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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

High T(sub g) Polymides for Resin Transfer Molding

A series of new polyimide resins with low melt viscosities and high glass transition temperatures (T(sub g)'s) of 340-350 C were developed for resin transfer molding (RTM) applications. The viscosities of these polyimide resins, based on 2,3,3'4'-Biphenyltetracarboxylic Dianhydride (a-BPDA), are in the range of 10-30 poise. The composites were fabricated successfully at 260-280 C with a pot life of 30-60 minutes by the RTM process. The viscosity profiles of the polyimide resins and the mechanical properties of the polyimide carbon fiber composites will be discussed.

Chuang, Kathy C.↗
NASA NTRS1999

Thermomechanical Fatigue Durability of T650-35/PMR-15 Sheet-Molding Compound Evaluated

High-performance polymer matrix composites (PMC's) continue to be the focus of a number of research efforts aimed at developing cost-effective, lightweight material alternatives for advanced aerospace and aeropropulsion applications. These materials not only offer significant advantages in specific stiffness and strength over their current metal counterparts, but they can be designed and manufactured to eliminate joints and fasteners by combining individual components into integral subassemblies, thus making them extremely attractive for commercial applications. With much emphasis on the low-cost manufacturing aspects of advanced composite structures, there is heightened interest in high-performance sheet-molding compounds (SMC's). Researchers at the NASA Lewis Research Center, in cooperation with the Allison Advanced Development Company, completed an investigation examining the use of T650-35/PMR-15 SMC for a midstage inner-vane endwall application within a gas turbine engine compressor. This component resides in the engine flow path and is subjected not only to high airflow rates, but also to elevated temperatures and pressures. This application is unique in that it represents a very aggressive use of high-performance SMC's, raising obvious concerns related to durability and property retention in the presence of microstructural damage. Therefore, it was necessary to evaluate the fatigue behavior and damage tolerance of this material subjected to a representative thermomechanical fatigue (TMF) mission-cycle loading spectrum.

Castelli, Michael G.↗
NASA NTRS2002

Low Melt Viscosity Resins for Resin Transfer Molding

In recent years, resin transfer molding (RTM) has become one of the methods of choice for high performance composites. Its cost effectiveness and ease of fabrication are major advantages of RTM. RTM process usually requires resins with very low melt viscosity (less than 10 Poise). The optimum RTM resins also need to display high thennal-oxidative stability, high glass transition temperature (T(sub g)), and good toughness. The traditional PMR-type polyimides (e.g. PMR-15) do not fit this requirement, because the viscosities are too high and the nadic endcap cures too fast. High T(sub g), low-melt viscosity resins are highly desirable for aerospace applications and NASA s Reusable Launch Vehicle (RLV) program. The objective of this work is to prepare low-melt viscosity polyimide resins for RTM or resin film infusion (RFI) processes. The approach involves the synthesis of phenylethynyl-terminated imide oligomers. These materials have been designed to minimize their melt viscosity so that they can be readily processed. During the cure, the oligomers undergo both chain extension and crosslinking via the thermal polymerization of the phenylethynyl groups. The Phenylethynyl endcap is preferred over the nadic group due to its high curing temperature, which provides broader processing windows. This work involved the synthesis and polymerization of oligomers containing zig-zag backbones and twisted biphenyl structures. Some A-B type precursors which possessed both nitro and anhydride functionality, or both nitro and amine functionality, were also synthesized in order to obtain the well defined oligomers. The resulting zig-zag structured oligomers were then end-capped with 4-phenylethynylphthalic anhydride (PEPA) for further cure. The properties of these novel imide oligomers are evaluated.

Harris, Frank W.↗
NASA NTRS2007

Low-melt Viscosity Polyimide Resins for Resin Transfer Molding (RTM) II

A series of polyimide resins with low-melt viscosities in the range of 10-30 poise and high glass transition temperatures (Tg s) of 330-370 C were developed for resin transfer molding (RTM) applications. These polyimide resins were formulated from 2,3,3 ,4 -biphenyltetracarboxylic dianhydride (a-BPDA) with 4-phenylethynylphthalic anhydride endcaps along with either 3,4 - oxyaniline (3,4 -ODA), 3,4 -methylenedianiline, (3,4 -MDA) or 3,3 -methylenedianiline (3,3 -MDA). These polyimides had pot lives of 30-60 minutes at 260-280 C, enabling the successful fabrication of T650-35 carbon fiber reinforced composites via RTM process. The viscosity profiles of the polyimide resins and the mechanical properties of the polyimide carbon fiber composites will be discussed.

