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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Effects of various consolidation techniques on microstructure, strength, and reliability of alpha-SiC

The effects of slurry pressing, HIP, and sinter-HIP on the strength, microstructure, and critical processing flaws in alpha-SiC are examined. Also, the feasibility of glass encapsulation is determined. Baseline strength was improved by about 25 percent by using slurry pressing instead of dry pressing. HIP further improved average strength to as high as 655 MPa. Sinter-HIP did not noticeably improve average strength. Although process-related flaws such as shrinkage cracks and large voids were not seen in HIPed alpha-SiC, surface-related flaws were observed. It is suggested that surface finishing by lapping, polishing, and heat treating might reduce the effect of surface-related flaws, improving the Weibull modulus in HIPed alpha-SiC.

Dutta, Sunil↗
NASA NTRS1988

Improved silicon carbide for advanced heat engines

This is the third annual technical report for the program entitled, Improved Silicon Carbide for Advanced Heat Engines, for the period February 16, 1987 to February 15, 1988. The objective of the original program was the development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines. Injection molding is the forming method selected for the program because it is capable of forming complex parts adaptable for mass production on an economically sound basis. The goals of the revised program are to reach a Weibull characteristic strength of 550 MPa (80 ksi) and a Weibull modulus of 16 for bars tested in 4-point loading. Two tasks are discussed: Task 1 which involves materials and process improvements, and Task 2 which is a MOR bar matrix to improve strength and reliability. Many statistically designed experiments were completed under task 1 which improved the composition of the batches, the mixing of the powders, the sinter and anneal cycles. The best results were obtained by an attritor mixing process which yielded strengths in excess of 550 MPa (80 ksi) and an individual Weibull modulus of 16.8 for a 9-sample group. Strengths measured at 1200 and 1400 C were equal to the room temperature strength. Annealing of machined test bars significantly improved the strength. Molding yields were measured and flaw distributions were observed to follow a Poisson process. The second iteration of the Task 2 matrix experiment is described.

Whalen, Thomas J.↗
NASA NTRS1998

A Novel Approach for Adaptive Signal Processing

Adaptive linear predictors have been used extensively in practice in a wide variety of forms. In the main, their theoretical development is based upon the assumption of stationarity of the signals involved, particularly with respect to the second order statistics. On this basis, the well-known normal equations can be formulated. If high- order statistical stationarity is assumed, then the equivalent normal equations involve high-order signal moments. In either case, the cross moments (second or higher) are needed. This renders the adaptive prediction procedure non-blind. A novel procedure for blind adaptive prediction has been proposed and considerable implementation has been made in our contributions in the past year. The approach is based upon a suitable interpretation of blind equalization methods that satisfy the constant modulus property and offers significant deviations from the standard prediction methods. These blind adaptive algorithms are derived by formulating Lagrange equivalents from mechanisms of constrained optimization. In this report, other new update algorithms are derived from the fundamental concepts of advanced system identification to carry out the proposed blind adaptive prediction. The results of the work can be extended to a number of control-related problems, such as disturbance identification. The basic principles are outlined in this report and differences from other existing methods are discussed. The applications implemented are speech processing, such as coding and synthesis. Simulations are included to verify the novel modelling method.

Chen, Ya-Chin↗
NASA NTRS1998

Thermal High- and Low-Cycle Fatigue Behavior of Thick Thermal Barrier Coating Systems

