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At least 1,207 records · Page 67

The Influence of Material Characterization on Thermal Loads Development and Flight Vehicle Design

The thermal management team faces a significant challenge to meet the aggressive thermal loading associated with hypersonic flight. Design strategies require the involvement of many engineering disciplines, as each must design their respective subsystem and then interface with all remaining subsystems to successfully close the vehicle design space. High fidelity thermal solid models will capture the variation in material properties and the effects of chemical reactions associated with hypersonic flight. Selection of the best materials for the mission will be based upon computational fluid dynamics and thermal modeling results. To enhance the probability for success, it is recommended that frequent communication occur between the thermal modeler and the materials scientist regarding design strategies and modeling assumptions. Early in the design process, lower fidelity modeling will be used to narrow the trade space. As promising designs are found, greater fidelity in the modeling process will be required to address more of the flowfield challenges and the material performance under the prescribed flight profile. The end goal is to select the most technically sound and physically advantageous material for the mission while avoiding overdesigning the vehicle due to modeling or material uncertainties. This presentation seeks to give an overview of the key thermal parameters that are affected through materials engineering, the interactions between a thermal engineer and other disciplines, and an example of the thermal design process, the X-43.

hypersonic↗

Metal Extraction from Trash via Trash-to-Gas Processing for Use in 3D Printing

This work synergized state-of-the-art trash-to-gas (TtG) and in-space manufacturing (ISM) technologies to successfully extract metals from astronaut waste items for use in 3D printing. This was accomplished by isolating pure aluminum (Al 1235) from astronaut multilayer food packaging via TtG processing, cleaning the extracted aluminum, and preparing it for compatibility with the bound metal deposition (BMD) 3D printing process. A suite of material analyses was performed on the extracted aluminum product to fully characterize the key properties linked to effective additive manufacturing, including particle size distribution, oxygen content quantitation, and elemental composition. Metal extraction from Lunar and Martian regolith has become a significant area of interest for the in-situ resource utilization (ISRU) community to produce metallic equipment for various mission scenarios. However, the extraction of metals from astronaut waste streams has yet to be investigated. This project demonstrated an end-to-end waste metallic reuse process which may garner considerable metal production that would otherwise be disposed of.

Ray Pitts↗

Modeling Large Dust Aerosols in the Community Earth System Model Version 2 (CESM2)

Dust aerosols have a wide size distribution from less than 0.1 to over 100 μm and dominate Earth's atmospheric aerosol mass. However, most Earth system models (ESMs) inadequately represent dust aerosols larger than 10 μm in diameter, limiting the accuracy of the simulated dust cycle and climate impacts. Here, we introduce a new modeling framework that captures the full observed size distribution of dust aerosols, incorporating recent advances into a mineral-resolved version of the Community ESM, while addressing known issues in previous versions. Comprehensive evaluation against diverse observations of bulk dust and component minerals demonstrates that the model reproduces the observed dust cycle across particle sizes. Incorporating the previously unrepresented large-dust fractions substantially alters dust budget estimates, highlighting potential changes in simulated climate impacts and underscoring the importance of comprehensive size-resolved dust modeling. Despite these advancements, uncertainties persist. Our results indicate that a size-dependent reduction in settling velocity is required to reproduce the observed dust size distribution downwind of source regions. Specifically, in the new model, the gravitational settling velocity of dust particles larger than 10 μm in diameter must be reduced by as much as 85% to achieve agreement with observations. This empirical reduction serves as a constraint on physics-based models of dust settling. Future developments should address misrepresented physical processes that hinder accurate modeling of the large dust aerosol transport. Expanding observational data sets covering the full-size distribution is also essential to better constrain the dust cycle and improve the representation of dust optical properties and climate effects.

mineral dust↗

Effects of Systematic and Random Errors on the Retrieval of Particle Microphysical Properties from Multiwavelength Lidar Measurements Using Inversion with Regularization

In this work we study the effects of systematic and random errors on the inversion of multiwavelength (MW) lidar data using the well-known regularization technique to obtain vertically resolved aerosol microphysical properties. The software implementation used here was developed at the Physics Instrumentation Center (PIC) in Troitsk (Russia) in conjunction with the NASA/Goddard Space Flight Center. Its applicability to Raman lidar systems based on backscattering measurements at three wavelengths (355, 532 and 1064 nm) and extinction measurements at two wavelengths (355 and 532 nm) has been demonstrated widely. The systematic error sensitivity is quantified by first determining the retrieved parameters for a given set of optical input data consistent with three different sets of aerosol physical parameters. Then each optical input is perturbed by varying amounts and the inversion is repeated. Using bimodal aerosol size distributions, we find a generally linear dependence of the retrieved errors in the microphysical properties on the induced systematic errors in the optical data. For the retrievals of effective radius, number/surface/volume concentrations and fine-mode radius and volume, we find that these results are not significantly affected by the range of the constraints used in inversions. But significant sensitivity was found to the allowed range of the imaginary part of the particle refractive index. Our results also indicate that there exists an additive property for the deviations induced by the biases present in the individual optical data. This property permits the results here to be used to predict deviations in retrieved parameters when multiple input optical data are biased simultaneously as well as to study the influence of random errors on the retrievals. The above results are applied to questions regarding lidar design, in particular for the spaceborne multiwavelength lidar under consideration for the upcoming ACE mission.

