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All sources NASA NTRS DOE OSTI

NASA NTRS1987

Review of thermal properties of graphite composite materials

Flammability, thermal, and selected mechanical properties of composites fabricated with epoxy and other thermally stable resin matrices are described. Properties which were measured included limiting-oxygen index, smoke evolution, thermal degradation products, total-heat release, heat-release rates, mass loss, flame spread, ignition resistance, thermogravimetric analysis, and selected mechanical properties. The properties of 8 different graphite composite panels fabricated using four different resin matrices and two types of graphite reinforcement are described. The resin matrices included: XU71775/H795, a blend of vinyl polystyryl pyridine and bismaleimide; H795, a bismaleimide; Cycom 6162, a phenolic; and PSP 6022M, a polystyryl pyridine. The graphite fiber used was AS-4 in the form of either tape or fabric. The properties of these composites were compared with epoxy composites. It was determined that the blend of vinyl polystyryl pyridine and bismaleimide (XU71775/H795) with the graphite tape was the optimum design giving the lowest heat release rate.

Kourtides, D. A.↗

NASA NTRS1988

Bismaleimide-vinylpolystyrylpyridine graphite composites

Flammability, thermal, and selected mechanical properties of composites fabricated with epoxy and other thermally stable resin matrices are described. Properties which were measured included limiting-oxygen index, smoke evolution, thermal degradation products, total-heat release, heat-release rates, mass loss, flame spread, ignition resistance, thermogravimetric analysis and selected mechanical properties. This paper describes the properties of eight different graphite composite panels fabricated using four different resin matrices and two types of graphite reinforcement. The resin matrices included: XU71775/H795, a blend of vinylpolystyrylpyridine and bismaleimide; H795, a bismaleimide; Cycom 6162, a phenolic; and PSP 6022M, a polystyrylpyridine. The graphite fiber used was AS-4 in the form of either tape or fabric. The properties of these composites were compared with epoxy composites. It was determined that the blend of vinylpolystyrylpyridine and bismaleimide (XU71775/H795) with the graphite tape was the optimum design giving the lowest heat release rate.

Kourtides, D. A.↗

NASA NTRS2013

Nickel-Graphite Composite Compliant Interface and/or Hot Shoe Material

Next-generation high-temperature thermoelectric-power-generating devices will employ segmented architectures and will have to reliably withstand thermally induced mechanical stresses produced during component fabrication, device assembly, and operation. Thermoelectric materials have typically poor mechanical strength, exhibit brittle behavior, and possess a wide range of coefficient of thermal expansion (CTE) values. As a result, the direct bonding at elevated temperatures of these materials to each other to produce segmented leg components is difficult, and often results in localized microcracking at interfaces and mec hanical failure due to the stresses that arise from the CTE mismatch between the various materials. Even in the absence of full mechanical failure, degraded interfaces can lead to increased electrical and thermal resistances, which adversely impact conversion efficiency and power output. The proposed solution is the insertion of a mechanically compliant layer, with high electrical and thermal conductivity, between the low- and high-temperature segments to relieve thermomechanical stresses during device fabrication and operation. This composite material can be used as a stress-relieving layer between the thermoelectric segments and/or between a thermoelectric segment and a hot- or cold-side interconnect material. The material also can be used as a compliant hot shoe. Nickel-coated graphite powders were hot-pressed to form a nickel-graphite composite material. A freestanding thermoelectric segmented leg was fabricated by brazing the compliant pad layer between the high-temperature p- Zintl and low-temperature p-SKD TE segments using Cu-Ag braze foils. The segmented leg stack was heated in vacuum under a compressive load to achieve bonding. The novelty of the innovation is the use of composite material that re duces the thermomechanical stresses en - countered in the construction of high-efficiency, high-temperature therm - o-electric devices. The compliant pad enables the bonding of dissimilar thermoelectric materials while maintaining the desired electrical and thermal properties essential for efficient device operation. The modulus, CTE, electrical, and thermal conductances of the composite can be controlled by varying the ratio of nickel to graphite.

