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NASA NTRS1993

Combustion synthesis of advanced composite materials

Self-propagating high temperature (combustion) synthesis (SHS), has been investigated as a means of producing both dense and expanded (foamed) ceramic and ceramic-metal composites, ceramic powders and whiskers. Several model exothermic combustion synthesis reactions were used to establish the importance of certain reaction parameters, e.g., stoichiometry, green density, combustion mode, particle size, etc. on the control of the synthesis reaction, product morphology and properties. The use of an in situ liquid infiltration technique and the effect of varying the reactants and their stoichiometry to provide a range of reactant and product species i.e., solids, liquids and gases, with varying physical properties e.g., volatility and thermal conductivity, on the microstructure and morphology of synthesized composite materials is discussed. Conducting the combustion synthesis reaction in a reactive gas environment to take advantage of the synergistic effects of combustion synthesis and vapor phase transport is also examined.

Moore, John J.↗

NASA NTRS1993

Marked point process models of raindrop-size distributions

The principal process considered in this paper is the flux of raindrops through a volume of the atmosphere. This process is of fundamental importance for a wide variety of engineering and environmental problems, notably remote sensing of precipitation, infiltration of rainfall, soil erosion, atmospheric deposition of pollutants, and design of microwave communication systems. A marked point process model is developed in which the point process represents the arrival times of drops at the upper surface of a sample volume and the mark associated with a drop is its diameter. In the model, both the rate of occurrence of raindrops and the distribution of drop diameters vary randomly over time. Results that relate the drop-size distribution within the sample volume to the probability law of the drop-arrival process are presented. These results allow straightforward comparisons between temporal characterizations of drop-size distributions and spatial characterizations. Representations for derived processes such as rainfall rate and reflectivity are shown to be quite accurate using raindrop data from North Carolina.

Smith, James A.↗

NASA NTRS1993

Preterrestrial aqueous alteration of the Lafayette (SNC) meteorite

The structure and chemical composition of the Lafayette meteorite were examined using several methods. The meteorite contains abundant hydrous post-magnetic alteration material consisting of ferroan smectite clays, magnetite, and ferrihydrite. The textural relations, mineralogy, and composition of these materials were examined and their preterrestrial nature was documented. Olivine, pyroxene, and glass alteration are described and the bulk compositions of the alteration veinlets is discussed. Essential features of the geochemistry of the alteration processes are described. It is suggested that the alteration of the Lafayette meteorite occurred during episodic infiltrations of small volumes of saline water. Constraints placed on water chemistry and water-rock interactions in the Martian crust are outlined.

Treiman, Allan H.↗

NASA NTRS1992

Properties of intermingled carbon/PEEK 3-D woven composites

The presence of voids is one of the major problems associated with resin infiltration techniques when using 3-D woven preforms. Efforts to reduce the voids invariably result in the creation of microcracks. In this paper, the use of PEEK fibers intermingled with carbon fibers into a multi-layer preform is discussed. Influence of processing parameters, such as temperature, pressure, and consolidation time, on the composite properties is presented. One of the issues emphasized is the effect of pressure on buckling of the Z-reinforcement fibers and the bending behavior.

Mohamed, M. H.↗

NASA NTRS1992

Combustion synthesis of advanced materials

The combustion synthesis of ceramic-metal composites using an in-situ liquid infiltration technique is described. The effect of varying the reactants and their stoichiometry to provide a range of reactant and product species i.e. solids, liquids and gases, with varying physical properties e.g. thermal conductivity, on the microstructure and morphology of synthesized products is also described. Alternatively, conducting the combustion synthesis reaction in a reactive gas environment is also discussed, in which advantages can be gained from the synergistic effects of combustion synthesis and vapor phase transport. In each case, the effect of the presence or absence of gravity (density) driven fluid flow and vapor transport is discussed as is the potential for producing new and perhaps unique materials by conducting these SHS reactions under microgravity conditions.

