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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 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Development of an impact- and solvent-resistant thermoplastic composite matrix, phase 4

Polyimides from BTDA with m-phenylenediamine and three aliphatic diamines were prepared in cresol and characterized. Characterization tests included compression strength and modulus, stressed solvent resistance, and melt-flow tests. Efforts to reduce the molecular weights of these polymers by either stoichiometric imbalance or phthalic anhydride end capping produced opacity in the polymer moldings when the stoichiometry was less than 99 percent. Use of 2,4-diaminotoluene in place of the m-phenylenediamine allowed clear polymer moldings to be obtained at all stoichiometries by end capping or stoichiometric imbalance. After melt-flow/molecular-weight studies, carbon fabric composites were prepared from three polyimide compositions containing BTDA, 2,4-diaminotoluene and two aliphatic diamines. Flexural strengths of two of the resins were in excess of 689 MPa (100 ksi) at both room temperature and 93 C. The polyimide from BTDA was selected for scale-up and neat resin characterization tests. The Tg of this polymer was 233 C.

Delano, C. B.↗
NASA NTRS1985

Improved silicon nitride for advanced heat engines

The AiResearch Casting Company baseline silicon nitride (92 percent GTE SN-502 Si sub 3 N sub 4 plus 6 percent Y sub 2 O sub 3 plus 2 percent Al sub 2 O sub 3) was characterized with methods that included chemical analysis, oxygen content determination, electrophoresis, particle size distribution analysis, surface area determination, and analysis of the degree of agglomeration and maximum particle size of elutriated powder. Test bars were injection molded and processed through sintering at 0.68 MPa (100 psi) of nitrogen. The as-sintered test bars were evaluated by X-ray phase analysis, room and elevated temperature modulus of rupture strength, Weibull modulus, stress rupture, strength after oxidation, fracture origins, microstructure, and density from quantities of samples sufficiently large to generate statistically valid results. A series of small test matrices were conducted to study the effects and interactions of processing parameters which included raw materials, binder systems, binder removal cycles, injection molding temperatures, particle size distribution, sintering additives, and sintering cycle parameters.

Yeh, H. C.↗
NASA NTRS1989

Differential Curing In Fiber/Resin Laminates

Modified layup schedule counteracts tendency toward delamination. Improved manufacturing process resembles conventional process, except prepregs partially cured laid on mold in sequence in degree of partial cure decreases from mold side to bag side. Degree of partial cure of each layer at time of layup selected by controlling storage and partial-curing temperatures of prepreg according to Arrhenius equation for rate of gel of resin as function of temperature and time from moment of mixing. Differential advancement of cure in layers made large enough to offset effect of advance bag-side heating in oven or autoclave. Technique helps prevent entrapment of volatile materials during manufacturing of fiber/resin laminates.

Webster, Charles N.↗
NASA NTRS1989

On processing development for fabrication of fiber reinforced composite, part 2

Fiber-reinforced composite laminates are used in many aerospace and automobile applications. The magnitudes and durations of the cure temperature and the cure pressure applied during the curing process have significant consequences for the performance of the finished product. The objective of this study is to exploit the potential of applying the optimization technique to the cure cycle design. Using the compression molding of a filled polyester sheet molding compound (SMC) as an example, a unified Computer Aided Design (CAD) methodology, consisting of three uncoupled modules, (i.e., optimization, analysis and sensitivity calculations), is developed to systematically generate optimal cure cycle designs. Various optimization formulations for the cure cycle design are investigated. The uniformities in the distributions of the temperature and the degree with those resulting from conventional isothermal processing conditions with pre-warmed platens. Recommendations with regards to further research in the computerization of the cure cycle design are also addressed.

Hou, Tan-Hung↗
NASA NTRS1990

Borescope Device Takes Impressions In Ducts

Maneuverable device built around borescope equipped to make impression molds of welded joints in interior surfaces of ducts. Molds then examined to determine degress of mismatch in welds. Inserted in duct, and color-coded handles on ends of cables used to articulate head to maneuver around corners. Use of device fairly easy and requires little training.

Walter, Richard F.↗
NASA NTRS1990

Braided Composite Threaded Fasteners

Fasteners of carbon/carbon or other fiber/matrix composite materials made by braiding-and-molding process. Preform of braided fibers impregnated with matrix material pressed and cured in internally threaded, split mold to make externally threaded rod. Process costs less, produces stronger fasteners by avoiding breakage of fibers, and adaptable to mass production. Intended for use with ceramic and composite-material structural parts at temperatures approximately greater than 2,500 degrees F (approximately greater than 1,400 degrees C), at which metal fasteners cannot be used.