Firdosy, Samad A.↗

NASA NTRS2015

Multidisciplinary Simulation of Graphite-Composite and Cermet Fuel Elements for NTP Point of Departure Designs

This paper compares the expected performance of two Nuclear Thermal Propulsion fuel types. High fidelity, fluid/thermal/structural + neutronic simulations help predict the performance of graphite-composite and cermet fuel types from point of departure engine designs from the Nuclear Thermal Propulsion project. Materials and nuclear reactivity issues are reviewed for each fuel type. Thermal/structural simulations predict thermal stresses in the fuel and thermal expansion mis-match stresses in the coatings. Fluid/thermal/structural/neutronic simulations provide predictions for full fuel elements. Although NTP engines will utilize many existing chemical engine components and technologies, nuclear fuel elements are a less developed engine component and introduce design uncertainty. Consequently, these fuel element simulations provide important insights into NTP engine performance.

Cermets↗

DOE OSTI2024

Modeling Reversible Volume Change in Automotive Battery Cells with Porous Silicon Oxide-Graphite Composite Anodes

Automotive battery manufacturers are working to improve the individual cell and overall pack design by increasing durability, performance, and range, while reducing cost, and active material volume change is a key aspect that needs to be considered during this design process. Recently, silicon oxide-graphite composite anodes are being explored to increase total anode capacity while maintaining a tolerable amount of cell level reversible volume expansion due to the relatively lower reversible volume change of the silicon oxide compared to pure battery grade or metallurgical grade silicon. To predict the blended anode response and contribution to the overall cell volume change, we integrated the mechanical behavior of the individual active materials with the multi-species, multi-reaction model to predict the state-of-lithiation of the active materials in the cell at a given potential. The resulting simulations illustrate the tradeoff in volume change between the silicon oxide and the graphite during cell operation. This type of modeling approach will allow designers to virtually consider the impact of cell level and pack level design changes on overall system mechanical performance for automotive and grid storage applications, namely that relatively small addition of silicon containing materials can drive a significant increase in the volume change at the cell level, as demonstrated by the 5 wt% addition of silicon oxide accounting for half of the overall volume change in the cell.

Garrick, Taylor R. (ORCID:0000000322518129)↗

NASA NTRS2000

Critical Heat Flux in Pool Boiling on Metal-Graphite Composite Surfaces

A study is conducted on high heat-flux pool boiling of pentane on micro-configured composite surfaces. The boiling surfaces are copper-graphite (Cu-Gr) and aluminum-graphite (Al-Gr) composites with a fiber volume concentration of 50%. The micro-graphite fibers embedded in the matrix contribute to a substantial enhancement in boiling heat-transfer performance. Correlation equations are obtained for both the isolated and coalesced bubble regimes, utilizing a mathematical model based on a metal-graphite, two-tier configuration with the aid of experimental data. A new model to predict the critical heat flux (CHF) on the composites is proposed to explain the fundamental aspects of the boiling phenomena. Three different factors affecting the CHF are considered in the model. Two of them are expected to become the main agents driving vapor volume detachment under microgravity conditions, using the metal-graphite composite surfaces as the heating surface and using liquids with an unusual Marangoni effect as the working fluid.

Zhang, Nengli↗

NASA NTRS1994

Selection process for trade study: Graphite Composite Primary Structure (GCPS)

This TA 2 document describes the selection process that will be used to identify the most suitable structural configuration for an SSTO winged vehicle capable of delivering 25,000 lbs to a 220 nm circular orbit at 51.6 degree inclination. The most suitable unpressurized graphite composite structures and material selections is within this configuration and will be the prototype design for subsequent design and analysis and the basis for the design and fabrication of payload bay, wing, and thrust structure full scale test articles representing segments of the prototype structures. The selection process for this TA 2 trade study is the same as that for the TA 1 trade study. As the trade study progresses additional insight may result in modifications to the selection criteria within this process. Such modifications will result in an update of this document as appropriate.

