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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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Explosive bonding process produces sheet composites of aluminum alloy reinforced by high-strength stainless steel wires. The bonds are excellent metallurgically, no external heat is required, various metals can be bonded, and the process is inexpensive.
Impact strength of Cu, Cu-Ni alloy and superalloy matrices reinforced with W fibers, studying temperature, heat treatment and fiber content and toughness effects
The application of fiber composites to aeronautical and space vehicle systems indicates the following: It appears quite probable that resin/fiber composites can be developed for service at 315 C for several thousand hours and at 370 C for a few hundred hours. The retention of resin/fiber strength at these high temperatures can be achieved by modifying the polymer molecular structure or by developing new processing techniques, or both. Carbon monofilament with attractive strength values has been produced and fabrication studies to reinforce aluminum with such monofilaments have been initiated. Refractory wire-superalloy composites have demonstrated sufficiently high strength and impact values to suggest that they have potential for application to turbine blades at temperatures to 1200 C and above.
The continuing efforts in upscaling to produce larger diameter Al/B tubes are described. While the basic methodology remains unchanged, the larger volume of acrylic binder material and its removal by dissolution in toluene had to be performed by dynamic scrubbing. Similarly, the boron and MCF continuous length requirements increased when a 6 foot long by 7 inches wide mat was needed. These modifications and associated problems are described fully with schematics. Also included are seven experiments conducted to prepare larger tubes. The thermal profile, drawing speeds, and furnace positions in the draw bench bay are presented along with metallographic evidence of composite cross sections.
Research directed toward the application of fiber composites to aeronautical and space vehicle systems indicates that resin/fiber composites can be developed for service at 315 C for several thousand hours and at 370 C for a few hundred hours. The retention of resin/fiber strength at these high temperatures can be achieved by modifying the polymer molecular structure or by developing new processing techniques, or both. Carbon monofilament with attractive strength values has been produced and fabrication studies to reinforce aluminum with such monofilaments have been initiated. Refractory wire-superalloy composites have demonstrated sufficiently high strength and impact values to suggest that they have potential for application to turbine blades at temperatures to 1200 C and above.
Glass composition research was conducted to produce a high modulus, high strength beryllium-free glass fiber. This program was built on the previous research for developing high modulus, high strength glass fibers which had a 5 weight percent beryllia content. The fibers resulting from the composition program were then used to produce fiber reinforced-epoxy resin composites which were compared with composites reinforced by commercial high modulus glass fibers, Thornel S graphite fiber, and hybrids where the external quarters were reinforced with Thornel S graphite fiber and the interior half with glass fiber as well as the reverse hybrid. The composites were given tensile strength, compressive strength, short-beam shear strength, creep and fatigue tests. Comments are included on the significance of the test data.
Attempts made to develop processes capable of producing metal composites in structural shapes and sizes suitable for space applications are described. The processes must be continuous and promise to lower fabrication costs. Special attention was given to the aluminum boride (Al/b) composite system. Results show that despite adequate temperature control, the consolidation characteristics did not improve as expected. Inadequate binder removal was identified as the cause responsible. An Al/c (aluminum-graphite) composite was also examined.
A report is presented of the current status of development of five materials which might be used in the design of components for advanced aircraft propulsion systems. Boron fiber/aluminum, boron fiber/titanium, and silicon carbide fiber/titanium composites are considered for lightweight compressor fan blades. Directionally solidified eutectic superalloy and tungsten wire/superalloy composites could possibly be used in the design of turbine blades for operational temperatures as high as 1100 C.
Residual stresses in composites are induced during fabrication and by environmental exposure. The theory formulated can describe the shrinkage commonly observed after a thermal expansion test. Comparison between the analysis and experimental data for laminates of various material systems indicates that the residual stress-free temperature can be lower than the curing temperature, depending on the curing process. Effects of residual stresses on ply failure including the acoustic emission characteristics are discussed.
Current epoxy resins utilized in high performance structural composites absorb moisture from high humidity environments. Such moisture absorption causes plasticization of the resin to occur with concurrent swelling and lowering of the glass transition temperature. Similar effects are observed in composites. Data are presented showing the effects of absorbed moisture on Hercules AS/3501-5 graphite/epoxy composites. Prediction of moisture content and distribution in composites, along with reduction in mechanical properties, are discussed.
Several multiply graphite polyimide composite specimens were examined by real-time infrared thermography in order to study the effects of moisture on their thermograms. Heat was injected from one side and IR emission detected on the opposite side using AGA Thermovision System-680. No differences between the thermograms of dry and water containing specimens were detected for defect-free specimens. However, the presence of trapped water in defective specimens modified the thermographic contrast significantly. It is concluded that: (1) IR thermography can be used to detect moisture in defective composites, and (2) because of the possibility of moisture camouflaging defects, IR thermography for subsurface defect detection should be supplemented by other techniques - such as acoustical imaging and X-radiography.
