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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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At least 1,567 records · Page 87
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Space Shuttle Orbiter - Leading edge structural design/analysis and material allowables

Reinforced Carbon-Carbon (RCC), a structural composite whose development was targeted for the high temperature reentry environments of reusable space vehicles, has successfully demonstrated that capability on the Space Shuttle Orbiter. Unique mechanical properties, particularly at elevated temperatures up to 3000 F, make this material ideally suited for the 'hot' regions of multimission space vehicles. Design allowable characterization testing, full-scale development and qualification testing, and structural analysis techniques will be presented herein that briefly chart the history of the RCC material from infancy to eventual multimission certification for the Orbiter. Included are discussions pertaining to the development of the design allowable data base, manipulation of the test data into usable forms, and the analytical verification process.

Johnson, D. W.↗
DOE OSTI2023

Remarkable enhancement in thermal conductivity of stainless-steel leveraging metal composite via laser powder bed fusion: 316L-Cu composite

This work aimed to significantly enhance the thermal conductivity of the SS matrix by fabricating a metal composite SS-Cu system utilizing a laser powder bed fusion process. The impact of process parameters on the microstructure of SS-Cu samples is investigated. Here, the processing and post-processing factors that influence the effective thermal conductivity of the metal composite SS-Cu system are discussed. Then, the effective thermal conductivity and mechanical properties of the SS-Cu composite are measured at room temperature and operating temperature of 300 °C. The optimized laser powder bed fusion parameters led to low Marangoni convection, high cooling rate, greater macro-segregation, and higher thermal conductivity values albeit at the cost of ductility in SS-Cu metal composite likely due to the presence of the unmelted powder particles. As-printed SS-60 vol % Cu and annealed SS-60 vol % Cu had 2.5X and 6.6X thermal conductivity enhancement, respectively. During annealing, phase separation, partial melting of Cu, and formation of a continuous network of Cu surrounding SS play a key role in enhancing the thermal conductivity of the SS-Cu metal composite structure.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Rapid adhesive bonding and field repair of aerospace materials

Adhesive bonding in the aerospace industry typically utilizes autoclaves or presses which have considerable thermal mass. As a consequence, the rates of heatup and cooldown of the bonded parts are limited and the total time and cost of the bonding process are often relatively high. Many of the adhesives themselves do not inherently require long processing times. Bonding could be performed rapidly if the heat was concentrated in the bond lines or at least in the adherends. Rapid Adhesive Bonding concepts are developed to utilize induction heating techniques to provide heat directly to the bond line and/or adherends without heating the entire structure, supports, and fixtures of a bonding assembly. Bonding times for specimens can be cut by a factor of 10 to 100 compared to standard press or autoclave bonding. The development of Rapid Adhesive Bonding for lap shear specimens (per ASTM D1002 and D3163), for aerospace panel or component bonding, and for field repair needs of metallic and advanced fiber reinforced polymeric-matrix composite structures is reviewed. Equipment and procedures are described for bonding and repairing thin sheets, simple geometries, and honeycomb core panels.

Stein, B. A.↗
NASA NTRS1989

Development and application of nonflammable, high-temperature beta fibers

Recent advances in fiber technology have contributed to the success of the U.S. space program. The inorganic fiber Beta, developed as a result of efforts begun in the early 1960's and heightened following the January 27, 1967 Apollo fire is unique among inorganic and organic fibers. It has been developed into woven, nonwoven, knitted, braided, coated and printed structures. All of these were used extensively for the Apollo, Skylab, Apollo-Soyuz test project, space shuttle, Spacelab, and satellite programs. In addition to being used successfully in the space program, Beta fibers are being used commercially as firesafe fabrics in homes, hospitals, institutions, public buildings, aircraft, and public transportation, wherever total nonflammability is required. One of the most unique applications of the Beta composite structure is the roofing material for the 80,000-seat Detroit Lion's Silverdome and 5 square miles of the Jeddah International Airport in Saudi Arabia. This fiber has been successfully incorporated into 165 major public construction projects around the globe. The United States alone has used more than 12 million square yards of the material. Beta fiber has been used successfully to date and has a promising future with unlimited potential for both space and commercial application. Efforts are currently underway to improve Beta fiber to meet the requirements of extended service life for the Space Station Freedom, lunar outpost, and Mars exploration missions.