Moore, J. J.↗

NASA NTRS1993

Monolithic catalytic igniters

Catalytic igniters offer the potential for excellent reliability and simplicity for use with the diergolic bipropellant oxygen/hydrogen as well as with the monopropellant hydrazine. State-of-the-art catalyst beds - noble metal/granular pellet carriers - currently used in hydrazine engines are limited by carrier stability, which limits the hot-fire temperature, and by poor thermal response due to the large thermal mass. Moreover, questions remain with regard to longevity and reliability of these catalysts. In this work, Ultramet investigated the feasibility of fabricating monolithic catalyst beds that overcome the limitations of current catalytic igniters via a combination of chemical vapor deposition (CVD) iridium coatings and chemical vapor infiltration (CVI) refractory ceramic foams. It was found that under all flow conditions and O2:H2 mass ratios tested, a high surface area monolithic bed outperformed a Shell 405 bed. Additionally, it was found that monolithic catalytic igniters, specifically porous ceramic foams fabricated by CVD/CVI processing, can be fabricated whose catalytic performance is better than Shell 405 and with significantly lower flow restriction, from materials that can operate at 2000 C or higher.

La Ferla, R.↗

NASA NTRS1993

Interfacial and capillary phenomena in solidification processing of metal-matrix composites

Chemical and hydrodynamic aspects of wetting and interfacial phenomena during the solidification processing of metal-matrix composites are reviewed. Significant experimental results on fiber-matrix interactions and wetting under equilibrium and non-equilibrium conditions in composites of engineering interest have been compiled, based on a survey of the recent literature. Finally, certain aspects of wetting relevant to stir-casting and infiltration processing of composites are discussed.

Asthana, R.↗

NASA NTRS1993

Graphite fiber textile preform/copper matrix composites

This project has the objective of exploring the use of graphite fiber textile preform/copper matrix composites in spacecraft heat transmitting and radiating components. The preforms are to be fabricated by braiding of tows and when infiltrated with copper will result in a 3-D reinforced, near net shape composite with improved specific properties such as lower density and higher stiffness. It is anticipated that the use of textile technology will result in a more robust preform and consequently better final composite; it is hard to anticipate what performance tradeoffs will result, and these will be explored through testing and characterization.

Filatovs, G. J.↗

NASA NTRS1993

On hydrologic similarity: A dimensionless flood frequency model using a generalized geomorphologic unit hydrograph and partial area runoff generation

One of the shortcomings of the original theory of the geomorphologic unit hydrograph (GUH) is that it assumes that runoff is generated uniformly from the entire catchment area. It is now recognized that in many catchments much of the runoff during storm events is produced on partial areas which usually form on narrow bands along the stream network. A storm response model that includes runoff generation on partial areas by both Hortonian and Dunne mechanisms was recently developed by the authors. In this paper a methodology for integrating this partial area runoff generation model with the GUH-based runoff routing model is presented; this leads to a generalized GUH. The generalized GUH and the storm response model are then used to estimate physically based flood frequency distributions. In most previous work the initial moisture state of the catchment had been assumed to be constant for all the storms. In this paper we relax this assumption and allow the initial moisture conditions to vary between storms. The resulting flood frequency distributions are cast in a scaled dimensionless framework where issues such as catchment scale and similarity can be conveniently addressed. A number of experiments are performed to study the sensitivity of the flood frequency response to some of the 'similarity' parameters identified in this formulation. The results indicate that one of the most important components of the derived flood frequency model relates to the specification of processes within the runoff generation model; specifically the inclusion of both saturation excess and Horton infiltration excess runoff production mechanisms. The dominance of these mechanisms over different return periods of the flood frequency distribution can significantly affect the distributional shape and confidence limits about the distribution. Comparisons with observed flood distributions seem to indicate that such mixed runoff production mechanisms influence flood distribution shape. The sensitivity analysis also indicated that the incorporation of basin and rainfall storm scale also greatly influences the distributional shape of the flood frequency curve.

Sivapalan, Murugesu↗

NASA NTRS1993

Textile composite processing science

A multi-dimensional model of the Resin Transfer Molding (RTM) process was developed for the prediction of the infiltration behavior of a resin into an anisotropic fiber preform. Frequency dependent electromagnetic sensing (FDEMS) was developed for in-situ monitoring of the RTM process. Flow visualization and mold filling experiments were conducted to verify sensor measurements and model predictions. Test results indicated good agreement between model predictions, sensor readings, and experimental data.