A composite that can be used at temperatures up to 875 K with mechanical properties equal or superior to graphite fiber reinforced epoxy composites is presented. The composite system consist of graphite fiber, uniaxially or biaxially, reinforced borosilicate glass. The mechanical and thermal properties of such a graphite fiber reinforced glass composite are described, and the system is shown to offer promise as a high performance structural material. Specific properties that were measured were: a modified borosilicate glass uniaxially reinforced by Hercules HMS graphite fiber has a three-point flexural strength of 1030 MPa, a four-point flexural strength of 964 MPa, an elastic modulus of 199 GPa and a failure strain of 0.0052. The preparation and properties of similar composites with Hercules HTS, Celanese DG-102, Thornel 300 and Thornel Pitch graphite fibers are also described.
Dynamic modulus and damping capacity property data were measured from 20 to over 500 C for unidirectional B/Al (1100), B/Al (6061), B/SiC/Al (6061), Al2O3/Al, SiC/Ti-6Al-4V, and SiC/Ti composites. The measurements were made under vacuum by the forced vibration of composite bars at free-free flexural resonance near 2000 Hz and at amplitudes below 0.000001. Whereas little variation was observed in the dynamic moduli of specimens with approximately the same fiber content (50 percent), the damping of B/Al composites was found at all temperatures to be significantly greater than the damping of the Al2O3/Al and SiC/Ti composites. For those few situations where slight deviations from theory were observed, the dynamic data were examined for information concerning microstructural changes induced by composite fabrication and thermal treatment. The 270 C damping peak observed in B/Al (6061) composites after heat treatment above 460 C appears to be the result of a change in the 6061 aluminum alloy microstructure induced by interaction with the boron fibers. The growth characteristics of the damping peak suggest its possible value for monitoring fiber strength degration caused by excess thermal treatment during B/Al (6061) fabrication and use.
Metal fiber reinforced superalloys are being considered for construction of critical components in turbine engines that operate at high temperature. The problems involved in fabricating refractory metal alloys into wire form in such a manner as to maximize their strength properties without developing excessive structural defects are described. The fundamental principles underlying the development of such alloy fibers are also briefly discussed. The progress made to date in developing tungsten, tantalum and columbium base alloys for fiber reinforcement is reported and future prospects for alloy fiber development considered.
Flexture and short beam shear specimens of a graphite epoxy and a graphite polymimide composite material were tested in an arc tunnel environment. The materials were subjected to seven heating rates from 12.5 to 308 kW/sw m for test times from 5 to 1000 seconds. The temperature response of the specimens was measured and the strength degradation caused by the various heating environments was determined.
Dynamic modulus and damping capacity property data were measured from 20 to over 500 C for unidirectional B/Al (1100), B/Al (6061), B/SiC/Al (6061), Al2O3/Al, SiC/Ti-6Al-4V, and SiC/Ti composites. The measurements were made under vacuum by the forced vibration of composite bars at free-free flexural resonance near 2000 Hz and at strain application below 0.000001. The damping of B/Al composites was found at all temperatures to be significantly greater than the damping of the Al2O3/Al and SiC/Ti composites, with little variation observed in the dynamic moduli of specimens having almost the same fiber content. It is concluded that on the practical level, the finding of a damping-strength correlation supports the use of composite damping measurements for the nondestructive evaluation of boron fiber strength in as-fabricated and heat-treated B/Al (6061) composites.
G/GI structural composite material made of graphite fibers embedded in borosilicate glass exhibit excellent strength, fracture toughness, and dimensional stability at elevated temperatures. It is made by passing graphite-fiber yarn through slurry containing suspension of fine glass particles in carrier liquid and winding on drum to produce prepegged uniaxial tape. After drying, tapes are cut into appropriate lengths and laid up in graphite die in desired stacking scheme. Stack is consolidated by hot pressing in furnace.
Design approaches and materials are described from which are fabricated pyrostatic graphite/epoxy (Gr/Ep) laminates that show improved retention of graphite particulates when subjected to burning. Sixteen hybridized plus two standard Gr/Ep laminates were designed, fabricated, and tested in an effort to eliminate the release of carbon (graphite) fiber particles from burned/burning, mechanically disturbed samples. The term pyrostatic is defined as meaning mechanically intact in the presence of fire. Graphite particulate retentive laminates were constructed whose constituent materials, cost of fabrication, and physical and mechanical properties were not significantly different from existing Gr/Ep composites. All but one laminate (a Celion graphite/bis-maleimide polyimide) were based on an off-the-shelf Gr/Ep, the AS-1/3501-5A system. Of the 16 candidates studied, four thin (10-ply) and four thick (50-ply) hybridized composites are recommended.