Chuang, Kathy C.↗
NASA NTRS2008

Noise Radiation from a Continuous Mold-Line Link Flap Configuration

The results of an experimental study of the noise from a Continuous Mold-Line Link (CML) flap are presented. Acoustic and unsteady surface pressure measurements were performed on a main element wing section with a half-span CML flap in NASA Langley s Quiet Flow Facility. The acoustic data were acquired with a medium aperture directional array (MADA) of microphones. The Deconvolution Approach for the Mapping of Acoustic Sources (DAMAS) method is applied to determine the spatial distribution and strength of the noise sources over the surface of the test model. A Coherent Output Power (COP) method which relates the output from unsteady surface pressure sensors to the output of the MADA is also used to obtain more detailed characteristics of the noise source distribution in the trailing edge region of the CML. These results are compared to those obtained for a blunt flap to quantify the level of noise benefit that is achieved with the CML flap. The results indicate that the noise from the CML region of the flap is 5 to 17 dB lower (depending on flap deflection and Mach number) than the noise from the side edge region of the blunt flap. Lower noise levels are obtained for all frequencies. Spectral analysis of the noise from the cove region of the CML and blunt flap models also reveal a spectral peak in the high frequency range that is related to noise scattering at the trailing edge of the main element. The peaks in the CML and blunt flap cove noise spectra are close in level and often exceed blunt side edge noise. Applying a strip of serrated tape to the trailing edge of the CML flap model main airfoil, reduced the peak but increased other noise somewhat. Directivity measurements show that the CML flap can be more directional than the blunt flap.

Hutcheson, Florence V.↗
NASA NTRS2005

PETIs as High-Temperature Resin-Transfer-Molding Materials

Compositions of, and processes for fabricating, high-temperature composite materials from phenylethynyl-terminated imide (PETI) oligomers by resin-transfer molding (RTM) and resin infusion have been developed. Composites having a combination of excellent mechanical properties and long-term high-temperature stability have been readily fabricated. These materials are particularly useful for the fabrication of high-temperature structures for jet-engine components, structural components on highspeed aircraft, spacecraft, and missiles. Phenylethynyl-terminated amide acid oligomers that are precursors of PETI oligomers are easily made through the reaction of a mixture of aromatic diamines with aromatic dianhydrides at high stoichiometric offsets and 4-phenylethynylphthalic anhydride (PEPA) as an end-capper in a polar solvent such as N-methylpyrrolidinone (NMP). These oligomers are subsequently cyclodehydrated -- for example, by heating the solution in the presence of toluene to remove the water by azeotropic distillation to form low-molecular-weight imide oligomers. More precisely, what is obtained is a mixture of PETI oligomeric species, spanning a range of molecular weights, that exhibits a stable melt viscosity of less than approximately 60 poise (and generally less than 10 poise) at a temperature below 300 deg C. After curing of the oligomers at a temperature of 371 deg C, the resulting polymer can have a glass-transition temperature (Tg) as high as 375 C, the exact value depending on the compositions.

Connell, John N.↗
NASA NTRS2004

Resin-Transfer-Molding of a Tool Face

A resin-transfer-molding (RTM) process has been devised for fabricating a matrix/graphite-cloth composite panel that serves as tool face for manufacturing other composite panels. Heretofore, RTM has generally been confined to resins with viscosities low enough that they can readily flow through interstices of cloth. The present process makes it possible to use a high-temperature, more-viscous resin required for the tool face. First, a release layer and then a graphite cloth are laid on a foam pattern that has the desired contour. A spring with an inside diameter of 3/8 in. (.9.5 mm) is placed along the long dimension of the pattern to act as a conduit for the resin. Springs with an inside diameter of 1/4 in. (.6.4 mm) are run off the larger lengthwise spring for distributing the resin over the tool face. A glass cloth is laid on top to act as breather. The whole layup is vacuum-bagged. Resin is mixed and made to flow under vacuum assistance to infiltrate the layup through the springs. The whole process takes less than a day, and the exposure of personnel to resin vapors is minimized.

Fowler, Mike↗
NASA NTRS2011

Noise Radiation from a Continuous Mold-Line Link Flap Configuration

The results of an experimental study of the noise from a Continuous Mold-Line Link (CML) flap are presented. Acoustic and unsteady surface pressure measurements were performed on a main element wing section with a half-span CML flap in NASA Langley s Quiet Flow Facility. The acoustic data were acquired with a medium aperture directional array (MADA) of microphones. The Deconvolution Approach for the Mapping of Acoustic Sources (DAMAS) method is applied to determine the spatial distribution and strength of the noise sources over the surface of the test model. A Coherent Output Power (COP) method which relates the output from unsteady surface pressure sensors to the output of the MADA is also used to obtain more detailed characteristics of the noise source distribution in the trailing edge region of the CML. These results are compared to those obtained for a blunt flap to quantify the level of noise benefit that is achieved with the CML flap. The results indicate that the noise from the CML region of the flap is 5 to 17 dB lower (depending on flap deflection and Mach number) than the noise from the side edge region of the blunt flap. Lower noise levels are obtained for all frequencies. Spectral analysis of the noise from the cove region of the CML and blunt flap models also reveal a spectral peak in the high frequency range that is related to noise scattering at the trailing edge of the main element. The peaks in the CML and blunt flap cove noise spectra are close in level and often exceed blunt side edge noise. Applying a strip of serrated tape to the trailing edge of the CML flap model main airfoil reduced the peak but increased other noise somewhat. Directivity measurements show that the CML flap can be more directional than the blunt flap.