Greenberg, H. S.↗

NASA NTRS2011

Graphite Composite Panel Polishing Fixture

The use of high-strength, lightweight composites for the fixture is the novel feature of this innovation. The main advantage is the light weight and high stiffness-to-mass ratio relative to aluminum. Meter-class optics require support during the grinding/polishing process with large tools. The use of aluminum as a polishing fixture is standard, with pitch providing a compliant layer to allow support without deformation. Unfortunately, with meter-scale optics, a meter-scale fixture weighs over 120 lb (.55 kg) and may distort the optics being fabricated by loading the mirror and/or tool used in fabrication. The use of composite structures that are lightweight yet stiff allows standard techniques to be used while providing for a decrease in fixture weight by almost 70 percent. Mounts classically used to support large mirrors during fabrication are especially heavy and difficult to handle. The mount must be especially stiff to avoid deformation during the optical fabrication process, where a very large and heavy lap often can distort the mount and optic being fabricated. If the optic is placed on top of the lapping tool, the weight of the optic and the fixture can distort the lap. Fixtures to support the mirror during fabrication are often very large plates of aluminum, often 2 in. (.5 cm) or more in thickness and weight upwards of 150 lb (68 kg). With the addition of a backing material such as pitch and the mirror itself, the assembly can often weigh over 250 lb (.113 kg) for a meter-class optic. This innovation is the use of a lightweight graphite panel with an aluminum honeycomb core for use as the polishing fixture. These materials have been used in the aerospace industry as structural members due to their light weight and high stiffness. The grinding polishing fixture consists of the graphite composite panel, fittings, and fixtures to allow interface to the polishing machine, and introduction of pitch buttons to support the optic under fabrication. In its operation, the grinding polishing fixture acts as a reaction structure to the polishing tool. It must be stiff enough to avoid imparting a distorted shape to the optic under fabrication and light enough to avoid self-deflection. The fixture must also withstand significant tangential loads from the polishing machine during operations.

Hagopian, John↗

NASA NTRS1974

Development of polyphenylquinoxaline graphite composites

This exploratory program was divided into four basic tasks. The initial phase was devoted toward investigating processing variables associated with previously developed PPO resins. These polymers were derived from p-bis(phenyl glyoxalyl)benzene reacted with 3,3'-diamino benzidine and/or 3,3',4,4'-tetramino benzophenone. Four new phenyl quinoxaline polymers were synthesized and characterized in Tasks 2 and 3. These consisted of a hydroxyl group containing PPQ synthesized from 3,3'-diamino benzidine (DAB), m-bis(phenyl glyoxal)benzene and m-bis(p'-hydroxy phenyl glyoxalyl) benzene; a cyano group containing PPQ from the reaction of DAB and p-bis(p'-cyano phenoxy phenyl glyoxalyl)benzene; an end-capped block copolymer; and a polymer from the reaction of 3,3',4,4'-tetraamino benzo phenone and m-bis(phenyl glyoxalyl)benzene. The latter two polymers were chosen for composite studies in the latter two tasks of the program. Mechanical properties of the graphite reinforced PPQ composites were determined over the temperature range of +21 C to 316 C. Flexural strengths of the HMS graphite fiber composites were in excess of 8.97 X 10 to the 8th power N/sq m (130,000 psi) at +21 C (70 F) with over 50% strength retention at +316 C.

Hoggatt, J. T.↗

NASA NTRS1989

Aging behavior and life prediction of graphite composites

This paper presents experimental data from two independent tests, designed to determine the long-term reliability of composite materials. The technique of accelerated aging at elevated temperatures is employed. In the first set, graphite fiber, epoxy composites in five ply layups are manufactured and tested in the standard short-beam shear mode. In the second set, Nomex honeycomb, graphite fiber/epoxy composite face and rear sheet sandwich coupons are tested. After satisfying simple consistency checks, data interpretation is attempted within the framework of an Arrhenius degradation model. The elevated temperature is assumed to influence the degradation according to this temperature-dependent rate law. From these tests on five-ply composites and honeycomb sandwiches, it is concluded that aging is not a serious problem.

Ramohalli, Kumar↗

NASA NTRS1986

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimeter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, C. C.↗

NASA NTRS1987

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimenter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, Ching-Cheh↗

NASA NTRS1984

An elastic potential for the nonlinear response of unidirectional graphite composites

An elastic potential is proposed that is capable of modeling the reversible portion of the observed nonlinear response of unidirectional graphite fiber composites. The model includes both the stiffening stress-strain behavior as well as the softening Poisson's response for loading in the fiber direction. The model is compared with experimental results for Celion 6000/PMR-15 graphite-polyimide.

