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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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All sources NASA NTRS DOE OSTI

NASA NTRS2000

Overview of TPS Tasks

The objectives of the project summarized in this viewgraph presentation are the following: (1) Develop a lightweight and low cost durable Thermal Protection System (TPS) for easy application to reusable launch vehicle payload launchers; (2) Develop quickly processed composite TPS processing and repair techniques; and (3) Develop higher temperature capability tile TPS. The benefits of this technology include reduced installation and operations cost, enhanced payload capability resulting from TPS weight reduction, and enhanced flight envelope and performance resulting from higher temperature capability TPS which can result in improved safety.

Johnson, Sylvia M.↗

NASA NTRS1994

Lamb Wave Response of Fatigued Composite Samples

Composite materials are being more widely used today by aerospace, automotive, sports equipment, and a number of other commercial industries because of their advantages over conventional metals. Composites have a high strength-to-weight ratio and can be constructed to meet specific design needs. Composite structures are already in use in secondary parts of the Douglas MD-11 and are planned to be used in the new MD-12X. Plans also exist for their use in primary and secondary structures on the Boeing 777. Douglas proposed MD-XX may also incorporate composite materials into primary structures such as the wings and tail. Use of composites in these structures offers weight savings, corrosion resistance, and improved aerodynamics. Additionally, composites have been used to repair cracks in many B-1Bs where traditional repair techniques were not very effective. Plans have also been made to reinforce all of the remaining B-1s with composite materials. Verification of the structural integrity of composite components is needed to insure safe operation of these aerospace vehicles. One aspect of the use of these composites is their response to fatigue. To track this progression of fatigue in aerospace structures, a convenient method to nondestructively monitor this damage needs to be developed. Traditional NDE techniques used on metals are not easily adaptable to composites due to the inhomogeneous and anisotropic nature of these materials. Finding an effective means of nondestructively monitoring fatigue damage is extremely important to the safety and reliability of such structures. Lamb waves offer one method of evaluating these composite materials. As a material is fatigued, the modulus degrades. Since the Lamb wave velocity can be related to the modulus of the material, an effective tool can be developed to monitor fatigue damage in composites by measuring the velocity of these waves. In this work, preliminary studies have been conducted which monitor fatigue damage in composite samples using strain gage measurements as well as Lamb wave velocity measurements. A description of the test samples is followed by the results of two different measurements of Lamb wave velocity. The first technique is a contact measurement done at a single frequency, while the second involves an immersion study of Lamb waves in which dispersion curves are obtained. The results of the Lamb wave monitoring of fatigue damage is compared to the damage progression measured by strain gages. The final section discusses the results and conclusions.

Seale, Michael↗

NASA NTRS2005

Glenn Refractory Adhesive for Bonding and Exterior Repair (GRABER) Developed for Repairing Shuttle Damage

Advanced in-space repair technologies for reinforced carbon/carbon composite (RCC) thermal protection system (TPS) structures are critically needed for the space shuttle Return To Flight (RTF) efforts. These technologies are also critical for the repair and refurbishment of thermal protection system structures of future Crew Exploration Vehicles of space exploration programs. The Glenn Refractory Adhesive for Bonding and Exterior Repair (GRABER) material developed at the NASA Glenn Research Center has demonstrated capabilities for repair of small cracks and damage in RCC leading-edge material. The concept consists of preparing an adhesive paste of desired ceramic in a polymer/phenolic resin matrix with appropriate additives, such as surfactants, and then applying the paste into the damaged or cracked area of the RCC composite components with caulking guns. The adhesive paste cures at 100 to 120 C and transforms into a high-temperature ceramic during simulated vehicle reentry testing conditions.

Singh, Mrityunjay↗

DOE OSTI2023

Chemical characterization of microplastic particles formed in airborne waste discharged from sewer pipe repairs

Microplastic particles are of increasing environmental concern due to the widespread uncontrolled degradation of various commercial products made of plastic and their associated waste disposal. Recently, common technology used to repair sewer pipes was reported as one of the emission sources of airborne microplastics in urban areas. This research presents results of the multi-modal comprehensive chemical characterization of the microplastic particles related to waste discharged in the pipe repair process and compares particle composition with the components of uncured resin and cured plastic composite used in the process. Analysis of these materials employs complementary use of surface-enhanced Raman spectroscopy, scanning transmission X-ray spectro-microscopy, single particle mass spectrometry, and direct analysis in real-time high-resolution mass spectrometry. Further, it is shown that the composition of the relatively large (100 μm) microplastic particles resembles components of plastic material used in the process. In contrast, the composition of the smaller (micrometer and sub-micrometer) particles is significantly different, suggesting their formation from unintended polymerization of water-soluble components occurring in drying droplets of the air-discharged waste. In addition, resin material type influences the composition of released microplastic particles. Results are further discussed to guide the detection and advanced characterization of airborne microplastics in future field and laboratory studies pertaining to sewer pipe repair technology.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1974

