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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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The purpose of the experiments was to determine the difference in the strength of steel tubes welded by different methods, as compared with one another and also with unwelded, unannealed tubes, including; moreover, a comparison of the results obtained by experienced and inexperienced welders.
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Thoriated tungsten extension rod fabricated to replace stainless-steel extension rod attached to linear variable-differential transformer in gap-measuring gauge. Threads formed on end of rod by machining with special fixtures and carefully chosen combination of speeds and feeds.
In order to understand and model the thermomechanical behavior of fiber-reinforced composites, stress-rupture, fast-fracture, and warm-up rupture studies were conducted on various advanced SiC and Al2O3-based fibers in the,temperature range from 20 to 1400 C in air as well as in inert environments. The measured stress-rupture, fast fracture, and warm-up rupture strengths were correlated into a single master time/temperature-dependent strength plot for each fiber type using thermal activation and slow crack growth theories. It is shown that these plots are useful for comparing and selecting fibers for CMC and MMC reinforcement and that, in comparison to stress rupture tests, the fast-fracture and warm-up tests can be used for rapid generation of these plots.
The influence of specimen polishing, configuration, and size on the transverse tension strength of two glass-epoxy materials, and one carbon-epoxy material, loaded in three and four point bending was evaluated. Polishing machined edges, arid/or tension side failure surfaces, was detrimental to specimen strength characterization instead of yielding a higher, more accurate, strength as a result of removing inherent manufacture and handling flaws. Transverse tension strength was typically lower for longer span lengths due to the classical weakest link effect. However, strength was less sensitive to volume changes achieved by increasing specimen width. The Weibull scaling law typically over-predicted changes in transverse tension strengths in three point bend tests and under-predicted changes in transverse tension strengths in four point bend tests. Furthermore, the Weibull slope varied with specimen configuration, volume, and sample size. Hence, this scaling law was not adequate for predicting transverse tension strength of heterogeneous, fiber-reinforced, polymer matrix composites.
The strengths of three continuous fiber-reinforced ceramic composites, including SiC/CAS-II, SiC/MAS-5 and SiC/SiC, were determined as a function of test rate in air at 1100 to 1200 C. All three composite materials exhibited a strong dependency of strength on test rate, similar to the behavior observed in many advanced monolithic ceramics at elevated temperatures. The application of the preloading technique as well as the prediction of life from one loading configuration (constant stress-rate) to another (constant stress loading) suggested that the overall macroscopic failure mechanism of the composites would be the one governed by a power-law type of damage evolution/accumulation, analogous to slow crack growth commonly observed in advanced monolithic ceramics. It was further found that constant stress-rate testing could be used as an alternative to life prediction test methodology even for composite materials, at least for short range of lifetimes and when ultimate strength is used as the failure criterion.
Strength of three continuous fiber-reinforced ceramic composites, including SiC/CAS-11, SiC/MAS-5 and SiC/SiC, was determined as a function of test rate in air at 1100 - 1200 C. All three composite materials exhibited a strong dependency of strength on test rate, similar to the behavior observed in many advanced monolithic ceramics at elevated temperatures. The application of the preloading technique as well as the prediction of life from one loading configuration (constant stress-rate) to another (constant stress loading) suggested that the overall macroscopic failure mechanism of the composites would be the one governed by a power-law tyw of damage evolution/accumulation, analogous to slow crack growth commonly observed in advanced monolithic ceramics. It was further found that constant stress-rate testing could be used as an alternative to life prediction test methodology even for the composite materials at least for the short range of lifetime.
The influence of specimen polishing, specimen configuration, and specimen size on the transverse tension strength of two glass epoxy materials loaded in three and four point bending was evaluated. Polishing machined edges, and/or tension side failure surfaces, was detrimental to specimen strength characterization instead of yielding a higher, more accurate, strength as a result of removing inherent manufacture and handling flaws. Transverse tension strength was sensitive to span length due to the classical weakest link effect. However, strength was less sensitive to volume changes achieved by increasing specimen width. The Weibull scaling law over-predicted changes in transverse tension strengths in three point bend tests and under-predicted changes in transverse tension strengths in four point bend tests. Furthermore, the Weibull slope varied with specimen configuration, volume, and sample size. Hence, the utility of this scaling law for predicting transverse tension strength is unclear.
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The through-thickness or flatwise strength of a uniaxial polymer matrix composite was investigated with several test specimen geometries and starting plate thicknesses. The use of thinner plates is desirable to save material and lower costs during materials development programs. The various configurations gave similar results with the exception of thin, straight-sided specimens. Thin specimens tended to provide invalid results per ASTM International D7291; however, the addition of a large, shallow radius improved the results. The Weibull distribution provided a good fit to the combined data.