Dawn, Frederic S.↗
NASA NTRS2017

Three-Dimensional High Fidelity Progressive Failure Damage Modeling of NCF Composites

Performance prediction of off-axis laminates is of significant interest in designing composite structures for energy absorption. Phenomenological models available in most of the commercial programs, where the fiber and resin properties are smeared, are very efficient for large scale structural analysis, but lack the ability to model the complex nonlinear behavior of the resin and fail to capture the complex load transfer mechanisms between the fiber and the resin matrix. On the other hand, high fidelity mesoscale models, where the fiber tows and matrix regions are explicitly modeled, have the ability to account for the complex behavior in each of the constituents of the composite. However, creating a finite element model of a larger scale composite component could be very time consuming and computationally very expensive. In the present study, a three-dimensional mesoscale model of non-crimp composite laminates was developed for various laminate schemes. The resin material was modeled as an elastic-plastic material with nonlinear hardening. The fiber tows were modeled with an orthotropic material model with brittle failure. In parallel, new stress based failure criteria combined with several damage evolution laws for matrix stresses were proposed for a phenomenological model. The results from both the mesoscale and phenomenological models were compared with the experiments for a variety of off-axis laminates.

Aitharaju, Venkat↗
NASA NTRS2019

Integration of MAC/GMC into CalculiX, an Open Source Finite Element Code

An analysis framework is presented that makes available multiscale analysis of composite structures using the open-source FEA solver package CalculiX CrunchiX (CCX). At the center of this framework is the coupling of the Finite Element Analysis - Micromechanics Analysis Code (FEAMAC) library from NASA's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) to allow micromechanics analysis. The results show that the proposed coupling can be used with appropriate care for multiscale FEA simulations of composite materials. The largest error reported in this validation was in a four-point bend test specimen with an error of less than 1% difference in the maximum deflection of the beam.

Yapor Genao, Francisco A.↗
DOE OSTI2023

Synthesis and Characterization of Carbon Microbeads

We report a microfluidic-based droplet generation platform for synthesizing micron-sized porous carbon microspheres. The setup employs carbon materials such as graphite, carbon nanotubes, graphene, fullerenes, and carbon black as starting materials. Custom composition, structure, and function are achieved through combinations of carbon materials, cross-linkers, and additives along with variations in process parameters. Carbon materials can be assembled into spheres with a mean diameter of units to hundreds of μm with relatively tight size distribution (<25% RSD). Pore structure and size (tens to hundreds of angstrom) can be modulated by incorporating porogen/coporogen dilutants during synthesis. The microbeads have excellent mechanical stability with an elastic modulus of hundreds of MPa. They can sustain high dynamic fluid flow pressures of up to 9000 psi. This work lays the foundation for synthesizing novel tailorable and customizable carbon microbeads. It opens avenues for applying these novel materials for composite and additive manufacturing, energy, life science, and biomedical applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1980

Analysis and measurements of low frequency lightning component penetration through aerospace vehicle metal and graphite skins

An analysis of the shielding properties of mixed metal and graphite composite structures has illustrated some important aspects of electromagnetic field penetration into the interior. These include: (1) that graphite access doors on metallic structures will attenuate lightning magnetic fields very little; conversely, metal doors on a graphite structure will also attenuate fields from lightning strike currents very little, i.e., homogeneity of the shield is a critical factor in shielding and (2) that continuous conductors between two points inside a graphite skin such as an air data probe metallic tubing connection to an air data computer can allow large current penetrations into a vehicle interior. The true weight savings resulting from the use of composite materials can only be evaluated after the resulting electromagnetic problems such as current penetrations have been solved, and this generally requires weight addition in the form of cable shields, conductor bonding or external metallization.