Design, manufacture, development, test, and evaluation of boron/aluminum structural components for space shuttle. Volume 4: Repairability

The repairability of boron/aluminum structural components was investigated. It was demonstrated that metal matrix composite material, damaged in service, can be repaired by techniques that are not very different from those currently in use for conventional materials. A list of repair guidelines was prepared to aid in determining the proper repair techniques for a given structure. The guidelines include specifying types of repair material and their applicability, corrosion prevention procedures, design criteria, and inspection criteria. Boron/aluminum structural components were repaired and tested to compare as-fabricated and repaired performance. All but one set of specimens, when repaired, exceeded the strength of the original specimens.

Miller, M. F.↗

NASA NTRS2003

Thermographic Inspection of Aerospace Tankage

Thermography has been shown to be the ideal technical and economic inspection method for two applications - post-machining evaluations and for field inspections of damage and repair. For most manufacturing applications ultrasonic inspections are already available and established. There is no question about the detectability or cost when inspecting hardware out of the autoclave. But when the part is too large to bring to the scanning inspection system or you do not want to remove the hardware from its current setup then a more portable or field applicable inspection is required. This paper will describe two applications of thermography on composite inspections. The NASA NDE Team and Lockheed Martin conducted the work at NASA s George C. Marshall Space Flight Center (MSFC). The first application was inspecting machined hardware. The technique and example data will be presented along with the advantages of thermography. Examples of drilling holes and trimming the edges will be discussed. The second application will be the evaluation of damage in a composite part and the subsequent repair of the region will be presented. The technique, data, and benefits of this application will also be presented along with the follow-up inspection of the post- repaired hardware.

Bouvier, Carl↗

NASA NTRS1982

Small Fixture Strains Composites for Environmental Tests

Fixture for long-term strain tests of composites is based on inexpensive tool for repairing motorcycle chains. (In normal use tool forces rivet out of chain element.) As modified for composite testing, tool has precision screw and shim. Qualification tests for graphite/epoxy composites are made less expensive by simple test fixture. Used in quantity, fixtures apply precisely similar loads to many samples.

Tervet, F. W.↗

NASA NTRS1972

Field repair of coated columbium Thermal Protection System (TPS)

The requirements for field repair of coated columbian panels were studied, and the probable cause of damage were identified. The following types of repair methods were developed, and are ready for use on an operational system: replacement of fused slurrey silicide coating by a short processing cycle using a focused radiant spot heater; repair of the coating by a glassy matrix ceramic composition which is painted or sprayed over the defective area; and repair of the protective coating by plasma spraying molybdenum disilicide over the damaged area employing portable equipment.

Culp, J. D.↗

NASA NTRS2005

STS-114: Discovery Return to Flight: Langley Engineers Analysis Briefing

This video features a briefing on NASA Langley Research Center (LaRC) contributions to the Space Shuttle fleet's Return to Flight (RTF). The briefing is split into two sections, which LaRC Shuttle Project Manager Robert Barnes and Deputy Manager Harry Belvin deliver in the form of a viewgraph presentation. Barnes speaks about LaRC contributions to the STS-114 mission of Space Shuttle Discovery, and Belvin speaks about LaRC contributions to subsequent Shuttle missions. In both sections of the briefing, LaRC contributions are in the following areas: External Tank (ET), Orbiter, Systems Integration, and Corrosion/Aging. The managers discuss nondestructive and destructive tests performed on ET foam, wing leading edge reinforced carbon-carbon (RCC) composites, on-orbit tile repair, aerothermodynamic simulation of reentry effects, Mission Management Team (MMT) support, and landing gear tests. The managers briefly answer questions from reporters, and the video concludes with several short video segments about LaRC contributions to the RTF effort.