Loos, Alfred C.↗

NASA NTRS1994

Evaluation of oxide-coated iridium-rhenium chambers

Iridium-coated rhenium (Ir-Re) provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase Ir-Re rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated Ir-Re, 22-N rocket chambers were tested with gaseous hydrogen/gaseous oxygen (GHz/G02) propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia (HfO2) or zirconia (ZrO2). Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of ZrO2 infiltrated with sol gel HfO2. The other chamber had a coating composed of an Ir-oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. Testing the Ir-oxide composite-coated chamber included over 29 min at mixture ratio 16. The thicker walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner walled coatings did not experience the macrocracking and chipping of the chambers that was seen with the thick, monolithic coatings. However, burn-throughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stoichiometric. The burn-throughs were probably the result of oxygen diffusion through the oxide coating that allowed the underlying Ir and Re layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗

NASA NTRS1994

Four advances in carbon-carbon materials technology

Carbon-carbon composites are a specialty class of materials having many unique properties making these composites attractive for a variety of demanding engineering applications. Chief among these properties are exceptional retention of mechanical properties at temperatures as high as 4000 F, excellent creep resistance, and low density (1.6 to 1.8 g/cu cm). Although carbon-carbon composites are currently in service in a variety of applications, much development work remains to be accomplished before these materials can be considered to be fully mature, realizing their full potential. Four recent technology advances holding particular promise for overcoming current barriers to the wide-spread commercialization of carbon-carbon composites are described. These advances are: markedly improved interlaminar strengths (more than doubled) of two dimensional composites achieved by whiskerization of the fabric reinforcing plies, simultaneously improved oxidation resistance and mechanical properties achieved by the incorporation of matrix-phase oxidation inhibitors based on carborane chemistry, improved oxidation resistance achieved by compositionally graded oxidation protective coatings, and markedly reduced processing times (hours as opposed to weeks or months) accomplished through a novel process of carbon infiltration and coatings deposition based on the use of liquid-phase precursor materials.

Maahs, Howard G.↗

NASA NTRS1993

Testing and evaluation of oxide-coated iridium/rhenium chambers

Iridium-coated rhenium provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase iridium/rhenium rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated iridium/rhenium, 22 N rocket chambers were tested on gaseous hydrogen/gaseous oxygen propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia or zirconia. Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of zirconia infiltrated with sol gel hafnia. The other chamber had a coating composed of an iridium/oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. The iridium/oxide composite coated chamber included testing for over 29 minutes at mixture ratio 16. The thicker-walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner-walled coatings did not experience the macrocracking and chipping of the chambers seen with the thick, monolithic coatings. However, burnthroughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stochiometric. The burn-throughs were probably the result of oxygen-diffusion through the oxide coating that allowed the underlying iridium and rhenium layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗

NASA NTRS1993

Analytical modeling and sensor monitoring for optimal processing of advanced textile structural composites by resin transfer molding

A two-dimensional model of the resin transfer molding (RTM) process was developed which can be used to simulate the infiltration of resin into an anisotropic fibrous preform. Frequency dependent electromagnetic sensing (FDEMS) has been developed for in situ monitoring of the RTM process. Flow visualization tests were performed to obtain data which can be used to verify the sensor measurements and the model predictions. Results of the tests showed that FDEMS can accurately detect the position of the resin flow-front during mold filling, and that the model predicted flow-front patterns agreed well with the measured flow-front patterns.

Loos, Alfred C.↗

NASA NTRS1995

Low Cost Fabrication of Silicon Carbide Based Ceramics and Fiber Reinforced Composites

A low cost processing technique called reaction forming for the fabrication of near-net and complex shaped components of silicon carbide based ceramics and composites is presented. This process consists of the production of a microporous carbon preform and subsequent infiltration with liquid silicon or silicon-refractory metal alloys. The microporous preforms are made by the pyrolysis of a polymerized resin mixture with very good control of pore volume and pore size thereby yielding materials with tailorable microstructure and composition. Mechanical properties (elastic modulus, flexural strength, and fracture toughness) of reaction-formed silicon carbide ceramics are presented. This processing approach is suitable for various kinds of reinforcements such as whiskers, particulates, fibers (tows, weaves, and filaments), and 3-D architectures. This approach has also been used to fabricate continuous silicon carbide fiber reinforced ceramic composites (CFCC's) with silicon carbide based matrices. Strong and tough composites with tailorable matrix microstructure and composition have been obtained. Microstructure and thermomechanical properties of a silicon carbide (SCS-6) fiber reinforced reaction-formed silicon carbide matrix composites are discussed.