Pindera, M.-J.↗

NASA NTRS2007

Formation and Growth of Micro and Macro Bubbles on Copper-Graphite Composite Surfaces

Micro scale boiling behavior in the vicinity of graphite micro-fiber tips on the coppergraphite composite boiling surfaces is investigated. It is discovered that a large number of micro bubbles are formed first at the micro scratches and cavities on the copper matrix in pool boiling. In virtue of the non-wetting property of graphite, once the growing micro bubbles touch the graphite tips, the micro bubbles are sucked by the tips and merged into larger micro bubbles sitting on the tips. The micro bubbles grow rapidly and coalesce to form macro bubbles, each of which sitting on several tips. The growth processes of the micro and macro bubbles are analyzed and formulated followed by an analysis of bubble departure on the composite surfaces. Based on these analyses, the enhancement mechanism of the pool boiling heat transfer on the composite surfaces is clearly revealed. Experimental results of pool boiling heat transfer both for water and Freon-113 on the composite surfaces convincingly demonstrate the enhancement effects of the unique structure of Cu-Gr composite surfaces on boiling heat transfer.

Chao, David F.↗

NASA NTRS1984

Matrix Resin Characterization in Cured Graphite Composites Using Diffuse Reflectance-Ftir

The chemical characterization of cured graphite fiber reinforced polymer matrix composites is complicated by the fact that the resins are insoluble and the composites are apaque. Standard analyses which depend either on the ability to dissolve the sample or to detect transmitted radiation are impossible. As a result, data reported on environmentally exposed composites primarily concern macroscopic information such as weight loss or changes in selected mechanical properties. Diffuse reflectance in combination with fourier transform infrared spectroscopy was developed to gain a basic chemical understanding of composite and adhesive behavior. Several composite and adhesive materials were characterized before and after environmental exposure. In each case significant changes in resin molecular structure were observed and correlated with changes in mechanical properties, providing new insights into material performance.

Young, P. R.↗

NASA NTRS1980

Spatial distribution of volatile compounds in graphite composites

The distribution of water and other volatile compounds such as acetone and phenol was measured as a function of depth in four graphite resin matrix composites. Precision abrasion mass spectrometry was used to qualitatively and quantitatively characterize the indigenous volatile compounds in the as received condition and after drying in an environmentally controlled oven. The total amount of water in the composites varied from 0.12 wt% to 1.1 wt% and the times required to dry the samples ranged from less than 96 h to much greater than 555 h.

Grayson, M. A.↗

NASA NTRS2006

Graphite Composite Booms with Integral Hinges

A document discusses lightweight instrument booms under development for use aboard spacecraft. A boom of this type comprises a thin-walled graphite fiber/ matrix composite tube with an integral hinge that can be bent for stowage and later allowed to spring back to straighten the boom for deployment in outer space. The boom design takes advantage of both the stiffness of the composite in tubular geometry and the flexibility of thin sections of the composite. The hinge is formed by machining windows in the tube at diametrically opposite locations so that there remain two opposing cylindrical strips resembling measuring tapes. Essential to the design is a proprietary composite layup that renders the hinge tough yet flexible enough to be bendable as much as 90 in either of two opposite directions. When the boom is released for deployment, the torque exerted by the bent hinge suffices to overcome parasitic resistance from harnesses and other equipment, so that the two sections of the hinge snap to a straight, rigid condition in the same manner as that of measuring tapes. Issues addressed in development thus far include selection of materials, out-of-plane bending, edge cracking, and separation of plies.

Alexander, Wes↗

NASA NTRS1974

Evaluation of graphite composite materials for bearingless helicopter rotor application

Small scale combined load fatigue tests were conducted on twelve unidirectional graphite-glass scrim-epoxy composite specimens. The specimens were 1 in. (2.54 cm) wide by 0.1 in. (.25 cm) thick by 5 in. (12.70 cm) long. The fatigue data was developed for the preliminary design of the spar for a bearingless helicopter main rotor. Three loading conditions were tested. Combinations of steady axial, vibratory torsion, and vibratory bending stresses were chosen to simulate the calculated stresses which exist at the root and at the outboard end of the pitch change section of the spar. Calculated loads for 150 knots (77.1 m/sec) level flight were chosen as the baseline condition. Test stresses were varied up to 4.4 times the baseline stress levels. Damage resulted in reduced stiffness; however, in no case was complete fracture of the specimen experienced.

Ulitchny, M. G.↗