC contractors. The conference excludes from consideration the many possible mission requirements for nuclear rockets. Also excluded is the direct comparison of nuclear rocket types with each other or with other modes of propulsion. The graphite reactor support work presented on the first day of the conference was partly inspired through a close cooperative effort between the Cleveland extension of the Space Nuclear Propulsion Office (headed by Robert W. Schroeder) and the Lewis Research Center. Much of this effort was supervised by Mr. John C. Sanders, chairman for the first day of the conference, and by Mr. Hugh M. Henneberry. The tungsten water-moderated reactor concept was initiated at Lewis by Mr. Frank E. Rom and his coworkers. The supervision of the recent engineering studies has been shared by Mr. Samuel J. Kaufman, chairman for the second day of the conference, and Mr. Roy V. Humble. Dr. John C. Eward served as general chairman for the conference.

Source record↗

NASA NTRS2001

Evaluation of the Structural Response and Failure of a Full-Scale Stitched Graphite-Epoxy Wing

Analytical and experimental results for an all-composite full-scale wing box are presented. The wing box is representative of a section of a 220-passenger commercial transport aircraft wing box and was designed and constructed by The Boeing Company as part of the NASA Advanced Subsonics Technology (AST) program. The semi-span wing was fabricated from a graphite-epoxy material system with cover panels and spars held together using Kevlar stitches through the thickness. No mechanical fasteners were used to hold the stiffeners to the skin of the cover panels. Tests were conducted with and without low-speed impact damage, discrete source damage and repairs. Upbending, down-bending and brake roll loading conditions were applied. The structure with nonvisible impact damage carried 97% of Design Ultimate Load prior to failure through a lower cover panel access hole. Finite element and experimental results agree for the global response of the structure.

Jegley, Dawn C.↗