Ceramic thermal barrier coatings have received increasing attention for advanced gas turbine and diesel engine applications because of their ability to provide thermal insulation to engine components. However, the durability of these coatings under the severe thermal cycling conditions encountered in a diesel engine (ref. 1) still remains a major issue. In this research at the NASA Lewis Research Center, a high-power laser was used to investigate the thermal fatigue behavior of a yttria-stabilized zirconia coating system under simulated diesel engine conditions. The mechanisms of fatigue crack initiation and propagation, and of coating failure under complex thermal low-cycle fatigue (LCF, representing stop/start cycles) and thermal high-cycle fatigue (HCF, representing operation at 1300 rpm) are described. Continuous wave and pulse laser modes were used to simulate pure LCF and combined LCF/HCF, respectively (ref. 2). The LCF mechanism was found to be closely related to the coating sintering and creep at high temperatures. These creep strains in the ceramic coating led to a tensile stress state during cooling, thus providing the major driving force for crack growth under LCF conditions. The combined LCF/HCF tests induced more severe coating surface cracking, microspallation, and accelerated crack growth than did the pure LCF test. HCF thermal loads also facilitated lateral crack branching and ceramic/bond coat interface delaminations. HCF is associated with the cyclic stresses originating from the high-frequency temperature fluctuation at the ceramic coating surface. The HCF thermal loads act on the crack by a wedging mechanism (ref. 1), resulting in continuous crack growth at temperature. The HCF stress intensity factor amplitude increases with the interaction depth and temperature swing, and decreases with the crack depth. HCF damage also increases with the thermal expansion coefficient and the Young's modulus of the ceramic coating (refs. 1 and 3).

Miller, Robert A.↗
NASA NTRS2016

Failure Analysis and Recovery of a 50-mm Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application

Ball bearings used inside the ISS Distillation Assembly centrifuge require superior corrosion and shock resistance to withstand acidic wastewater exposure and heavy spacecraft launch related loads. These requirements challenge conventional steel bearings and provide an ideal pathfinder application for 50-mm bore, deep-groove ball bearings made from the corrosion immune and highly elastic intermetallic material 60NiTi. During early ground testing in 2014 one 60NiTi bearing unexpectedly and catastrophically failed after operating for only 200 hr. A second bearing running on the same shaft was completely unaffected. An investigation into the root cause of the failure determined that an excessively tight press fit of the bearing outer race coupled with NiTi's relatively low elastic modulus were key contributing factors. The proposed failure mode was successfully replicated by experiment. To further corroborate the root cause theory, a successful bearing life test using improved installation practices (selective fitting) was conducted. The results show that NiTi bearings are suitable for space applications provided that care is taken to accommodate their unique material characteristics.

DellaCorte, Christopher↗
NASA NTRS1991

Viscoelastic properties of addition-cured polyimides used in high temperature polymer matrix composites

Viscoelastic properties of the addition cured polyimide, PMR-15, were studied using dynamic mechanical and stress relaxation tests. For temperatures below the glass transition temperature, T sub g, the dynamic mechanical properties measured using a temperature scan rate of 10 C/min were strongly affected by the presence of absorbed moisture in the resin. Dynamic mechanical properties measured as a function of time during an isothermal hold provided an indication of chemical changes occurring in the resin. For temperatures above (T sub g + 20 C), the storage modulus increased continuously as a function of time indicating that additional crosslinking is occurring in the resin. Because of these changes in chemical structures, the stress relaxation modulus could not be measured over any useful time interval for temperatures above T sub g. For temperatures below T sub g, dynamic mechanical properties appeared to be unaffected by chemical changes for times exceeding 1 hr. Since the duration of the stress relaxation tests was less than 1 hr, the stress relaxation modulus could be measured. As long as the moisture content of the resin was less than 2 pct, stress relaxation curves measured at different temperatures could be superimposed using horizontal shifts along the log(time) axis with only small shifts along the vertical axis.

Roberts, Gary D↗
NASA NTRS1984

Processing of sintered alpha SiC

Processing methods of sintered alpha SiC for engine applications are developed in a cost effective manner, using a submicron sized powder blended with sintering aids (boron and carbon). The processes for forming a green powder compact, such as dry pressing, cold isostatic pressing and green machining, slip casting, aqueous extrusion, plastic extrusion, and injection molding, are described. Dry pressing is the simplest route to component fabrication, and is carried out at approximately 10,000 psi pressure, while in the cold isostatic method the pressure could go as high as 20,000 psi. Surfactants are added to control settling rates and casting characteristics in the slip casting. The aqueous extrusion process is accomplished by a hydraulic ram forcing the aqueous mixture through a die. The plastic forming processes of extrusion and injection molding offer the potential of greater diversity in shape capacity. The physical properties of sintered alpha SiC (hardness, Young's modulus, shear modulus, and thermal diffusivity) are extensively tested. Corrosion resistance test results of silicon carbide are included.

