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At least 667 records · Page 37

Effects of thermal and environmental exposure on the mechanical properties of graphite/polyimide composites.

Composites were exposed in circulating and static air environments up to 600 F for a maximum of 1000 hours. Composites of HT-S, HM-S, Thornel 50S, and Fortafil 5-Y fiber and a new addition type polyimide resin were laminated in a matched-die mold. Flexural strength, flexural modulus, and interlaminar shear strengths were determined at 75, 500 and 600 F after various durations of exposure. Composite and fiber weight loss characteristics were determined by isothermal gravimetric analysis in air. Properties of composites exposed and tested at the environment temperatures are compared with those determined under short-term exposure. A new short beam interlaminar shear fixture is described. Environmental effects of long-term (up to one year) ambient temperature exposure on the elevated temperature mechanical properties of graphite/polyimide composites are presented.

Hanson, M. P.↗

Microstructure and mechanical properties of bulk and plasma-sprayed y2O3-partially stabilized zirconia

Bulk 8.0 weight percent yttria partially stabilied zirconia (PSZ) was studied by light microscopy, transmission electron microscopy, X-ray analysis, microhardness testing, and fracture toughness testing. The as received PSZ contained spheroidal and grain boundary precipitates up to 4 micrometers in size. Spheroids up to 1.26 micrometers were metastable tetragonal; large spheroids were monoclinic. Grinding the PSZ into powder did not cause a significant amount of tetragonal to transform to monoclinic. This indicates that transformation toughness is not a significant mechanism in PSZ. Aging the PSZ at 1500 C caused the fine tetragonal precipitates to grow from 0.06 to 0.12 micrometers, in 250 minutes. A peak hardness of 1400 kg/sq mm was attained after 50 minutes. Solution annealing and quenching the as received PSZ eliminated the large precipitates, but fine tetragonal precipitates reformed on quenching. Aging at 1500 C caused the fine 0.02 micrometers tetragonal precipitates to grow into plates about 0.10 by 0.50 micrometers. A peak hardness of 1517 kg/sq mm was obtained after 250 minutes. On further aging, monoclinic percipitates formed along grain boundaries. The fracture toughness of the aged and unaged solution annealed and quenched PSZ was found to be between 2 and 3 MN /square root of m cubed. This range of fracture toughness is consistent with PSZ's that do not undergo transformation toughening.

Valentine, P. G.↗

Application of advanced material systems to composite frame elements

A three phase program has been conducted to investigate DuPont's Long Discontinuous Fiber (LDF) composites. Additional tests were conducted to compare LDF composites against toughened thermosets and a baseline thermoset system. Results have shown that the LDF AS4/PEKK offers improved interlaminar (flange bending) strength with little reduction in mechanical properties due to the discontinuous nature of the fibers. In the third phase, a series of AS4/PEKK LDF C-section curved frames (representing a typical rotorcraft light frame) were designed, manufactured and tested. Specimen reconsolidation after 'stretch forming' and frame thickness were found to be key factors in this light frame's performance. A finite element model was constructed to correlate frame test results with expected strain levels determined from material property tests. Adequately reconsolidated frames performed well and failed at strain levels at or above baseline thermoset material test strains. Finally a cost study was conducted which has shown that the use of LDF for this frame would result in a significant cost savings, for moderate to large lot sizes compared with the hand lay-up of a thermoset frame.

Llorente, Steven↗

Properties of powder-impregnated graphite/PEKK

Poly Ether Ketone Ketone (PEKK) powders were prepregged on AS4 (12K), IM7 (12K), and G30-500 (12K) carbon fibers and consolidated into unidirectional laminates. The preferred formulation of PEKK for the dry powder process was identified. Mechanical test data on panels prepared via the powder process agreed well with flex, short beam shear, and double cantilever beam values obtained previously on melt-impregnated material. IM7/PEKK composites showed superior mechanical properties to AS4/PEKK and G30-500/PEKK composites. Transverse flexural strength and fiber/resin contact angle correlated well as measures of the fiber/matrix interfacial strength.

Bucher, R. A.↗

Effect of bond coat creep and oxidation on TBC integrity

The potential of thermal barrier coatings (TBCs) on high-pressure turbine (HPT) nozzles and blades is limited at present by the inability to quantitatively predict TBC life for these components. The goal is to isolate the major TBC failure mechanisms, which is part of the larger program aimed at developing TBC life prediction models. Based on the results of experiments to isolate TBC failure mechanisms, the effects of bond coat oxidation and bond coat creep on TBC integrity is discussed. In bond coat oxidation experiments, Rene prime 80 specimens coated with a NiCrAlY/ZrO2-8 percent Y2O3 TBC received isothermal pre-exposures at 2000 F in static argon, static air, or received no pre-exposure. The effects of oxidation due to the pre-exposures were determined by thermal cycle tests in both static air and static argon at 2000 F. To study the effect of bond coat creep on TBS behavior, four bond coats with different creep properties were evaluated by thermal cycle tests in air at 2000 F. The test results, the relative importance of these two failure mechanisms, and how their effects may be quantified will also be discussed.

