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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Autoclave processing for composite material fabrication. 1: An analysis of resin flows and fiber compactions for thin laminate

High quality long fiber reinforced composites, such as those used in aerospace and industrial applications, are commonly processed in autoclaves. An adequate resin flow model for the entire system (laminate/bleeder/breather), which provides a description of the time-dependent laminate consolidation process, is useful in predicting the loss of resin, heat transfer characteristics, fiber volume fraction and part dimension, etc., under a specified set of processing conditions. This could be accomplished by properly analyzing the flow patterns and pressure profiles inside the laminate during processing. A newly formulated resin flow model for composite prepreg lamination process is reported. This model considers viscous resin flows in both directions perpendicular and parallel to the composite plane. In the horizontal direction, a squeezing flow between two nonporous parallel plates is analyzed, while in the vertical direction, a poiseuille type pressure flow through porous media is assumed. Proper force and mass balances have been made and solved for the whole system. The effects of fiber-fiber interactions during lamination are included as well. The unique features of this analysis are: (1) the pressure gradient inside the laminate is assumed to be generated from squeezing action between two adjacent approaching fiber layers, and (2) the behavior of fiber bundles is simulated by a Finitely Extendable Nonlinear Elastic (FENE) spring.

Hou, T. H.↗
NASA NTRS1971

The development of autoclave processable, thermally stable adhesives for titanium alloy and graphite composite structures

The A-type polyimide adhesive resin P11B was modified by use of mixed diamines (thio-dianiline and meta phenylene diamine) which provided the desired autoclave processability. This new resin was termed P11BA. It was shown that copolymeric blends of P11BA and Amoco AI-1137 amide-imide resin provided improved adhesive properties when autoclave processed over the properties obtained previously by press bonding with P11B based copolymeric blended adhesives. Properties of bonded assemblies are presented for long-term aging at both elevated and low temperatures, and also stress-rupture tests at elevated temperature.

Vaughan, R. W.↗
NASA NTRS1992

Intelligent sensor-model automated control of PMR-15 autoclave processing

An intelligent sensor model system has been built and used for automated control of the PMR-15 cure process in the autoclave. The system uses frequency-dependent FM sensing (FDEMS), the Loos processing model, and the Air Force QPAL intelligent software shell. The Loos model is used to predict and optimize the cure process including the time-temperature dependence of the extent of reaction, flow, and part consolidation. The FDEMS sensing system in turn monitors, in situ, the removal of solvent, changes in the viscosity, reaction advancement and cure completion in the mold continuously throughout the processing cycle. The sensor information is compared with the optimum processing conditions from the model. The QPAL composite cure control system allows comparison of the sensor monitoring with the model predictions to be broken down into a series of discrete steps and provides a language for making decisions on what to do next regarding time-temperature and pressure.

Hart, S.↗
NASA NTRS2010

Evaluation of Sandwich Structure Bonding In Out-of-Autoclave Processing

The out-of-autoclave-vacuum-bag-only (OOA-VBO) process is low in capital expenditures compared to the traditional autoclave, however, the material challenges for OOA-VBO workable material systems are high. Presently there are few such aerospace grade prepreg materials available commercially. In this study, we evaluated processing and properties of honeycomb sandwich structure (HC/SS) panels fabricated by co-curing composite face sheet with adhesives by the OOA-VBO process in an oven. The prepreg materials were IM7/MTM 45-1 and T40-800B/5320. Adhesives studied were AF-555M, XMTA-241/PM15, FM-309-1M and FM-300K. Aluminum H/C cores with and without perforations were included. It was found that adhesives in IM7/MTM 45-1/AF-555M, T40-800B/5320/FM 309-1M and T40-800B/5320/FM-300K panels all foamed but yielded high flatwise tensile (FWT) strength values above 8,275 kPA (1,200 psi). IM7/MTM 45-1/XMTA-241/PM15 did not foam, yet yielded a low FWT strength. SEM photomicrographs revealed that the origin of this low strength was poor adhesion in the interfaces between the adhesive and face sheet composite due to poor wetting associated with the high initial viscosity of the XMTA-241/PM15 adhesive.