Storm, R. S.↗
NASA NTRS1984

Theory of the spin-1 bosonic liquid metal - Equilibrium properties of liquid metallic deuterium

The theory of a two-component quantum fluid comprised of spin-1/2 fermions and nonzero spin bosons is examined. This system is of interest because it embodies a possible quantum liquid metallic phase of highly compressed deuterium. Bose condensation is assumed present and the two cases of nuclear-spin-polarized and -unpolarized systems are considered. A significant feature in the unpolarized case is the presence of a nonmagnetic mode with quadratic dispersion owing its existence to nonzero boson spin. The physical character of this mode is examined in detail within a Bogoliubov approach. The specific heat, bulk modulus, spin susceptibility, and thermal expansion are all determined. Striking contrasts in the specific heats and thermal-expansion coefficients of the liquid and corresponding normal solid metallic phase are predicted.

Oliva, J.↗
NASA NTRS2004

Fiber Optic Sensors for Cure/Health Monitoring of Composite Materials

The objective of the current program is to develop techniques for using optical fibers to monitor the cure of composite materials in real time during manufacture and to monitor the in-service structural health of composite structures. Single and multimode optical fibers containing Bragg gratings have been used to perform Near Infrared (NIR) spectroscopy on high refractive index resins and show promise as embedded sensors. In order for chemical spectroscopy to be possible, intimate contact must be achieved between the fiber core and the composite resin. This contact is often achieved by stripping the cladding off of a portion of the fiber, thus making it brittle and easily broken in the composite processing environment. To avoid weakening the fiber to this extent, high refractive index fibers have been fabricated that use a low refractive index acrylate coating which serves as the cladding. This is ideal, as the coating is easily solvent stripped and intimate contact with the glass core can be achieved. Real time resin and composite chemical spectra have been obtained, with possible multifunctional capability using Bragg gratings to assess physical properties such as strain, modulus and other parameters of interest.

Wood, K. H.↗
NASA NTRS2005

A Comparison Study: The New Extended Shelf Life Isopropyl Ester PMR Technology versus The Traditional Methyl Ester PMR Approach

Polymerization of Monomeric Reactants (PMR) monomer solutions and carbon cloth prepregs of PMR II-50 and VCAP-75 were prepared using both the traditional limited shelf life methanol based PMR approach and a novel extended shelf life isopropanol based PMR approach. The methyl ester and isopropyl ester based PMR monomer solutions and PMR prepregs were aged for up to four years at freezer and room temperatures. The aging products formed were monitored using high pressure liquid chromatography (HPLC). The composite processing flow characteristics and volatile contents of the aged prepregs were also correlated versus room temperature storage time. Composite processing cycles were developed and six ply cloth laminates were fabricated with prepregs after various extended room temperature storage times. The composites were then evaluated for glass transition temperature (Tg), thermal decomposition temperature (Td), initial flexural strength (FS) and modulus (FM), long term (1000 hours at 316 C) thermal oxidative stability (TOS), and retention of FS and FM after 1000 hours aging at 316 C. The results for each ester system were comparable. Freezer storage was found to prevent the formation of aging products for both ester systems. Room temperature storage of the novel isopropyl ester system increased PMR monomer solution and PMR prepreg shelf life by at least an order of magnitude while maintaining composite properties.