Duderstadt, E. C.↗

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and facesheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Damage↗

The MECA Payload as a Dust Analysis Laboratory on the MSP 2001 Lander

In a companion abstract, the "Mars Environmental Compatibility Assessment" (MECA) payload for Mars Surveyor Program 2001 (MSP 2001) is described in terms of its capabilities for addressing exobiology on Mars. Here we describe how the same payload elements perform in terms of gathering data about surface dust on the planet. An understanding of the origin and properties of dust is important to both human exploration and planetary geology. The MECA instrument is specifically designed for soil/dust investigations: it is a multifunctional laboratory equipped to assess particulate properties with wet chemistry, camera imagery, optical microscopy (potentially with LTV fluorescence capability), atomic force microscopy (AFM; potentially with mineral-discrimination capabilities), electrometry, active & passive external materials-test panels, mineral hardness testing, and electrostatic & magnetic materials testing. Additionally, evaluation of soil chemical and physical properties as a function of depth down to about 50 cm will be facilitated by the Lander/MECA robot arm on which the camera (RAC) and electrometer are mounted. Types of data being sought for the dust include: (1) general textural and grain-size characterization of the soil as a whole --for example, is the soil essentially dust with other components or is it a clast-supported material in which dust resides only in the clast interstices, (2) size frequency distribution for dust particles in the range 0.01 to 10.00 microns, (3) particle-shape distribution of the soil components and of the fine dust fraction in particular, (4) soil fabric such as grain clustering into clods, aggregates, and cemented/indurated grain amalgamations, as well as related porosity, cohesiveness, and other mechanical soil properties, (5) cohesive relationship that dust has to certain types of rocks and minerals as a clue to which soil materials may be prime hosts for dust "piggybacking", (6) particle, aggregate, and bulk soil electrostatic properties, (7) particle hardness, (8) particle magnetic properties, (9) bulk dust geochemistry (solubility, reactivity, ionic and mineral species). All of these quantities are needed in order for the human exploration program to make assessments of hazards on Mars, and to better enable the production on earth, of soil/dust simulants that can act as realistic test materials in terms of those properties that render dust a contaminant.Such properties include the small grain size that enables penetration of space-suit joints, mechanical interfaces and bearings, seals, etc., and presents difficulty for filtration systems. Size also plays a critical role in the potential for lung disease in long-term habitats. The properties of grain shape and hardness are important parameters in determining the abrasiveness of dust as it enters mechanical systems, or bombards helmet visors and habitat windows in dust-laden winds. Adhesive electrostatic and magnetic properties of dust will be prime causes of contamination of space suits and equipment. Contamination causes mechanical malfunction, tracking of dirt into habitats, "piggybacking" of toxins on dust into habitats, changes in albedo and efficiency of solar arrays and heat exchangers, and changes in electrical conductivity of suit surfaces and other materials that may have specific safety requirements regarding electrical conductivity. Other potentially hazardous properties of dust include the possibility of high solubility of some component grains (rendering them reactive), and toxicity of some materials --grains of superoxidants and heavy metals (there is always the slim, but not inconceivable possibility of biogenic components such as spores). Because Mars has no active surface aqueous regime, volcanic emissions, meteoritic debris, weathering products, and photochemical products of Mars have nowhere to go except reside in the surface; there are few mechanical or chemical (buffering) processes to remove the accumulation of eons. From a planetology perspective, there are many enigmatic issues relating to dust and the aeolian regime in general. MECA will be able to address many questions in this area. For example, if MECA determines a particular particle size distribution (size and sorting values), it will be possible to make inferences about the origin of the dust - - is it all aeolian, or a more primitive residue of weathering, volcanic emissions, and meteoritic gardening? Trenching with the Lander/MECA robot arm will enable local stratigraphy to be determined in terms of depositional rates, amounts and cyclicity in dust storms and/or local aeolian transport. Grain shape will betray the origin of the dust fragments as being the product of recent or ancient weathering, or the comminution products of aeolian transport --the dust-silt ratio might be a measure of aeolian comminution energy. Additional information is contained in the original.