Robb, J. D.↗
NASA NTRS1995

Electron density power spectrum in the local interstellar medium

Interstellar scintillation (ISS), fluctuations in the amplitude and phase of radio waves caused by scattering in the interstellar medium, is important as a diagnostic of interstellar plasma turbulence. ISS is also of interest because it is noise for other radio astronomical observations. The unifying concern is the power spectrum of the interstellar electron density. Here we use ISS observations through the nearby (less than or approximately =1 kpc) (ISM) to estimate the spectrum. From measurements of angular broadening of pulsars and extragalactic sources, decorrelation bandwidth of pulsars, refractive steering of features in pulsar dynamic spectra, dispersion measured fluctuations of pulsars, and refractive scintillation index measurements, we construct a composite structure function that is approximately power law over 2 x 10(exp 6) m less than scale less than 10(exp 13) m. The data are consistent with the structure function having a logarithmic slope versus baseline less than 2; thus there is a meaningful connection between scales in the radiowave fluctuation field and the scales in the electron density field causing the scattering. The data give an upper limit to the inner scale, l(sub o) less than or approximately 10(exp 8) m and are consistent with much smaller values. We construct a composite electron density spectrum that is approximately power law over at least the approximately = 5 decade wavenumber range 10(exp -13)/m less than wavenumber less than 10(exp -8)/m and that may extend to higher wavenumbers. The average spectral index of electron density over this wavenumber range is approximately = 3.7, very close to the value expected for a Kolmogorov process. The outer scale size, L(sub o), must be greater than or approximately = 10(exp 13) m (determined from dispersion measure fluctuations). When the ISS data are combined with measurements of differential Faraday rotation angle, and gradients in the average electron density, constraints can be put on the spectrum at much smaller wave numbers. The composite spectrum is consistent with a Kolmogorov-like power law over a huge range (10 or more decades) of spatial wavenumber with an infrared outer scale L(sub o) greater than or approximately 10(exp 18)m. This power-law subrange-expressed as ratio of outer to inner scales-is comparable to or larger than that of other naturally occurring turbulent fluids, such as the oceans or the solar wind. We outline some of the theories for generating and maintaining such a spectrum over this huge wavenumber range.

Armstrong, J. W.↗
NASA NTRS1999

Hollow Polyimide Microspheres

A shaped article composed of an aromatic polyimide has a hollow, essentially spherical structure and a particle size of about 100 to about 1500 microns, a density of about I to about 6 pounds/ft3 and a volume change of 1 to about 20% by a pressure treatment of 30 psi for 10 minutes at room temperature. A syntactic foam, made of a multiplicity of the shaped articles which are bounded together by a matrix resin to form an integral composite structure, has a density of about 3 to about 30 pounds/cu ft and a compression strength of about 100 to about 1400 pounds/sq in.

Weiser, Erik S.↗
NASA NTRS1980

Application of the cubic polynomial strength criterion to the failure analysis of composite materials

A comparative failure analysis is presented based on the application of quadratic and cubic forms of the tensor polynomial lamina strength criterion to various composite structural configurations in a plane stress state. Failure loads have been predicted for off-angle laminates under simple loading conditions and for symmetric-balanced laminates subject to varying degrees of biaxial tension, including configurations subject to multimode failures. Some experimental data are also provided to support these calculations. From these results, the necessity of employing a cubic strength criterion to accurately predict the failure of composite laminae is demonstrated.

Tennyson, R. C.↗
NASA NTRS2001

Hollow Polyimide Microspheres

A shaped article composed of an aromatic polyimide has a hollow, essentially spherical structure and a particle size of about 100 to about 1500 micrometers, a density of about 1 to about 6 pounds/cubic foot and a volume change of 1 to about 20% by a pressure treatment of 30 psi for 10 minutes at room temperature. A syntactic foam, made of a multiplicity of the shaped articles which are bonded together by a matrix resin to form an integral composite structure, has a density of about 3 to about 30 pounds/cubic feet and a compression strength of about 100 to about 1400 pounds/sq inch.

Weiser, Erik S.↗
DOE OSTI2022

Cs 3 Bi 2 I 9 -hydroxyapatite composite waste forms for cesium and iodine immobilization

Perovskite-based ceramic composites were developed as potential waste form materials for immobilizing cesium (Cs) and iodine (I) with high waste loadings and chemical durability. The perovskite Cs 3 Bi 2 I 9 has high Cs (22 wt%) and I (58 wt%) content, and thus can be used as a potential host phase to immobilize these critical radionuclides. In this work, the perovskite Cs 3 Bi 2 I 9 phase was synthesized by a cost effective solution-based approach, and was embedded into a highly durable hydroxyapatite matrix by spark plasma sintering to form dense ceramic composite waste forms. The chemical durabilities of the monolithic Cs 3 Bi 2 I 9 and Cs 3 Bi 2 I 9 -hydroxyapatite composite pellets were investigated by static and semi-dynamic leaching tests, respectively. Cs and I are incongruently released from the matrix for both pure Cs 3 Bi 2 I 9 and composite structures. The normalized Cs release rate is faster than that of I, which can be explained by the difference in the strengths between Cs-I and Bi-I bonds as well as the formation of insoluble micrometer-sized BiOI precipitates. The activation energies of elemental releases based on dissolution and diffusion-controlled mechanisms are determined with significantly higher energy barriers for dissolution from the composite versus that of the monolithic Cs 3 Bi 2 I 9 . The ceramic-based composite waste forms exhibit excellent chemical durabilities and waste loadings, commensurate with the state-of-the-art glass-bonded perovskite composites for I and Cs immobilization.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Formation and energetics of amorphous rare earth (RE) carbonates in the RE 2 O 3 –CO 2 –H 2 O system