Alston, William B.↗
NASA NTRS1991

High strain rate properties of off-axis composite laminates, part 2

Unidirectional off-axis graphite/epoxy and graphite/S-glass/epoxy laminates were characterized in uniaxial tension at strain rates ranging from quasi-static to over 500 s(sup -1). Laminate ring specimens were loaded by internal pressure with the tensile stress at 22.5, 30, and 45 degrees relative to the fiber direction. Results were presented in the form of stress-strain curves to failure. Properties determined included moduli, Poisson's ratios, strength, and ultimate strain. In all three laminates of both materials the modulus and strength increase sharply with strain rate, reaching values roughly 100, 150, and 200 percent higher than corresponding static values for the 22.5(sub 8), 30(sub 8), and 45(sub 8) degree laminates, respectively. In the case of ultimate strain no definite trends could be established, but the maximum deviation from the average of any value for any strain rate was less than 18 percent.

Daniel, I. M.↗
NASA NTRS1991

Computational simulation of microfracture in high temperature metal matrix composites

A computational simulation procedure, using three-dimensional finite element method and global strain energy release rates, is described to predict the microfracture process and identify/quantify the hierarchy of respective fracture modes in metal matrix composites. The procedure is used to predict the microfracture in unidirectional composites under longitudinal loads and accounts for the interphase strength in the in situ state. A novel procedure to computationally simulate the fiber pushthrough process is also described. In this simulation, the interface material is replaced by an anisotropic material with greatly reduced shear modulus in order to simulate the fiber pushthrough process using a linear analysis. Such a procedure is easily implemented and is computationally very effective.

Mital, Subodh K.↗
NASA NTRS1984

The Chemical Nature of the Fiber/resin Interface in Composite Materials

Carbon fiber/epoxy resin composites are considered. The nature of the fiber structure and the interaction that occurs at the interface between fiber and matrix are emphasized. Composite toughness can be improved by increased axial tensile and compressive strengths in the fibers. The structure of carbon fibers indicates that the fiber itself can fail transversely, and different transverse microstructures could provide better transverse strengths. The higher surface roughness of lower modulus and surface-treated carbon fibers provides better mechanical interlocking between the fiber and matrix. The chemical nature of the fiber surface was determined, and adsorption of species on this surface can be used to promote wetting and adhesion. Finally, the magnitude of the interfacial bond strength should be controlled such that a range of composites can be made with properties varying from relatively brittle and high interlaminar shear strength to tougher but lower interlaminar shear strength.

Diefendorf, R. J.↗
NASA NTRS1985

Analysis of stress-strain, fracture, and ductility behavior of aluminum maxtrix composites containing discontinuous silicon carbide reinforcement

Mechanical properties and stress-strain behavior were evaluated for several types of commercially fabricated aluminum matrix composites, containing up to 40 vol pct discontinuous SiC whisker, nodule, or particulate reinforcement. The elastic modulus of the composites was found to be isotropic, to be independent of type of reinforcement, and to be controlled solely by the volume percentage of SiC reinforcement present. The yield/tensile strengths and ductility were controlled primarily by the matrix alloy and temper condition. Type and orientation of reinforcement had some effect on the strengths of composites, but only for those in which the whisker reinforcement was highly oriented. Ductility decreased with increasing reinforcement content; however, the fracture strains observed were higher than those reported in the literature for this type of composite. This increase in fracture strain was probably attributable to cleaner matrix powder, better mixing, and increased mechanical working during fabrication. Comparison of properties with conventional aluminum and titanium structural alloys showed that the properties of the low-cost, lightweight composites demonstrated very good potential for application to aerospace structures.