Marshall, J.↗

Long-time dynamic compatibility of two ethylene propylene elastomers with hydrazine

A test method is described for predicting the long-time survivability of elastomers in hydrazine under dynamic stressing conditions. The method selected is based upon the existence and approximate invariance of a 'physical property surface' relating the mechanical response of the elastomer in terms of stress, strain, time, and temperature. The property surface was generated for two selected elastomers (EPT-10 and AF-E-332). A novel carousel testing tank was designed to allow sequential testing of eight tensile specimens immersed in liquid hydrazine within a constant-temperature water bath. The test procedure and data reduction methods used to generate the property surface are described. The utility and validity of these results applied to fatigue and flexure loading to these elastomeric materials over long-time periods are discussed.

Coulbert, C. D.↗

1300 K compressive properties of several dispersion strengthened NiAl materials

To examine the potential of rapid solidification technology (RST) as a means to fabricate dispersion-strengthened aluminides, cylindrical compression samples were machined from the gauge section of their tensile specimens and tested in air at 1300 K. While microscopy indicates that RST can produce fine dispersions of TiB2, TiC and HfC in a NiAl matrix, the mechanical property data reveal that only HfC successfully strengthens the intermetallic matrix. The high stress exponents (above 10) and/or independence of strain rate on stress for NiAl-HfC materials suggest elevated temperature mechanical behavior similar to that found in oxide dispersion-strengthened alloys. Furthermore, an apparent example of departure side pinning has been observed, and as such, it is indicative of a threshold stress for creep.

Whittenberger, J. Daniel↗

Simulating the Response of a Composite Honeycomb Energy Absorber: Dynamic Crushing of Components and Multi-Terrain Impacts - Part 1

This paper describes the experimental and analytical evaluation of an externally deployable composite honeycomb structure that is designed to attenuate impact energy during helicopter crashes. The concept, designated the Deployable Energy Absorber (DEA), utilizes an expandable Kevlar (Registered Trademark) honeycomb to dissipate kinetic energy through crushing. The DEA incorporates a unique flexible hinge design that allows the honeycomb to be packaged and stowed until needed for deployment. Experimental evaluation of the DEA included dynamic crush tests of multi-cell components and vertical drop tests of a composite fuselage section, retrofitted with DEA blocks, onto multi-terrain. Finite element models of the test articles were developed and simulations were performed using the transient dynamic code, LSDYNA (Registered Trademark). In each simulation, the DEA was represented using shell elements assigned two different material properties: Mat 24, an isotropic piecewise linear plasticity model, and Mat 58, a continuum damage mechanics model used to represent laminated composite fabrics. DEA model development and test-analysis comparisons are presented.

Jackson, Karen E.↗

Ground Laboratory Soft X-Ray Durability Evaluation of Aluminized Teflon FEP Thermal Control Insulation

Metallized Teflon fluorinated ethylene propylene (FEP) thermal control insulation is mechanically degraded if exposed to a sufficient fluence of soft x-ray radiation. Soft x-ray photons (4-8 A in wavelength or 1.55 - 3.2 keV) emitted during solar flares have been proposed as a cause of mechanical properties degradation of aluminized Teflon FEP thermal control insulation on the Hubble Space Telescope (HST). Such degradation can be characterized by a reduction in elongation-to-failure of the Teflon FER Ground laboratory soft x-ray exposure tests of aluminized Teflon FEP were conducted to assess the degree of elongation degradation which would occur as a result of exposure to soft x-rays in the range of 3-10 keV. Tests results indicate that soft x-ray exposure in the 3-10 keV range, at mission fluence levels, does not alone cause the observed reduction in elongation of flight retrieved samples. The soft x-ray exposure facility design, mechanical properties degradation results and implications will be presented.

Banks, Bruce A.↗

Ground Laboratory Soft X-Ray Durability Evaluation of Aluminized Teflon FEP Thermal Control Insulation

Metallized Teflon fluorinated ethylene propylene (FEP) thermal control insulation is mechanically degraded if exposed to a sufficient fluence of soft x-ray radiation. Soft x-ray photons (4-8 A in wavelength or 1.55 - 3.2 keV) emitted during solar flares have been proposed as a cause of mechanical properties degradation of aluminized Teflon FEP thermal control insulation on the Hubble Space Telescope (HST). Such degradation can be characterized by a reduction in elongation-to-failure of the Teflon FEP. Ground laboratory soft x-ray exposure tests of aluminized Teflon FEP were conducted to assess the degree of elongation degradation which would occur as a result of exposure to soft x-rays in the range of 3-10 keV. Tests results indicate that soft x-ray exposure in the 3-10 keV range, at mission fluence levels, does not alone cause the observed reduction in elongation of flight retrieved samples. The soft x-ray exposure facility design, mechanical properties degradation results and implications will be presented.