Amorphous materials are of interest in the genesis of crystalline solids. They are often the first to precipitate from supersaturated solutions and are in the nanometer size range, transforming into a nanocrystalline metastable phase, and then to thermodynamically stable phases. One must seek knowledge of the composition, structure, thermodynamics, kinetics, and reaction pathways that relate the amorphous and crystalline phases. The subject of this study is the amorphous phases in the system RE 2 O 3 -CO 2 –H 2 O (RE- La, Nd, Dy,Yb). They were synthesized via direct precipitation and urea hydrolysis, and characterized by powder XRD, DTA with mass spectrometric analysis of the evolved gases. Phases have the non-stoichiometric composition RE 2 O 3 ·xCO 2 ·yH 2 O (1 < x < 3, 3 < y <7), which is different from that of crystalline simple carbonates and hydroxycarbonates. Thus we consider them to be amorphous precursors, rather than amorphous carbonates. High temperature oxide melt solution calorimetry in molten sodium molybdate solvent was used to derive their enthalpies of formation from oxides and elements. Increase of energetic stability per mole of RE 2 O 3 compounds occurs in the order: RE 2 O 3 → 2RE(OH)3→ 2REO(OH) → RE 2 O 2 CO 3 → Amorphous precursor → 2(REOHCO 3 ) → RE 2 (CO 3 ) 3 ·yH 2 O. We calculated the enthalpies of possible transformations of amorphous precursors to crystalline phases and conclude that thermodynamics determines the dependence of the crystallizing products on the temperature and partial pressure of CO 2 and H 2 O. Amorphous precursors are clearly intermediate in the synthesis, and ternary phases containing both H 2 O and CO 2 compete with each other in terms of thermodynamic stability. The energy landscape obtained here will allow one to directly synthesize specific products and control their functionality.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2000

Hollow Polyimide Microspheres

A shaped article composed of an aromatic polyimide has a hollow, essentially spherical structure and a particle size of about 100 to about 1500 microns a density of about 1 to about 6 pounds/cubic ft and a volume change of 1 to about 20 percent by a pressure treatment of 30 psi for 10 minutes at room temperature. A syntactic foam, made of a multiplicity of the shaped articles which are bonded together by a matrix resin to form an integral composite structure, has a density of about 3 to about 30 pounds/cubic ft and a compression strength 2 of about 100 to about 1400 pounds/sq in.

Weiser, Erik S.↗
NASA NTRS2017

Application of the Quadrupole Method for Simulation of Passive Thermography

Passive thermography has been shown to be an effective method for in-situ and real time nondestructive evaluation (NDE) to measure damage growth in a composite structure during cyclic loading. The heat generation by subsurface flaw results in a measurable thermal profile at the surface. This paper models the heat generation as a planar subsurface source and calculates the resultant temperature profile at the surface using a three dimensional quadrupole. The results of the model are compared to finite element simulations of the same planar sources and experimental data acquired during cyclic loading of composite specimens.

Winfree, William P.↗
DOE OSTI2020

Revealing the Structural Evolution and Phase Transformation of O3-Type NaNi 1/3 Fe 1/3 Mn 1/3 O 2 Cathode Material on Sintering and Cycling Processes

O-type layered oxide cathode materials can be easily synthesized for a full sodium stoichiometry with high specific capacity, but they all suffer from a capacity fade on cycling. The sintering process control and optimization are critical to ensure a high quality and consistency of the prepared cathode materials with stable structure. Herein, in situ high-energy X-ray diffraction (HEXRD) was first employed to investigate the phase evolution of the oxides during the sintering process of O3-type NaNi 1/3 Fe 1/3 Mn 1/3 O 2 . The in situ HEXRD and both operando Bragg coherent diffraction (BCXD) and coherent multicrystal diffraction (CMCD) were utilized to investigate the phase transformation of the cathode materials during the sodiation/desodiation process. A composite structure comprised of O-type and P-type oxides was formed after the initial electrochemical activation of the cathode material, resulting in good structural and electrochemical stability. This finding implies that strain engineering can be a new design philosophy for the development of next generation high-performance sodium ion cathodes.

25 ENERGY STORAGE↗