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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 advancement of material performance and design methodology as related to brittle materials was investigated. The processing and properties of ceramic materials as related to design requirements was also studied.
The results of experimental studies of the anisotropy of elastic and strength characteristics of various structural materials, including pressure worked metals and alloys, laminated fiberglass plastics, and laminated wood plastics, are correlated and classified. Strength criteria under simple and complex stresses are considered as applied to anisotropic materials. Practical application to determining the strength of machine parts and structural materials is discussed.
Insight is provided into the scientific rotationale for materials processing in space (MPS), and a comprehensive and cohesive approach for implementation and integration of the many, diverse aspects of MPS is described. The programmatic and management functions apply to all projects and activities implemented under MPS. It is intended that specific project plans, providing project unique details, will be appended to this document for endeavors such as the Space Processing Applications Rocket (SPAR) Project, the Materials Experiment Assembly (MEA) Project, the MPS/Spacelab (MPS/SL) Project, and the Materials Experiment Carrier (MEC) Payloads.
The Phase 3 study of the NASA 'Improved Fire Resistant Aircraft Seat Materials' involved fire tests of improved materials in multilayered combinations representative of cushion configurations. Tests were conducted to determine their thermal, smoke, and fire resistance characteristics. Additionally, a 'Design Guideline' for Fire Resistant Passenger Seats was written outlining general seat design considerations. Finally, a three-abreast 'Tourist Class' passenger seat assembly fabricated from the most advanced fire-resistant materials was delivered.
Both materials possess a high degree of thermal stability, with total heat release values being essentially identical under piloted ignition conditions over a range of 5 to 10 W/sq cm incident heat flux. The graphite/epoxy material had a tendency to auto-ignite at a lower heat flux (about 7 W/sq cm) and produced about 23 percent higher peak heat release rates, approximately 42 percent more carbon monoxide and considerably more smoke than the graphite/bismaleimide under conditions of piloted ignition. Toxicological potencies of smoke produced from the two composites were equivalent for 30 minute exposures. Potencies were also comparable to many common materials, such as wood. There was no evidence for the formation of an "unusual toxicant" nor for any short term post-exposure toxicological effects.
To promote potential commercial applications of low-g technology, the materials processing and manufacturing in space program is structured to: (1) analyze the scientific principles of gravitational effects on processes used in producing materials; (2) apply the research toward the technology used to control production process (on Earth or in space, as appropriate); and (3) establish the legal and managerial framework for commercial ventures. Presently federally funded NASA research is described as well as agreements for privately funded commercial activity, and a proposed academic participation process. The future scope of the program and related capabilities using ground based facilities, aircraft, sounding rockets, and space shuttles are discussed. Areas of interest described include crystal growth; solidification of metals and alloys; containerless processing; fluids and chemical processes (including biological separation processes); and processing extraterrestrial materials.
Recent activities of the Lewis Research Center are reviewed which are directed toward developing materials for rotating hot section components for aircraft gas turbines. Turbine blade materials activities are directed at increasing metal temperatures approximately 100 C compared to current directionally solidified alloys by use of oxide dispersion strengthening or tungsten alloy wire reinforcement of nickel or iron base superalloys. The application of thermal barrier coatings offers a promise of increasing gas temperatures an additional 100 C with current cooling technology. For turbine disk alloys, activities are directed toward reducing the cost of turbine disks by 50 percent through near net shape fabrication of prealloyed powders as well as towards improved performance. In addition, advanced alloy concepts and fabrication methods for dual alloy disks are being studied as having potential for improving the life of future high performance disks and reducing the amount of strategic materials required in these components.
Research efforts to reduce the dependence of the aerospace industry on strategic metals, such as cobalt (Co), columbium (Cb), tantalum (Ta), and chromium (Cr), by providing the materials technology needed to minimize the strategic metal content of critical aerospace components for gas turbine engines are addressed. Thrusts in three technology areas are identified: near term activities in the area of strategic element substitution; intermediate-range activities in the area of materials processing; and long term, high risk activities in the area of 'new classes' of high temprature metallic materials. Specifically, the role of cobalt in nickel-base and cobalt-base superalloys vital to the aerospace industry is examined along with the mechanical and physical properties of intermetallics that will contain a minimum of the stragetic metals.
The test program for the basic prepreg materials used in process development work and planned fabrication of the national transonic facility fan blade is presented. The basic prepreg materials and the design laminate are characterized at 89 K, room temperature, and 366 K. Characterization tests, test equipment, and test data are discussed. Material tests results in the warp direction are given for tensile, compressive, fatigue (tension-tension), interlaminar shear and thermal expansion.
The room temperature fatigue behavior of 0.41-cm (0.16-in) thick strain-isolation-pad (SIP) material was explored in a series of constant- and random-amplitude loading tests. The SIP material is used on the Space Shuttle to isolate the ceramic insulating tiles from the strains and deflections of the aluminum alloy airframe. In all tests, 12.7 by 12.7 cm (5.0 by 5.0 in) SIP specimens were subjected to tension-tension loading in the through-the-thickness direction at a frequency of 10 Hz. When subjected to cyclic loading, the SIP material exhibited a monotonic increase in thickness and a monotonic increase in tensile tangent moduli. The rate of thickness growth increased with increasing test stress level and decreased with increasing number cycles endured. Power law equations were found to provide a good representation of the thickness growth rate data. Tensile tangent moduli increased by as much as 80 percent during fatigue tests. Simple cumulative damage fatigue models predicted the mean thickness growth under random-amplitude loading with reasonable accuracy (factor of 2 on life).