Sawyer, James Wayne↗
NASA NTRS1987

Improved silicon carbide for advanced heat engines

This is the second annual technical report entitled, Improved Silicon Carbide for Advanced Heat Engines, and includes work performed during the period February 16, 1986 to February 15, 1987. The program is conducted for NASA under contract NAS3-24384. The objective is the development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines. The fabrication methods used are to be adaptable for mass production of such parts on an economically sound basis. Injection molding is the forming method selected. This objective is to be accomplished in a two-phase program: (1) to achieve a 20 percent improvement in strength and a 100 percent increase in Weibull modulus of the baseline material; and (2) to produce a complex shaped part, a gas turbine rotor, for example, with the improved mechanical properties attained in the first phase. Eight tasks are included in the first phase covering the characterization of the properties of a baseline material, the improvement of those properties and the fabrication of complex shaped parts. Activities during the first contract year concentrated on two of these areas: fabrication and characterization of the baseline material (Task 1) and improvement of material and processes (Task 7). Activities during the second contract year included an MOR bar matrix study to improve mechanical properties (Task 2), materials and process improvements (Task 7), and a Ford-funded task to mold a turbocharger rotor with an improved material (Task 8).

Whalen, Thomas J.↗
NASA NTRS1989

The 3F condensation polyimides: Review and update

Nine new condensation polyimides containing the phenyltrifluoroethylidene (3F) linkage were synthesized by the amic-acid route. Several other polyimides, including some with hexafluoroisopropylidene (6F) linkage, were also prepared as controls. Amic-acid solutions were characterized by determining their inherent viscosities prior to thermal conversion into polyimide films. Glass transition temperatures (T sub g), thermogravimetric analysis (TGA), and isothermal weight loss data (at 316, 371, and 371 C under 0.5 MPa air pressure) were obtained for the films. The films were pulverized into molding powders which, in turn, were thermally processed under pressure into neat resin disks. The disks were also characterized by T sub g's and 316 and 371 C isothermal weight losses. The film study identified two new polyimides with T sub g's greater than 371 C and two new polyimides with low rates of weight loss. The resin disks exhibited the same overall trends in T sub g and weight loss as the respective films, however the weight loss per unit surface area was always greater, presumably due to molecular degradation induced during preparation of the molding powders. The overall results indicate that polyimides containing the 3F linkage have T sub g's and thermo-oxidative stability comparable to polyimides containing the 6F group. Alternate technology was also shown by the synthesis of two new polyalkyl substituted 3F diamines and five more new 3F polymers. Their potential as photoresists was demonstrated by T sub g advancement after ultraviolet exposure. Last, four U.S. patents on 3F monomers and polymers were issued and up to eight more are pending.

Alston, William B.↗
NASA NTRS1989

Pressure rig for repetitive casting

The invention is a pressure rig for repetitive casting of metal. The pressure rig performs like a piston for feeding molten metal into a mold. Pressure is applied to an expandable rubber diaphragm which expands like a balloon to force the metal into the mold. A ceramic cavity which holds molten metal is lined with blanket-type insulating material, necessitating only a relining for subsequent use and eliminating the lengthy cavity preparation inherent in previous rigs. In addition, the expandable rubber diaphragm is protected by the insulating material thereby decreasing its vulnerability to heat damage. As a result of the improved design the life expectancy of the pressure rig contemplated by the present invention is more than doubled. Moreover, the improved heat protection has allowed the casting of brass and other alloys with higher melting temperatures than possible in the conventional pressure rigs.

Vasquez, Peter↗
NASA NTRS1990

Plastic superconductor bearings any size, any shape, 77 k and up

Friction free bearings at 77 k or higher are possible using the high T(sub c) copper oxide ceramic superconductors. The conventional method for making such bearings is to use a sintered ceramic monolith. This puts great restraints on size, shape and postforming machining. The material is hard and abrasive. It's possible to grind up ceramic superconductors and suspend the granules in a suitable matrix. Mechanical properties improve and are largely dependent on the binder. The Meissner effect is confined to individual grains containing electron vortices. Tracks, rails, levitation areas and bearings can be made this way with conventional plastic molding and extruding machines or by painting. The parts are easily machined. The sacrifice is in bulk electrical conductivity. A percolating wick feel for LN2 can be used to cool remote superconductors and large areas quite effectively. A hollow spheroid or cylinder of superconductor material can be molded with the internal surfaces shielded by the Meissner effect. It might be thought of as the dc magnetic analogue of the Faraday cage and the inside can be called the Meissner space. It's selective. The ac fields are transmitted with minor attenuation. Particle size and distribution have a profound effect on final magnetic and electrical characteristics.

Reick, Franklin G.↗
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 NTRS1989

Manufacture of composite test specimens for delamination studies

This paper describes the process for manufacturing high-quality test specimens for uses in evaluations of interlaminar tensile strength of laminated composites. The chosen specimen configuration is a curved beam which experiences interlaminar tension in the region of greatest curvature when the beam is subjected to 'opening' forces. The manufacturing process uses a lock-mold tooling approach, the principle of which relies upon the difference in coefficients of thermal expansion between the internal rubber mandrel and the surrounding steel female mold. With this method, compaction pressures above those provided by a typical autoclave can be achieved.