Hou, Tan-Hung↗
NASA NTRS2013

Elevated Temperature, Notched Compression Performance of Out of Autoclave Processed Composites

Curved honeycomb sandwich panels composed of carbon fiber reinforced toughened-epoxy polymer facesheets are being evaluated for potential use as payload fairing components on the NASA heavy-lift space launch system (HL-SLS). These proposed composite sandwich panels provide the most efficient aerospace launch structures, and offer mass and thermal advantages when compared with existing metallic payload fairing structures. NASA and industry are investigating recently developed carbon fiber epoxy prepreg systems which can be fabricated using out-of autoclave (OOA) processes. Specifically, OOA processes using vacuum pressure in an oven and thereby significantly reducing the cost associated with manufacturing large (up to 10 m diameter) composite structures when compared with autoclave. One of these OOA composite material systems, CYCOM(R) 5320-1, was selected for manufacture of a 1/16th scale barrel portion of the payload fairing; such that, the system could be compared with the well-characterized prepreg system, CYCOM(R) 977-3, typically processed in an autoclave. Notched compression coupons for each material were obtained from the minimum-gauge flat laminate [60/-60/0]S witness panels produced in this manufacturing study. The coupons were also conditioned to an effective moisture equilibrium point and tested according to ASTM D6484M-09 at temperatures ranging from 25 C up to 177 C. The results of this elevated temperature mechanical characterization study demonstrate that, for thin coupons, the OHC strength of the OOA laminate was equivalent to the flight certified autoclave processed composite laminates; the limitations on the elevated temperature range are hot-wet conditions up to 163 C and are only within the margins of testing error. At 25 C, both the wet and dry OOA material coupons demonstrated greater OHC failure strengths than the autoclave processed material laminates. These results indicate a substantial improvement in OOA material development and processing since previous studies have consistently reported OOA material strengths on par or below those of autoclave processed composite laminates.

Grimsley, Brian W.↗
NASA NTRS1985

Optimal cure cycle design for autoclave processing of thick composites laminates: A feasibility study

The thermal analysis and the calculation of thermal sensitivity of a cure cycle in autoclave processing of thick composite laminates were studied. A finite element program for the thermal analysis and design derivatives calculation for temperature distribution and the degree of cure was developed and verified. It was found that the direct differentiation was the best approach for the thermal design sensitivity analysis. In addition, the approach of the direct differentiation provided time histories of design derivatives which are of great value to the cure cycle designers. The approach of direct differentiation is to be used for further study, i.e., the optimal cycle design.

Hou, Jean W.↗
NASA NTRS1971

Development of a low void polyimide resin for autoclave processing of glass and graphite reinforced composites.

Experimental studies are described in which new A-type polyimide prepolymer chemical modifications were investigated with the aim of increasing the melt phase duration and temperature range permitting autoclave processing, yet retaining the addition-type cure mechanism required for low-void content composites. Several modification candidates were examined, and one specific formulation was selected for detailed investigation. This A-type polyimide prepolymer formulation is shown to possess the desired characteristics.

Vaughan, R. W.↗
NASA NTRS1972

Low-void polyimide resins for autoclave processing

Development of an advanced A-type polyimide, which can be used to produce autoclave molded, low-void content composites suitable for use at temperatures up to 316 C is reported. It consists of a mixture of methyl nadic anhydride, an 80:20 molar ratio of methylene dianaline and thiodianilene, and pyromellitic dianhydride.

Jones, R. J.↗
NASA NTRS2000

NASA Out-of-Autoclave Process Technology Development

Polymer matrix composites (PMCS) will play a significant role in the construction of large reusable launch vehicles (RLVs), mankind's future major access to low earth orbit and the international space station. PMCs are lightweight and offer attractive economies of scale and automated fabrication methodology. Fabrication of large RLV structures will require non-autoclave methods which have yet to be matured including (1) thermoplastic forming: heated head robotic tape placement, sheet extrusion, pultrusion, molding and forming; (2) electron beam curing: bulk and ply-by-ply automated placement; (3) RTM and VARTM. Research sponsored by NASA in industrial and NASA laboratories on automated placement techniques involving the first 2 categories will be presented.