A program implementation model is presented which covers the early stages of space material processing and manufacturing. The model includes descriptions of major program elements, development and experiment requirements in space materials processing and manufacturing, and an integration of the model into NASA's long range plans as well as its evolution from present Materials Processing in Space plans.
Recent advances and future trends in aerospace materials technology are reviewed with reference to metal alloys, high-temperature composites and adhesives, tungsten fiber-reinforced superalloys, hybrid materials, ceramics, new ablative materials, such as carbon-carbon composite and silica tiles used in the Shuttle Orbiter. The technologies of powder metallurgy coupled with hot isostatic pressing, near net forging, complex large shape casting, chopped fiber molding, superplastic forming, and computer-aided design and manufacture are emphasized.
The United States imports 50-100 percent of certain metals critical to the aerospace industry, namely, cobalt, columbium, chromium, and tantalum. In an effort to reduce this dependence on foreign sources, NASA is planning a program called Conservation of Strategic Aerospace Materials (COSAM), which will provide technology minimizing strategic metal content in the components of aerospace structures such as aircraft engines. With a proposed starting date of October 1981, the program will consist of strategic element substitution, process technology development, and alternate materials research. NASA's two-fold pre-COSAM studies center on, first, substitution research involving nickel-base and cobalt-base superalloys (Waspaloy, Udimet-700, MAE-M247, Rene 150, HA-188) used in turbine disks, low-pressure blades, turbine blades, and combustors; and, second, alternate materials research devoted initially to investigating possible structural applications of the intermetallic alloys nickel aluminide and iron aluminide.
A specific lot of bisphenol A polycarbonate has been used for almost four years as the reference material for the NASA-USF-PSC toxicity screening test method. The reproducibility of the test results over this period of time indicate that certain plastics may be more suitable reference materials than the more traditional cellulosic materials.
Conceptual design studies and mission analyses within the NASA Materials Processing in Space (MPS) program of the Materials Experiment Carrier (MEC) approach to conducting near-term as well as future free-flying experiments in materials processing in space are discussed. The experimental background of the MPS program is reviewed, and it is pointed out that the use of the MEC coupled with the 25-kW power system can provide an order-of-magnitude cost savings over conventional Shuttle-based systems, as well as increased orbital stay time and microgravity stability. The determination of the physical and engineering requirements for future MEC scientific/commercial candidate payloads is then discussed, and two proposed candidates for the MEC configuration, which is intended to be a self-contained, general-purpose, versatile and reusable carrier, are illustrated. Possible MEC operations are considered, including mission profiles, deployment sequences, on-orbit payload/sample change-out, optimal power system utilization, the use of real-time, ground-based control and advanced automatic payload operation. Areas in which technology development could benefit the MEC project are also identified.
A comprehensive test apparatus has been developed for the evaluation of the effects of thermal cycling, high temperatures and high electric fields on the quality and stability of electrical insulating materials used in spacecraft systems. The system includes a test chamber in which the specimen can be subjected to thermal and electrical stresses encountered in the space environment (temperatures from -50 to 200 C and voltages from 0 to 10 kV rms, respectively) simultaneously. The system instrumentation includes provisions for the measurement of the change in capacitance, the thermal dissipation factor of the material, and complex dielectric constants with changes in temperature, corona intensity and voltages at frequencies from 22 kHz to 70 MHz, as well as the volume and surface resistivities of the materials.
The paper reviews studies of the role of the microenvironment in the adhesion, friction, and wear behavior of materials in solid-state contact. The microenvironment is defined as the environment on the surface of solids in solid-state contact. Properties of the environment are discussed which exert an influence on the adhesion, friction, wear, and lubrication of materials in contact. The effect of the environment on lubricants and their properties is considered with respect to the interaction of lubricants with material surfaces in contact; the effect on the ability of lubricants to provide protective surface films is also considered. It is concluded that naturally occurring oxides are probably the best available natural solid-film lubricants.
Three candidate materials were examined: Brunsbond (R) Pad; plasma sprayed porous NiCrAlY; and plasma sprayed low modulus microcracked zirconia. Evaluation consisted of mechanical, thermophysical, and oxidation resistance testing along with optical microscopy and a feasibility demonstration of attaching the material to a suitable substrate. The goals of the program were the following: feasibility of fastening or depositing the low modulus system onto a broad range of substrate alloys; feasibility of depositing or forming the low modulus system to a thickness of 0.19 cm to 0.38 cm; potential to attain a modulus of elasticity in the range of 3.4 to 6.9 GPa (0.5 to 1.0 MSI), and an ultimate strength of 17.2 MPa (2.5 ksi); suitable thermal conductivity; and static oxidation life of at least 1000 hours at 1311 K. The results of the program indicate that all three systems offer attractive properties as a strain isolator material.