Sumich, M.↗
NASA NTRS1990

A new fabrication method for precision antenna reflectors for space flight and ground test

The use of higher frequencies on communications satellites has led to the requirement for increasingly precise antenna reflectors for use in space. Typical industry fabrication methods for space antenna reflectors employ successive molding techniques for reflector face sheets and a final fit-up to a master mold in order to achieve the required accuracies. However, new missions at much higher frequencies will require greater accuracies than may be achievable using these present methods. A new approach for the fabrication of ground-test antenna reflectors is to machine the reflective surface into a stainless steel and fiberglass composite structure. A 2.7-m diameter ground-test antenna reflector fabricated using this method has an accuracy of better than 0.013 mm (0.0005 in.) rms. A similar design concept for a solid surface reflector for use on spacecraft would involve fabrication in a similar manner but using space-qualified materials. This report describes the design, analysis, and fabrication of the 2.7-m-diameter precision antenna reflector for antenna ground test and the extension of this technology to precision space antenna reflectors.

Sharp, G. Richard↗
NASA NTRS1991

New Polyimide Has Many Uses

Low-toxicity and low-mutogenicity monomer key to new high-performance polyimide. LaRC-IA is thermoplastic polyimide made from 3-4'-oxydianiline and 4,4'-oxydiphthalic anhydride. Good processing characteristics, low toxicity, and no mutagenicity. Adhesives, composite matrix resins, heat resin moldings, and coating films made of new polymer found to exhibit properties identical or superior to commercially available polyimides. Potential applications wide ranging. With and without end capping, employed to prepare unfilled moldings, coatings and free films, adhesive tape, adhesively bonded substrates, prepregs, and composites.

St. Clair, Terry L.↗
NASA NTRS1991

A semi-automated process for the production of custom-made shoes

A more efficient, cost-effective and timely way of designing and manufacturing custom footware is needed. A potential solution to this problem lies in the use of computer-aided design and manufacturing (CAD/CAM) techniques in the production of custom shoes. A prototype computer-based system was developed, and the system is primarily a software entity which directs and controls a 3-D scanner, a lathe or milling machine, and a pattern-cutting machine to produce the shoe last and the components to be assembled into a shoe. The steps in this process are: (1) scan the surface of the foot to obtain a 3-D image; (2) thin the foot surface data and create a tiled wire model of the foot; (3) interactively modify the wire model of the foot to produce a model of the shoe last; (4) machine the last; (5) scan the surface of the last and verify that it correctly represents the last model; (6) design cutting patterns for shoe uppers; (7) cut uppers; (8) machine an inverse mold for the shoe innersole/sole combination; (9) mold the innersole/sole; and (10) assemble the shoe. For all its capabilities, this system still requires the direction and assistance of skilled operators, and shoemakers to assemble the shoes. Currently, the system is running on a SUN3/260 workstation with TAAC application accelerator. The software elements of the system are written in either Fortran or C and run under a UNIX operator system.

Farmer, Franklin H.↗
NASA NTRS1986

Composite ingot casting

A method and system for continuously or semicontinuously casting a composite metal article, such as a structurally composite ingot or the like, wherein one of the principal structural components of the ingot comprises an aluminum-lithium alloy. During such casting by a D.C. (direct chill) conventional tubular mold or electromagnetic process, the aluminum-lithium structural component of a structurally composite ingot is encircled or peripherally encased by a· further outer metal cladding component that can be cast simultaneously with the aluminum-lithium component such as another outer aluminous alloy from which lithium is absent as a constituent or impurity, although it may be present and tolerated as a trace element. In this arrangement the aluminum-lithium structural component is prevented during casting from coming into direct contact with the chilling coolant, normally water, with which lithium can react violently. Only the outer aluminous alloy envelope is subjected to the direct contact of a liquid coolant whereby as it solidifies, this outer envelope or . peripheral sheath acts as an impervious secondary mold for and protects the inner aluminum--lithium alloy structural component which is then directly controllably chilled and solidified.

George J Binczewski↗
NASA NTRS1992

Durable, Low-Surface-Energy Treatments

Chemical treatment for creation of durable, low-surface-energy coatings for glass, ceramics and other protonated surfaces easily applied, and creates very thin semipermanent film with extremely low surface tension. Exhibits excellent stability; surfaces retreated if coating becomes damaged or eroded. Uses include water-repellent surfaces, oil-repellent surfaces, antimigration barriers, corrosion barriers, mold-release agents, and self-cleaning surfaces. Film resists wetting by water, alcohols, hydrocarbon solvents, and silicone oil. Has moderate resistance to abrasion, such as rubbing with cloths, and compression molding to polymers and composite materials.

Willis, Paul B.↗
NASA NTRS1992

Masks For Deposition Of Aspherical Optical Surfaces

Masks of improved design developed for use in fabrication of aspherical, rotationally symmetrical surfaces of mirrors, lenses, and lens molds by evaporative deposition onto rotating substrates. In deposition chamber, source and mask aligned with axis of rotation of substrate. Mask shadows source of rotating substrate. Azimuthal opening (as function of radius) in mask proportional to desired thickness (as function of radius) to which material deposited on substrate. Combination of improved masks and modern coating chambers provides optical surfaces comparable or superior to those produced by conventional polishing, computer-controlled polishing, replication from polished molds, and diamond turning, at less cost in material, labor, and capital expense.

Rogers, John R.↗