Johnston, Norman, J.↗
NASA NTRS1992

ASRM test report: Autoclave cure process development

ASRM insulated segments will be autoclave cured following insulation pre-form installation and strip wind operations. Following competitive bidding, Aerojet ASRM Division (AAD) Purchase Order 100142 was awarded to American Fuel Cell and Coated Fabrics Company, Inc. (Amfuel), Magnolia, AR, for subcontracted insulation autoclave cure process development. Autoclave cure process development test requirements were included in Task 3 of TM05514, Manufacturing Process Development Specification for Integrated Insulation Characterization and Stripwind Process Development. The test objective was to establish autoclave cure process parameters for ASRM insulated segments. Six tasks were completed to: (1) evaluate cure parameters that control acceptable vulcanization of ASRM Kevlar-filled EPDM insulation material; (2) identify first and second order impact parameters on the autoclave cure process; and (3) evaluate insulation material flow-out characteristics to support pre-form configuration design.

Nachbar, D. L.↗
NASA NTRS2010

Out-Life Characteristics of IM7/977-3 Composites

The capability to manufacture large structures leads to weight savings and reduced risk relative to joining smaller components. However, manufacture of increasingly large composite components is pushing the out-time limits of epoxy/ carbon fiber prepreg. IM7/977-3 is an autoclave processable prepreg material, commonly used in aerospace structures. The out-time limit is reported as 30 days by the manufacturer. The purpose of this work was to evaluate the material processability and composite properties of 977-3 resin and IM7/977-3 prepreg that had been aged at room temperature for up to 60 days. The effects of room temperature aging on the thermal and visco-elastic properties of the materials were investigated. Neat resin was evaluated by differential scanning calorimetry to characterize thermal properties and change in activation energy of cure. Neat resin was also evaluated by rheometry to characterize its processability in composite fabrication. IM7/977-3 prepreg was evaluated by dynamic mechanical analysis to characterize the curing behavior. Prepreg tack was also evaluated over 60 days. The overall test results suggested that IM7/977-3 was a robust material that offered quality laminates throughout this aging process when processed by autoclave.

Miller, Sandi G.↗
NASA NTRS2015

No-Oven, No-Autoclave Composite Processing

Very large composite structures, such as those used in NASA's Space Launch System, push the boundaries imposed by current autoclaves. New technology is needed to maintain composite performance and free manufacturing engineers from the restraints of curing equipment size limitations. Recent efforts on a Phase II project by Cornerstone Research Group, Inc. (CRG), have advanced the technology and manufacturing readiness levels of a unique two-part epoxy resin system. Designed for room-temperature infusion of a dry carbon preform, the system includes a no-heat-added cure that delivers 350 F composite performance in a matter of hours. This no-oven, no-autoclave (NONA) composite processing eliminates part-size constraints imposed by infrastructure and lowers costs by increasing throughput and reducing capital-specific, process-flow bottlenecks. As a result of the Phase II activity, NONA materials and processes were used to make high-temperature composite tooling suitable for further production of carbon-epoxy laminates and honeycomb/ sandwich-structure composites with an aluminum core. The technology platform involves tooling design, resin infusion processing, composite part design, and resin chemistry. The various technology elements are combined to achieve a fully cured part. The individual elements are not unusual, but they are combined in such a way that enables proper management of the heat generated by the epoxy resin during cure. The result is a self-cured carbon/ epoxy composite part that is mechanically and chemically stable at temperatures up to 350 F. As a result of the successful SBIR effort, CRG has launched NONA Composites as a spinoff subsidiary. The company sells resin to end users, fabricates finished goods for customers, and sells composite tooling made with NONA materials and processes to composite manufacturers.