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Sustainable aviation in the form of electrified propulsion is likely to lead to an increase in the electrical assets contained within a single aircraft. As a result, it is desirable to design light weight conductor materials, thus reducing the payload of components like motor windings, low voltage signal cables, and transmission cables for data and power. One approach involves replacing pure Cu wiring with metalized CNT composites. This paper evaluates a framework for modeling overall conductivity and current sharing within such composites. Processing methods and parameters were refined. Select electroplated samples outperformed pure Cu in conductivity and had comparable ultimate tensile strengths. Tensile strengths are expected to improve with an additional densification step during processing. Acoustic emission data was used to predict the failure mechanism of the composite. Theories explaining improved intrinsic conductivity are discussed, with a focus on chemical and mechanical interactions at the Cu-CNT interface. These include Cu infiltration of CNT crevices, CNT oxidation, activity at defects in CNT walls, and the release of carbide-forming metals from CNT walls. Validating any or all these theories will require further work replicating data, collecting electron micrographs and conducting chemical analyses.
Engineers today are presented with the opportunity to design and build the next generation of space vehicles out of the lightest, strongest, and most durable materials available. Composites offer excellent structural characteristics and outstanding reliability in many forms that will be utilized in future aerospace applications including the Commercial Crew and Cargo Program and the Orion space capsule. NASA's Composites for Exploration (CoEx) project researches the various methods of manufacturing composite materials of different fiber characteristics while using proven infusion methods of different resin compositions. Development and testing on these different material combinations will provide engineers the opportunity to produce optimal material compounds for multidisciplinary applications. Through the CoEx project, engineers pursue the opportunity to research and develop repair patch procedures for damaged spacecraft. Working in conjunction with Raptor Resins Inc., NASA engineers are utilizing high flow liquid infusion molding practices to manufacture high-temperature composite parts comprised of intermediate modulus 7 (IM7) carbon fiber material. IM7 is a continuous, high-tensile strength composite with outstanding structural qualities such as high shear strength, tensile strength and modulus as well as excellent corrosion, creep, and fatigue resistance. IM7 carbon fiber, combined with existing thermoset and thermoplastic resin systems, can provide improvements in material strength reinforcement and deformation-resistant properties for high-temperature applications. Void analysis of the different layups of the IM7 material discovered the largest total void composition within the [ +45 , 90 , 90 , -45 ] composite panel. Tensile and compressional testing proved the highest mechanical strength was found in the [0 4] layup. This paper further investigates the infusion procedure of a low-cost/high-performance BMI resin into an IM7 carbon fiber material and the optical, chemical, and mechanical analyses performed.
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.
The effects of the load/temperature environment of the shuttle on the fatigue life of the body-flap were investigated by conducting real time and accelerated flight-by-flight tests up to 500 flights on coupons containing holes. On the fracture side, much is known about the sensitivity of the tensile strengths of composites to holes and other flaws, predominantly at room temperature. The effects of notches were assessed for graphite/polyimides at the expected temperature extremes of the body-flap: 117K (-250 F) to 589K (600 F). Results indicate that the shuttle temperature extremes may affect fatigue properties HTS/PMR-15. There is no significant effect of temperature on notch-strength. Tensile strengths for specimens with holes and slots are equal.
Abstract Wood flour (WF) at 10 wt.% and 20 wt.% loadings was used as a reinforcing filler to enhance the applicability of polypropylene (PP) for 3D printing. After performing printability tests of PP wood plastic composites (WPCs), the mechanical properties of both injection‐molded and 3D‐printed PP WPC specimens were explored. Test specimens were prepared from 3D printed hexagons for analyzing the mechanical properties. Adding WF to neat PP increased the storage modulus and the glass transition temperature while decreasing the degree of crystallinity and the coefficient of thermal expansion, while enhancing the printability of neat PP. The tensile strength, tensile modulus of elasticity, flexural strength, and flexural modulus of elasticity of injection‐molded neat PP improved by up to 21%, 59%, 30%, and 56%, respectively, with 20 wt.% WF. However, the impact strength of injection‐molded neat PP decreased by 85%, with 20 wt.% WF. After 3D printing, the tensile strength and tensile modulus of elasticity of printed neat PP increased by up to 84% and 60%, respectively, with 20 wt.% WF. The flexural strength and flexural modulus of elasticity of neat printed PP remained unchanged compared to those of PP filled with 20 wt.% WF, while the impact strength decreased by 87%. Highlights WF was used as a reinforcement in polypropylene designed for 3D printing A pilot‐scale, pellet‐fed 3D printer was used to print hollow hexagons, and then test specimens were fabricated from these hexagons for mechanical properties The tensile and flexural properties of 3D printed neat polypropylene improved, while the impact strength decreased after adding 20 wt.% WF to the neat PP.
Law-of-mixtures relationship applied to fiber-metal composites - Determination of yield strengths, tensile strengths, and other properties of composites