Hutcheson, Florence V.↗
NASA NTRS2012

Processing and Properties of Vacuum Assisted Resin Transfer Molded Phenylethynyl Terminated Imide Composites

Polyimide composites are very attractive for applications that require a high strength to weight ratio and thermal stability. Recent work at NASA Langley Research Center (LaRC) has concentrated on developing new polyimide resin systems that can be processed without the use of an autoclave for advanced aerospace applications. Due to their low melt viscosities and long melt stability, certain phenylethynyl terminated imides (PETI) can be processed into composites using high temperature vacuum assisted resin transfer molding (HT-VARTM). VARTM has shown the potential to reduce the manufacturing cost of composite structures. In the current study, two PETI resins, LARC(Trademark) PETI-330 and LARC(Trademark) PETI-9, were infused into carbon fiber preforms at 260 C and cured at temperatures up to 371 C. Photomicrographs of polished cross sections were taken and void contents, determined by acid digestion, were below 4.5%. Mechanical properties including short block compression (SBC), compression after impact (CAI), and open hole compression (OHC) were determined at room temperature, 177 C, and 288 C. Both PETI-9 and PETI-330 composites demonstrated very good retention of mechanical properties at elevated temperatures. SBC and OHC properties after aging for 1000 hours at temperatures up to 288 C were also determined.

Cano, Roberto J.↗
NASA NTRS2012

Space Shuttle Orbiter Digital Outer Mold Line Scanning

The Space Shuttle Orbiters Discovery and Endeavor have been digitally scanned to produce post-flight configuration outer mold line surfaces. Very detailed scans of the windward side of these vehicles provide resolution of the detailed tile step and gap geometry, as well as the reinforced carbon carbon nose cap and leading edges. Lower resolution scans of the upper surface provide definition of the crew cabin windows, wing upper surfaces, payload bay doors, orbital maneuvering system pods and the vertical tail. The process for acquisition of these digital scans as well as post-processing of the very large data set will be described.

Campbell, Charles H.↗
NASA NTRS2014

Producing Zirconium Diboride Components with Complex, Near-Net Shape Geometries by Aqueous Room-Temperature Injection Molding

Room-temperature injection molding is proposed as a novel, low-cost and more energy efficient manufacturing process capable of forming complex-shaped zirconium diboride (ZrB2) parts. This innovative processing method utilized aqueous suspensions with high powder loading and a minimal amount (5 vol.) of water-soluble polyvinylpyrrolidone (PVP), which was used as a viscosity modifier. Rheological characterization was performed to evaluate the room-temperature flow properties of ZrB2-PVP suspensions. ZrB2 specimens were fabricated with high green body strength and were machinable prior to binder removal despite their low polymer content. After binder burnout and pressureless sintering, the bulk density and microstructure of specimens were characterized using Archimedes technique and scanning electron microscopy. X-Ray Diffraction was used to determine the phase compositions present in sintered specimens. Ultimate strength of sintered specimens will be determined using ASTM C1323-10 compressive C-ring test.

Near-Net Shape Forming↗
NASA NTRSDate not supplied

Evaluation of Hydrolytic Degradation of Poly(lactic acid) (PLA) Matrices in Compression Molded Flax/PLA Composites

Poly(lactic acid) (PLA) is a bio-based plastic that is an attractive alternative to its petroleum-based counterparts because of its high strength and ease of thermal processing. In an effort to reduce the carbon footprint of fossil-fuel based polymer matrix composites, PLA along with naturally-occurring fibers are being explored to produce entirely bio-based replacements. Challenges in producing these composites occur due to the water affinity of the natural fibers and the susceptibility of the PLA to hydrolytic degradation. Hydrolysis of PLA occurs at elevated processing temperatures and can further be accelerated by the presence of water contained in the natural fibers. This talk will discuss the challenges and considerations associated with processing PLA in the presence of water-absorbing flax fibers to produce composites via compression molding. The thermal, physical, and mechanical properties of PLA/flax composites will be characterized at various processing times in an effort to identify optimal manufacturing conditions.

Natural Materials↗
NASA NTRS1967

Precision metal molding

Method provides precise alignment for metal-forming dies while permitting minimal thermal expansion without die warpage or cavity space restriction. The interfacing dowel bars and die side facings are arranged so the dies are restrained in one orthogonal angle and permitted to thermally expand in the opposite orthogonal angle.

Townhill, A.↗
NASA NTRS1971

Improved wax mold technique forms complex passages in solid structures

Low-cost fabricating technique produces minute, complex air passages in fluidic devices. Air jet interactions in these function as electronic and electromechanical control systems. Wax cores are fabricated without distortion by two-wax process using nonsoluble pattern-wax and water-soluble wax. Significant steps in fabrication process are discussed.

Hellbaum, R. F.↗
NASA NTRS1971

Sprue cutoff tool for molded FCC plugs

Sprue removal operation is accomplished by positioning plug on tool bed, adjusting blades, and moving handle down for cutting process. Blades are raised to remove trimmed plug.

Angele, W.↗