Rauscher, Michael D.↗
NASA NTRS1998

Hybrid IR-Gas Heater for Automated Tow Placement

A hybrid infrared-hot gas heat source has been developed and tested for the NASA Langley Tow Placement Facility. The IR heat source provides supplemental heat to the nip region. The additional heat is intended to reduce the need for conduction heating by the compaction roller, which causes (he roller to stick to the panel surface. Initial bench scale testing was performed to identify the most effective means of focusing IR energy into the nip region. A compact lamp and reflector that placed the lamp as close to the nip point as possible was found to deliver the highest heat flux in the nip region. A prototype heater was installed on the NASA Langley tow placement robot. Panels placed with a 400 C (sticking) compaction roller gave DCB initiation toughness numbers comparable to those reported for autoclave processed panels but were found to have unexpectedly high void contents. Placement with compaction roller temperatures that prevented roller sticking resulted in mode I fracture toughness approximately 70% that reported for autoclave processed panels. The variability in strength among specimens placed with reduced roller temperature was found to be greatly reduced, which implies that use of supplemental nip point heat may improve the robustness of the tow placement process. Use of the IR heat source permitted placement with a compaction roller temperature that would have resulted in negligible interfacial strength with the hot gas torch alone. The roller temperature reductions eliminated the need for the robot operator to attend placement operations.

Grenoble, Ray W.↗
NASA NTRS1990

Process For Autoclaving HMW PMR-II Composites

Parts made of graphite-reinforced, high-molecular-weight (HMW) PMR-II polyimide easy to fabricate by autoclaving. Study showed autoclaved HMW PMR-II parts equal in quality to those made by compression molding. Well suited to use at temperatures up to 700 degrees F (371 degrees C). In aircraft engines, they offer advantages of strength and light weight.

Vannucci, Raymond D.↗
NASA NTRS2001

Large Composite Structures Processing Technologies for Reusable Launch Vehicles

Significant efforts have been devoted to establishing the technology foundation to enable the progression to large scale composite structures fabrication. We are not capable today of fabricating many of the composite structures envisioned for the second generation reusable launch vehicle (RLV). Conventional 'aerospace' manufacturing and processing methodologies (fiber placement, autoclave, tooling) will require substantial investment and lead time to scale-up. Out-of-autoclave process techniques will require aggressive efforts to mature the selected technologies and to scale up. Focused composite processing technology development and demonstration programs utilizing the building block approach are required to enable envisioned second generation RLV large composite structures applications. Government/industry partnerships have demonstrated success in this area and represent best combination of skills and capabilities to achieve this goal.

Clinton, R. G., Jr.↗
NASA NTRS2018

Composite Bonded Joint: Repair Development

This report documents the details of my work as a NASA KSC intern for the Fall Session from August 27th to December 14th, 2018. My efforts and contributions were with the Materials Science Branch, a staffed organization within the Laboratories, Development, & Testing (NE-L) Division of the Engineering Directorate. The principle responsibilities of the Materials Science group are to support the design, development, and operations activities for materials and processes with the purpose of providing unique solutions for flight hardware, ground support equipment, and customer requests. My role as an intern focused on assisting engineers in developing repair processes to mature bonded joint technology in support of SLS ? scale hardware. My primary goals for this internship were to become more familiar with composite materials and learn more about processes I was unfamiliar with, such as prepregs and out-of-autoclave processing. This project allowed me to learn new skills such as scarfing and curing composites. Additional goals I had were to learn more about NASA's laboratories and projects under development. This internship not only provided me with those experiences, but also allowed me to build relationships with inspiring engineers; a takeaway I will never forget.

Composite Materials↗
NASA NTRS1999

Modified Phenylethynyl Containing Imides for Secondary Bonding: Non-Autoclave, Low Temperature Processable Adhesives

As part of a program to develop structural adhesives for high performance aerospace applications, research continued on the development of modified phenylethynyl containing imides, LaRC(trademark)MPEIs. In previous reports, the polymer properties were controlled by varying the molecular weight, the amount of branching, and the phenylethynyl content and by blending with low molecular weight materials. This research involves changing the flexibility in the copolyimide backbone of the branched, phenylethynyl terminated adhesives. These adhesives exhibit excellent processability at pressures as low as 15 psi and temperatures as low as 288 C. The Ti/Ti lap shear specimens are processable in an autoclave or a temperature programmable oven under a vacuum bag at 288-300 C without external pressure. The cured polymers exhibit high mechanical properties and excellent solvent resistance. The chemistry and properties of these adhesives are presented.

Dezern, James F.↗