Source record↗

NASA NTRS2009

NASA Tech Briefs, March 2009

Topics covered include: Improved Instrument for Detecting Water and Ice in Soil; Real-Time Detection of Dust Devils from Pressure Readings; Determining Surface Roughness in Urban Areas Using Lidar Data; DSN Data Visualization Suite; Hamming and Accumulator Codes Concatenated with MPSK or QAM; Wide-Angle-Scanning Reflectarray Antennas Actuated by MEMS; Biasable Subharmonic Membrane Mixer for 520 to 600 GHz; Hardware Implementation of Serially Concatenated PPM Decoder; Symbolic Processing Combined with Model-Based Reasoning; Presentation Extensions of the SOAP; Spreadsheets for Analyzing and Optimizing Space Missions; Processing Ocean Images to Detect Large Drift Nets; Alternative Packaging for Back-Illuminated Imagers; Diamond Machining of an Off-Axis Biconic Aspherical Mirror; Laser Ablation Increases PEM/Catalyst Interfacial Area; Damage Detection and Self-Repair in Inflatable/Deployable Structures; Polyimide/Glass Composite High-Temperature Insulation; Nanocomposite Strain Gauges Having Small TCRs; Quick-Connect Windowed Non-Stick Penetrator Tips for Rapid Sampling; Modeling Unsteady Cavitation and Dynamic Loads in Turbopumps; Continuous-Flow System Produces Medical-Grade Water; Discrimination of Spore-Forming Bacilli Using spoIVA; nBn Infrared Detector Containing Graded Absorption Layer; Atomic References for Measuring Small Accelerations; Ultra-Broad-Band Optical Parametric Amplifier or Oscillator; Particle-Image Velocimeter Having Large Depth of Field; Enhancing SERS by Means of Supramolecular Charge Transfer; Improving 3D Wavelet-Based Compression of Hyperspectral Images; Improved Signal Chains for Readout of CMOS Imagers; SOI CMOS Imager with Suppression of Cross-Talk; Error-Rate Bounds for Coded PPM on a Poisson Channel; Biomorphic Multi-Agent Architecture for Persistent Computing; and Using Covariance Analysis to Assess Pointing Performance.

Source record↗

NASA NTRS2013

Spring 2013 Graduate Engineering Internship Summary

In the spring of 2013, I participated in the National Aeronautics and Space Administration (NASA) Pathways Intern Employment Program at the Kennedy Space Center (KSC) in Florida. This was my final internship opportunity with NASA, a third consecutive extension from a summer 2012 internship. Since the start of my tenure here at KSC, I have gained an invaluable depth of engineering knowledge and extensive hands-on experience. These opportunities have granted me the ability to enhance my systems engineering approach in the field of payload design and testing as well as develop a strong foundation in the area of composite fabrication and testing for repair design on space vehicle structures. As a systems engineer, I supported the systems engineering and integration team with final acceptance testing of the Vegetable Production System, commonly referred to as Veggie. Verification and validation (V and V) of Veggie was carried out prior to qualification testing of the payload, which incorporated the process of confirming the system's design requirements dependent on one or more validation methods: inspection, analysis, demonstration, and testing.

Ehrlich, Joshua↗

NASA NTRS2004

On-Orbit Repair of RCC Structures

On-orbit repair technologies for reinforced carbon-carbon composite (RCC) structures are critically needed for space shuttle return to flight (RTF) efforts. These technologies are also critically needed for the repair and refurbishment of thermal protection system of future Crew Entry Vehicles (CEV) of space exploration programs. GRABER (Glenn Adhesive Refractory for Bonding and Exterior Repair) has shown multiuse capability for in-space repair of both large repairs and small cracks in space shuttle Reinforced Carbon Carbon (RCC) leading edge material. The concept consists of preparing an adhesive paste and then applying the paste tot he damaged/cracked area of the RCC composites with caulking gun. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during vehicle re-entry conditions. Further development and testing are underway to optimize the materials properties and extend the application temperature.

Singh, M.↗

NASA NTRS1979

A review of issues and strategies in nondestructive evaluation of fiber reinforced structural composites

Techniques for quantitative assessment of the mechanical strength and integrity of fiber composites during manufacture and service and following repair operations are presented. Problems and approaches are discussed relative to acceptance criteria, calibrating standards, and methods for nondestructive evaluation of composites in strength-critical applications. Acousto-ultrasonic techniques provide the methods of choice in this area.