Singh, M.↗

NASA NTRS1994

Chemical composition of the atmospheric aerosol in the troposphere over the Hudson Bay lowlands and Quebec-Labrador regions of Canada

Atmospheric aerosols were collected in the boundary layer and free troposphere over continental and coastal subarctic regions of Canada during the July - August 1990 joint U.S.-Canadian Arctic Boundary Layer Expedition (ABLE) 3B/Northern Wetlands Study (NOWES). The samples were analyzed for the following water soluble species: sulfate, nitrate, ammonium, potassium, sodium, chloride, oxalate, methylsulfonate, and total amine nitrogen. Ammonium and sulfate were the major water soluble components of these aerosols. The nearly neutral (overall) chemical composition of summertime aerosol particles contrasts their strongly acidic wintertime composition. Aerosol samples were separated into several air mass categories and characterized in terms of chemical composition, associated mixing ratios of gaseous compounds, and meteorological parameters. The fundamental category represented particles associated with 'background' air masses. The summertime atmospheric aerosols in background air over the North American subarctic and Arctic regions were characterized by relatively small and spatially uniform mixing ratios of the measured species. These aerosol particles were aged to the extent that they had lost their primary source signature. The chemical profile of the background air aerosols was frequently modified by additions from biomass fire plumes, aged tropical marine air, and intrusions of upper tropospheric/lower stratospheric air. Aerosols in boundary layer background air over the boreal forest region of Quebec-Labrador had significantly larger mixing ratios of ammonium and sulfate relative to the Hudson Bay region. This may reflect infiltration of anthropogenic pollution or be due to natural emissions from this region.

Gorzelska, K.↗

NASA NTRS1994

Evaluating GCM land surface hydrology parameterizations by computing river discharges using a runoff routing model: Application to the Mississippi basin

To relate general circulation model (GCM) hydrologic output to readily available river hydrographic data, a runoff routing scheme that routes gridded runoffs through regional- or continental-scale river drainage basins is developed. By following the basin overland flow paths, the routing model generates river discharge hydrographs that can be compared to observed river discharges, thus allowing an analysis of the GCM representation of monthly, seasonal, and annual water balances over large regions. The runoff routing model consists of two linear reservoirs, a surface reservoir and a groundwater reservoir, which store and transport water. The water transport mechanisms operating within these two reservoirs are differentiated by their time scales; the groundwater reservoir transports water much more slowly than the surface reservior. The groundwater reservior feeds the corresponding surface store, and the surface stores are connected via the river network. The routing model is implemented over the Global Energy and Water Cycle Experiment (GEWEX) Continental-Scale International Project Mississippi River basin on a rectangular grid of 2 deg X 2.5 deg. Two land surface hydrology parameterizations provide the gridded runoff data required to run the runoff routing scheme: the variable infiltration capacity model, and the soil moisture component of the simple biosphere model. These parameterizations are driven with 4 deg X 5 deg gridded climatological potential evapotranspiration and 1979 First Global Atmospheric Research Program (GARP) Global Experiment precipitation. These investigations have quantified the importance of physically realistic soil moisture holding capacities, evaporation parameters, and runoff mechanisms in land surface hydrology formulations.

Liston, G. E.↗

NASA NTRS1994

The development and validation of a simple snow model for the GISS GCM

Five years of meteorological and hydrological data from a typical New England watershed where winter snow cover is significant were used to drive and validate two off-line land surface schemes suitable for use in the Goddard Institute for Space Studies (GISS) general circulation model (GCM): a baseline scheme that does not model the physics of a snowpack and therefore, neglects the insulating properties of snow cover; and a modified scheme in which a three-layer snowpack is modeled. Comparing baseline model results with validation data reveals several model deficiencies. Surface radiation temperatures could not adequately be modeled and the ground froze to unreasonable depths. Furthermore, because of ground cooling resulting from large surface heat fluxes to the atmosphere from the uninsulated surface, deeper model layers did not unfreeze until midsummer. As such, the normal hydrologic processes of runoff, ground water infiltration, and movement, etc., are compromised for a good part of the year. With the inclusion of a simple three-layer snow model into the baseline model, not only are the ground and surface radiation temperatures adequately modeled but all the features of snowpack ripening that characterize pack growth/ablation are simulated.

Lynch-Stieglitz, Marc↗