Banks, Bruce A.↗

Radiation Durability of Candidate Polymer Films for the Next Generation Space Telescope Sunshield

The Next Generation Space Telescope (NGST), anticipated to be launched in 2009 for a 10-year mission, will make observations in the infrared portion of the spectrum to examine the origins and evolution of our universe. Because it must operate at cold temperatures in order to make these sensitive measurements, it will use a large, lightweight, deployable sunshield, comprised of several polymer film layers, to block heat and stray light. This paper describes laboratory radiation durability testing of candidate NGST sunshield polymer film materials. Samples of fluorinated polyimides CP1 and CP2, and a polvarylene ether benzimidazole. TOR-LM(TM), were exposed to 40 keV electron and 40 keV proton radiation followed by exposure to vacuum ultraviolet (VUV) radiation in the 115 to 200 nm wavelength range. Samples of these materials were also exposed to VUV without prior electron and proton exposure. Samples of polyimides Kapton HN, Kapton E, and Upilex-S were exposed to electrons and protons only, due to limited available exposure area in the VUV facility. Exposed samples were evaluated for changes in solar absorptance and thermal emittance and mechanical properties of ultimate tensile strength and elongation at failure. Data obtained are compared with previously published data for radiation durability testing of these polymer film materials.

Dever, Joyce↗

Assessment of Technologies for the Space Shuttle External Tank Thermal Protection System and Recommendations for Technology Improvement - Part III: Material Property Characterization, Analysis, and Test Methods

The objective of this report is to contribute to the independent assessment of the Space Shuttle External Tank Foam Material. This report specifically addresses material modeling, characterization testing, data reduction methods, and data pedigree. A brief description of the External Tank foam materials, locations, and standard failure modes is provided to develop suitable background information. A review of mechanics based analysis methods from the open literature is used to provide an assessment of the state-of-the-art in material modeling of closed cell foams. Further, this report assesses the existing material property database and investigates sources of material property variability. The report presents identified deficiencies in testing methods and procedures, recommendations for additional testing as required, identification of near-term improvements that should be pursued, and long-term capabilities or enhancements that should be developed.

Gates, Thomas S.↗

The influence of growth speed, orientation and environment on fracture of aligned Al-CuAl2

There has been considerable interest in the mechanical properties of aligned eutectics as functions of microstructure, orientation between reinforcement and stress axis, and temperature of testing. However, little is known about the behavior of these alloys in aggressive environments, such as liquid metals, with the exception of a recent paper on embrittlement of several eutectic alloys in gallium and gallium-indium alloys. This paper is concerned with the effects of a liquid Ga-16%In solution on tensile behavior of an aligned Al-CuAl2 eutectic.

Skiff, P. K.↗

Weld geometry strength effect in 2219-T87 aluminum

A theory of the effect of geometry on the mechanical properties of a butt weld joint is worked out based upon the soft interlayer weld model. Tensile tests of 45 TIG butt welds and 6 EB beads-on-plate in 1/4-in. 2219-T87 aluminum plate made under a wide range of heat sink and power input conditions are analyzed using this theory. The analysis indicates that purely geometrical effects dominate in determining variations in weld joint strength with heat sink and power input. Variations in weld dimensions with cooling rate are significant as well as with power input. Weld size is suggested as a better indicator of the condition of a weld joint than energy input.

Nunes, A. C., Jr.↗

Materials for Advanced Turbine Engines (MATE): Project 3: Design, fabrication and evaluation of an oxide dispersion strengthened sheet alloy combustor liner, volume 1

The suitability of wrought oxide dispersion strengthened (ODS) superalloy sheet for gas turbine engine combustor applications was evaluated. Incoloy MA 956 (FeCrAl base) and Haynes Developmental Alloy (HDA) 8077 (NiCrAl base) were evaluated. Preliminary tests showed both alloys to be potentially viable combustor materials, with neither alloy exhibiting a significant advantage over the other. Both alloys demonstrated a +167C (300 F) advantage of creep and oxidation resistance with no improvement in thermal fatigue capability compared to a current generation combustor alloy (Hastelloy X). MA956 alloy was selected for further demonstration because it exhibited better manufacturing reproducibility than HDA8077. Additional property tests were conducted on MA956. To accommodate the limited thermal fatigue capability of ODS alloys, two segmented, mechanically attached, low strain ODS combustor design concepts having predicted fatigue lives or = 10,000 engine cycles were identified. One of these was a relatively conventional louvered geometry, while the other involved a transpiration cooled configuration. A series of 10,000 cycle combustor rig tests on subscale MA956 and Hastelloy X combustor components showed no cracking, thereby confirming the beneficial effect of the segmented design on thermal fatigue capability. These tests also confirmed the superior oxidation and thermal distortion resistance of the ODS alloy. A hybrid PW2037 inner burner liner containing MA956 and Hastelloy X components was designed and constructed.

Henricks, R. J.↗