vertical profiles↗

Composite structural materials

Progress is reported in studies of constituent materials composite materials, generic structural elements, processing science technology, and maintaining long-term structural integrity. Topics discussed include: mechanical properties of high performance carbon fibers; fatigue in composite materials; experimental and theoretical studies of moisture and temperature effects on the mechanical properties of graphite-epoxy laminates and neat resins; numerical investigations of the micromechanics of composite fracture; delamination failures of composite laminates; effect of notch size on composite laminates; improved beam theory for anisotropic materials; variation of resin properties through the thickness of cured samples; numerical analysis composite processing; heat treatment of metal matrix composites, and the RP-1 and RP2 gliders of the sailplane project.

Ansell, G. S.↗

The effect of solid phase reactions on the ballistic properties of propellants

The combustion of NH4ClO4 composite propellants has been studied between 15 and 3000 psi. The emphasis in the program has been on determining the mechanisms by which the fuel components influence the burning rate of the composites. In order to have flexibility in the choice and concentration of the fuel component all combustion experiments were performed with pressed power strands. The fuels studied included those which affected the combustion mechanism of the composite primarily through their effect on: (1) the oxidizer decomposition mechanism and (2) the composite surface temperature. The combustion of pure and doped NH4ClO4 was studied using both pressed powder strands and pressed end burning motor grains. The experimental approach has been essentially a chemical one with emphasis on perturbing those reactions which occur on or immediately adjacent to the surface (zone of influence) of the composite.

Schmidt, W. G.↗

Effects of thermal and environmental exposure on the mechanical properties of graphite/polyimide composites

Composites were exposed in circulating and static air environments up to 589 K for a maximum of 1000 hours. Composites of HT-S, HM-S, Thornel 50S, and Fortafil 5-Y fiber and a new addition type polyimide resin were laminated in a matched-die mold. Flexural strengths, flexural modulus, and interlaminar shear strengths were determined at 297, 533, and 598 K after various durations of exposure. Composite and fiber weight loss characteristics were determined by isothermal gravimetric analysis in air. Properties of composites exposed and tested at the environment temperatures were compared with those determined under short-term exposure. A new short beam interlaminar shear fixture is described. Environmental effects of long-term ambient temperature exposure on the elevated temperature mechanical properties of graphite/polyimide composites are presented.

Hanson, M. P.↗

Metallurgical and tensile property analysis of several silicon carbide/titanium composite systems

Several silicon-carbide fiber reinforced titanium matrix composite systems were investigated to determine composite degradation mechanisms and to develop techniques to minimize loss of mechanical properties during fabrication and in service. Emphasis was on interface control by fiber or matrix coatings. Fibers and matrix materials were sputter coated with various metals to determine the effects of the coatings on basic fiber properties, fiber-matrix interactions, and on composite properties. The effects of limited variations in fabrication temperature on composite properties were determined for composites consolidated by standard press-diffusion-bonding techniques.

Brewer, W. D.↗

Effect of thermal cycling in a Mach 0.3 burner rig on properties and structure of directionally solidified gamma/gamma prime-delta eutectic

An experimental study was carried out to evaluate the effect of cyclic thermal exposures on the mechanical properties of a gamma/gamma prime-delta eutectic alloy parallel to the growth direction. The alloy had a nominal composition by weight of Ni-20 Nb-6 Cr-2.5 Al and was directionally solidified at 3 cm/hr in a furnace with a thermal gradient of at least 200 C/cm. Bars of the alloy were exposed in a Mach 0.3 burner rig and cycled 300 times between 1100 and 425 C. Oxidation-erosion characteristics of the alloy were determined by weight loss measurements at 300-cycle intervals. After cyclic exposure, stress rupture and tensile tests were performed at both 760 and 1040 C. Microstructural changes from cyclic exposure were determined. Thermal cycling resulted in gamma prime coarsening and Widmanstaetten delta precipitation in the gamma phase. An unidentified precipitate, presumably gamma prime, was observed within the delta phase. These microstructural changes did not affect the mechanical properties of the eutectic. High oxidation-erosion weight loss rate was observed.

Gray, H. R.↗

Effect of the degree of disorder on electronic and optical properties in random superlattices

A three-dimensional tight-binding calculation is developed and used to study disorder effects in a realistic random superlattice. With increasing disorder, a tendency of possible indirect-direct band-gap transition is suggested. Direct evidence of mobility edges between localized and extended states in three-dimensional random systems is given. As system disorder increases, the optical absorption intensities increase dramatically from five to forty-five times stronger than the ordered (GaAs)(sub 1)/(AlAs)(sub 1) superlattice. It is believed that the degree of disorder significantly affects electronic and optical properties of GaAs/AlAs random superlattices.