Mcdanels, D. L.↗
NASA NTRS1988

A study of thermal transitions in a new semicrystalline thermoplastic polyimide

A polyimide derive from 4,4'-isophthaloyl diphthalic anhydride (IDPA) and 1,3-bis (4-aminophenoxy 4'-benzoyl) benzene (1,3-BABB) having semicrystalline behavior was prepared and characterized by differential scanning calorimetry (DSC) and wide angle X-ray scattering (WAXS). Thus a poly(amic acid) film cured in air for one hour each at 100 and 200 C displayed an endotherm at 286 C, followed by a crystallization exotherm at 317 C, and a second melting transition at 350 C. The 286 C melting point appeared to result from earlier solvent-induced crystallization. Films cast from DMAc, air dried, and soaked in methylene chloride could not be induced into semicrystallinity. The fully cured polyimide has a Tg of 216 C. Films heated to temperatures as high as 100 C for one hour in air were transparent and light yellow in color. Those films heated to or above 125 C were translucent. Polarized light microscopy revealed the presence of spherulites 608 micrometers in diameter in a sample cured to 275 C in air. Two film samples, one cured to 275 and the other to 325 C, were evaluated for tensile and ultimate strength, modulus, and percent elongation at 25 and 200 C. These values remained essentially constant at each test temperature.

Pratt, J. Richard↗
NASA NTRS1992

Properties of Graphite Fiber Reinforced Copper Matrix Composites for Space Power Applications

The thermal and mechanical properties of pitch-based graphite fiber reinforced copper matrix (Gr/Cu) composites usable for space applications such as radiator fins were investigated. Thermal conductivity was measured as a function of fiber volume fraction and architecture. Results showed for unidirectional P-100 Gr/Cu composites, the longitudinal thermal conductivity was nearly independent of fiber volume fraction. Transverse thermal conductivities (perpendicular to the fibers) were strongly affected by the fiber volume fraction with higher volume fractions resulting in lower thermal conductivities. The effect of architecture on thermal conductivity followed the cosine squared law for simple architectures. Insufficient data are available currently to model more complex architectures, but adding fibers in the direction of the heat flow increases the thermal conductivity as low conductivity plies are supplemented by high conductivity plies. Thermal expansion tests were conducted on the Gr fibers and Gr/Cu composites. The results show a considerable thermal expansion mismatch between the fibers and the Cu matrix. The longitudinal thermal expansion showed a strong dependence on the architecture of the Gr/Cu composites. The composites also show a thermal expansion hysteresis. The hysteresis was eliminated by an engineered interface. Mechanical testing concentrated on the dynamic modulus and strength of the composites. The dynamic modulus of the Gr/Cu composites was 305 GPa up to 400 C, a value equivalent to Be. The strengths of the composites were less than expected, but this is attributed to the poor bond across the interface between the Gr fibers and Cu matrix. Testing of composites with an engineered interface is expected to yield strengths nearer the values predicted by the rule of mixtures.

Ellis, David L.↗
NASA NTRSDate not supplied

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytic methods for the design of the discrete elements of ultralight lattice structures. This modular building block strategy allows for relatively simple element manufacturing as well as relatively simple robotic assembly of low mass-density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small, mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

digital materials↗
NASA NTRS1987

Invar and Elinvar type amorphous Fe-Cr-B alloys with high corrosion resistance

Amorphous (Fe(1-x)Cr(x))85B15 alloys (x = 0 to 0.15) were prepared from the melts by rapid quenching using a single roller techinque, and their Invar and Elinvar characteristics and corrosion resistance were investigated. With an increase in chromium content the Curie temperature and the saturation magnetic moment per iron atom decreased monotonically, while the crystallization temperature incresed gradually. The thermal expansion coefficient alpha around room temperature became slightly larger with increasing chromium content. Nevertheless, these amorphous alloys exhibited excellent Invar characteristics below the Curie temperature. The value of Young's modulus increased remarkably in a relatively low magnetic field and then saturated at a field of about 80 kA/m, showing a large delta E effect. Its value as well as a longitudinal linear magnetostriction became smaller with an increase in chromium content. The temperature coefficient of Young's modulus changed from postive to negative, and the temperature range showing the Elinvar characteristics became narrower with chromium content. The temperature coefficient of delay time determined from the values of alpha and e was very small. The corrosion resistance of these alloys was extremely improved by chromium addition.

Kikuci, M.↗