Vary, A.↗

NASA NTRS1991

Advanced composite applications for sub-micron biologically derived microstructures

A major thrust of advanced material development is in the area of self-assembled ultra-fine particulate based composites (micro-composites). The application of biologically derived, self-assembled microstructures to form advanced composite materials is discussed. Hollow 0.5 micron diameter cylindrical shaped microcylinders self-assemble from diacetylenic lipids. These microstructures have a multiplicity of potential applications in the material sciences. Exploratory development is proceeding in application areas such as controlled release for drug delivery, wound repair, and biofouling as well as composites for electronic and magnetic applications, and high power microwave cathodes.

Schnur, J. M.↗

NASA NTRS2015

Puncture-Healing Thermoplastic Resin Carbon-Fiber-Reinforced Composites

A composite comprising a combination of a self-healing polymer matrix and a carbon fiber reinforcement is described. In one embodiment, the matrix is a polybutadiene graft copolymer matrix, such as polybutadiene graft copolymer comprising poly(butadiene)-graft-poly(methyl acrylate-co-acrylonitrile). A method of fabricating the composite is also described, comprising the steps of manufacturing a pre-impregnated unidirectional carbon fiber preform by wetting a plurality of carbon fibers with a solution, the solution comprising a self-healing polymer and a solvent, and curing the preform. A method of repairing a structure made from the composite of the invention is described. A novel prepreg material used to manufacture the composite of the invention is described.

Gordon, Keith L.↗

NASA NTRS2017

Puncture-Healing Thermoplastic Resin Carbon-Fiber Reinforced Composites

Gordon, Keith L.↗

DOE OSTI2025

Pultrusion and Vitrimer Composites: Emerging Pathways for Sustainable Structural Materials

Pultrusion is a manufacturing process used to produce fiber-reinforced polymer composites with excellent mechanical, thermal, and chemical properties. The resulting materials are lightweight, durable, and corrosion-resistant, making them valuable in aerospace, automotive, construction, and energy sectors. However, conventional thermoset composites remain difficult to recycle due to their infusible and insoluble cross-linked structure. This review explores integrating vitrimer technology a novel class of recyclable thermosets with dynamic covalent adaptive networks into the pultrusion process. As only limited studies have directly reported vitrimer pultrusion to date, this review provides a forward-looking perspective, highlighting fundamental principles, challenges, and opportunities that can guide future development of recyclable high-performance composites. Vitrimers combine the mechanical strength (tensile strength and modulus) of thermosets with the reprocessability and reshaping of thermoplastics through dynamic bond exchange mechanisms. These polymers offer high-temperature reprocessability, self-healing, and closed-loop recyclability, where recycling efficiency can be evaluated by the recovery yield retention of mechanical properties and reuse cycles meeting the demand for sustainable manufacturing. Key aspects discussed include resin formulation, fiber impregnation, curing cycles, and die design for vitrimer systems. The temperature-dependent bond exchange reactions present challenges in achieving optimal curing and strong fiber–matrix adhesion. Recent studies indicate that vitrimer-based composites can maintain structural integrity while enabling recycling and repair, with mechanical performance such as flexural and tensile strength comparable to conventional composites. Incorporating vitrimer materials into pultrusion could enable high-performance, lightweight products for a circular economy. The remaining challenges include optimizing curing kinetics, improving interfacial adhesion, and scaling production for widespread industrial adoption.

Fiber composites↗

NASA NTRS1990

Residual strength of repaired graphite/epoxy laminates after 5 years of outdoor exposure

The NASA Langley Research Center has sponsored research to develop generic repair techniques and processes for advanced graphite/epoxy (Gr/Ep) composites applicable to secondary structures for commercial transport aircraft. The long-term durability of such repairs is being addressed in a 10-year outdoor exposure program at the Langley Research Center. Details of the program and results of residual strength tests after 5 years of outdoor exposure are presented. Four repair methods are being evaluated. These include: (1) externally bolted aluminum-plus adhesive; (2) precured, bonded external Gr/Ep; (3) cure-in-place external Gr/Ep; and (4) cure-in-place flush Gr/Ep. Repaired specimens as well as undamaged and damaged unrepaired controls are being exposed outdoors for 1, 3, 5, 7, and 10 years. The residual tensile strength of stressed, unstressed, and fatigue specimens from each group is reported and compared with the tensile strength of baseline specimens which received no outdoor exposure. Identification of the commercial products and companies is used to describe adequately the test materials. The identification of these commercial products does not constitute endorsement, expressed or implied, of such products by the National Aeronautics and Space Administration.

Deaton, Jerry W.↗