Wang, E. G.↗

Polymer-Oxygen Compatibility Testing: Effect of Oxygen Aging on Ignition and Combustion Properties

The oxygen compatibility of six polymers used in oxygen service was evaluated after exposure for 48 hours to oxygen pressures ranging from 350 to 6200 kPa (50 to 900 psia), and temperatures ranging from 50 to 250 C (122 to 302 F). Three elastomers were tested: CR rubber (C873-70), FKM fluorocarbon rubber (Viton A), and MPQ silicone rubber (MIL-ZZ-765, Class 2); and three thermoplastics were tested: polyhexamethylene adipamide (Zytel 42), polytetrafluoroethylene (Teflon TFE), and polychlorotrifluoroethylene (Neoflon CTFE M400H). Post-aging changes in mass, dimensions, tensile strength, elongation at break, and durometer hardness were determined. Also, the compression set was determined for the three elastomers. Results show that the properties under investigation were more sensitive to oxygen pressure at low to moderate temperatures, and more sensitive to temperature at low to moderate oxygen pressures. Inspection of the results also suggested that both chain scissioning and cross-linking processes were operative, consistent with heterogeneous oxidation. Attempts are underway to verify conclusively the occurrence of heterogeneous oxidation using a simple modulus profiling technique. Finally, the effect of aging at 620 kpa (90 psia) and 121 C (250 F) on ignition and combustion resistance was determined. As expected, aged polymers were less ignitable and combustible (had higher AlTs and lower heats of combustion). Special attention was given to Neoflon CTFE. More specifically, the effect of process history (compression versus extrusion molding) and percent crystallinity (quick- versus slow-quenched) on the AIT, heat of combustion, and impact sensitivity of Neoflon CTFE was investigated. Results show the AIT, heat of combustion, and impact sensitivity to be essentially independent of Neoflon CTFE process history and structure.

Waller, Jess M.↗

Effects of Thermal Cycling on Thermal Expansion and Mechanical Properties of Sic Fiber-reinforced Reaction-bonded Si3n4 Composites

Thermal expansion curves for SiC fiber-reinforced reaction-bonded Si3N4 matrix composites (SiC/RBSN) and unreinforced RBSN were measured from 25 to 1400 C in nitrogen and in oxygen. The effects of fiber/matrix bonding and cycling on the thermal expansion curves and room-temperature tensile properties of unidirectional composites were determined. The measured thermal expansion curves were compared with those predicted from composite theory. Predicted thermal expansion curves parallel to the fiber direction for both bonding cases were similar to that of the weakly bonded composites, but those normal to the fiber direction for both bonding cases resulted in no net dimensional changes at room temperature, and no loss in tensile properties from the as-fabricated condition. In contrast, thermal cycling in oxygen for both composites caused volume expansion primarily due to internal oxidation of RBSN. Cyclic oxidation affected the mechanical properties of the weakly bonded SiC/RBSN composites the most, resulting in loss of strain capability beyond matrix fracture and catastrophic, brittle fracture. Increased bonding between the SiC fiber and RBSN matrix due to oxidation of the carbon-rich fiber surface coating and an altered residual stress pattern in the composite due to internal oxidation of the matrix are the main reasons for the poor mechanical performance of these composites.

Bhatt, R. T.↗

Effects of Fiber/Matrix Interface and its Composition on Mechanical Properties of Hi Nicalon/Celsian Composites

Fiber-reinforced ceramic matrix composites (CMC) are prospective candidate materials for high temperature structural applications in aerospace, energy conservation, power generation, nuclear, petrochemical, and other industries. At NASA Lewis, we are investigating celsian matrix composites reinforced with various types of silicon carbide fibers. The objective of the present study was to investigate the effects of fiber/matrix interface and its composition on the mechanical properties of silicon carbide (Hi-Nicalon) fiber-reinforced celsian matrix composites.

Bansal, Narottam P.↗

Constitutive properties of hypertrophied myocardium: cellular contribution to changes in myocardial stiffness

Recent studies have suggested that pressure overload hypertrophy (POH) alters the viscoelastic properties of individual cardiocytes when studied in isolation. However, whether these changes in cardiocyte properties contribute causally to changes in the material properties of the cardiac muscle as a whole is unknown. Accordingly, a selective, isolated, acute change in cardiocyte constitutive properties was imposed in an in vitro system capable of measuring the resultant effect on the material properties of the composite cardiac muscle. POH caused an increase in both myocardial elastic stiffness, from 20.5 +/- 1.3 to 28.4 +/- 1.8, and viscous damping, from 15.2 +/- 1.1 to 19.8 +/- 1.5 s (normal vs. POH, P < 0.05), respectively. Recent studies have shown that cardiocyte constitutive properties could be acutely altered by depolymerizing the microtubules with colchicine. Colchicine caused a significant decrease in the viscous damping in POH muscles (19.8 +/- 1.5 s at baseline vs. 14.7 +/- 1.3 s after colchicine, P < 0.05). Therefore, myocardial material properties can be altered by selectively changing the constitutive properties of one element within this muscle tissue, the cardiocyte. Changes in the constitutive properties of the cardiocytes themselves contribute to the abnormalities in myocardial stiffness and viscosity that develop during POH.

Non-NASA Center↗