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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 NTRS2006

An Overview of Spray-On Foam Insulation Applications on the Space Shuttle's External Tank: Foam Applications and Foam Shedding Mechanisms

The Columbia Accident Investigation Board (CAIB) concluded that the cause of the tragic loss of the Space Shuttle Columbia and its crew was a breach in the thermal protection system on the leading edge of the left wing. The breach was initiated by a piece of insulating foam that separated from the left bipod ramp of the External Tank and struck the wing in the vicinity of the lower half of Reinforced Carbon-Carbon panel No. 8 at 81.9 seconds after launch. The CAIB conclusion has spawned numerous studies to identify the cause of and factors influencing foam shedding and foam debris liberation from the External Tank during ascent. The symposium on the Thermo-mechanics and Fracture of Space Shuttle External Tank Spray-On Foam Insulation is a collection of presentations that discuss the physics and mechanics of the ET SOFI with the objective of improving analytical and numerical methods for predicting foam thermo-mechanical and fracture behavior. This keynote presentation sets the stage for the presentations contained in this symposium by introducing the audience to the various types of SOFI applications on the Shuttle s External Tank and by discussing the various mechanisms that are believed to be the cause of foam shedding during the Shuttle s ascent to space

Sullivan, Roy M.↗
NASA NTRS1995

Foam, Foam-resin composite and method of making a foam-resin composite

This invention relates to a foam, a foam-resin composite and a method of making foam-resin composites. The foam set forth in this invention comprises a urethane modified polyisocyanurate derived from an aromatic amino polyol and a polyether polyol. In addition to the polyisocyanurate foam, the composite of this invention further contains a resin layer, wherein the resin may be epoxy, bismaleimide, or phenolic resin. Such resins generally require cure or post-cure temperatures of at least 350.degree. F.

Cranston, John A.↗
DOE OSTI2024

A novel digital lifecycle for Material‐Process‐Microstructure‐Performance relationships of thermoplastic olefins foams manufactured via supercritical fluid assisted foam injection molding

Abstract This research significantly enhances the applicability of thermoplastic olefins (TPOs) in the automotive industry using supercritical N 2 as a physical foaming agent, effectively addressing the limitations of traditional chemical agents. It merges experimental results with simulations to establish detailed material‐process‐microstructure‐performance (MP2) relationships, targeting 5–20% weight reductions. This innovative approach labeled digital lifecycle (DLC) helps accurately predict tensile, flexural, and impact properties based on the foam microstructure, along with experimentally demonstrating improved paintability. The study combines process simulations with finite element models to develop a comprehensive digital model for accurately predicting mechanical properties. Our findings demonstrate a strong correlation between simulated and experimental data, with about a 5% error across various weight reduction targets, marking significant improvements over existing analytical models. This research highlights the efficacy of physical foaming agents in TPO enhancement and emphasizes the importance of integrating experimental and simulation methods to capture the underlying foaming mechanism to establish material‐process‐microstructure‐performance (MP2) relationships. Highlights Establishes a material‐process‐microstructure‐performance (MP2) for TPO foams Sustainably produces TPO foams using supercritical (ScF) N 2 with 20% lightweighting Shows enhanced paintability for TPO foam improved surface aesthetics Digital lifecycle (DLC) that predicts both foam microstructure and properties DLC maps process effects & microstructure onto FEA mesh for precise prediction

Engineering↗
NASA NTRS1983

Rigid closed-cell polyimide foams for aircraft applications and foam-in-place technology

Significant accomplishments generated are summarized. Testing of closed cell foams, which has resulted in the characterization of compositions which produce rigid foams for use in galley structure applications is reported. It is shown that the density, compressive strength and shear strength of the foams are directly related to the concentrations of the microballoons. The same properties are also directly related to the resin loading. Prototype samples of rigid closed cell foams meeting the requirements of the program were submitted. Investigation of the apparatus to produce polyimide foams using foam in place techniques, resulted in the selection of a spray gun apparatus, capable to deliver a mixture of microballoons and resin binder on substrates which cures to yield a closed cell foam. It is found that the adhesion of the foam on aluminum, titanium and steel substrates is satisfactory. It is concluded that the material meets the mechanical and thermal requirements of the program.

Gagliani, J.↗
NASA NTRS2002

Morphologies, Processing and Properties of Ceramic Foams from Pre-Ceramic Foams from Pre-Ceramic Polymer Routes

The current research is focused on processing ceramic foams that have potential as a thermal protection material. Ceramic foams with different architectures were formed from the pyrolysis of pre-ceramic polymers at 1200 C in different atmospheres. In some systems a sacrificial polyurethane was used as the blowing agent. We have also processed foams using sacrificial fillers to introduce controlled cell sizes. Each sacrificial filler or blowing agent leads to a unique morphology. The effect of different fillers on foam morphologies will be presented. The presentation will also focus on characterization of these foams in terms of mechanical and thermal properties. Foams processed using these approaches having bulk densities ranging from 0.15 to 0.9 g per cubic centimeter and a cell sizes from 5 to 500 micrometers. Compression strengths ranged from 2 to 7 MPa for these materials.

Stackpoole, Mairead↗
NASA NTRS2010

Microstructural Characterization of Metal Foams: An Examination of the Applicability of the Theoretical Models for Modeling Foams

Establishing the geometry of foam cells is useful in developing microstructure-based acoustic and structural models. Since experimental data on the geometry of the foam cells are limited, most modeling efforts use the three-dimensional, space-filling Kelvin tetrakaidecahedron. The validity of this assumption is investigated in the present paper. Several FeCrAlY foams with relative densities varying between 3 and 15 percent and cells per mm (c.p.mm.) varying between 0.2 and 3.9 c.p.mm. were microstructurally evaluated. The number of edges per face for each foam specimen was counted by approximating the cell faces by regular polygons, where the number of cell faces measured varied between 207 and 745. The present observations revealed that 50 to 57 percent of the cell faces were pentagonal while 24 to 28 percent were quadrilateral and 15 to 22 percent were hexagonal. The present measurements are shown to be in excellent agreement with literature data. It is demonstrated that the Kelvin model, as well as other proposed theoretical models, cannot accurately describe the FeCrAlY foam cell structure. Instead, it is suggested that the ideal foam cell geometry consists of 11 faces with 3 quadrilateral, 6 pentagonal faces and 2 hexagonal faces consistent with the 3-6-2 cell.

Raj, S. V.↗
NASA NTRS2011

Microstructural Characterization of Metal Foams: An Examination of the Applicability of the Theoretical Models for Modeling Foams

Establishing the geometry of foam cells is useful in developing microstructure-based acoustic and structural models. Since experimental data on the geometry of the foam cells are limited, most modeling efforts use an idealized three-dimensional, space-filling Kelvin tetrakaidecahedron. The validity of this assumption is investigated in the present paper. Several FeCrAlY foams with relative densities varying between 3 and 15 percent and cells per mm (c.p.mm.) varying between 0.2 and 3.9 c.p.mm. were microstructurally evaluated. The number of edges per face for each foam specimen was counted by approximating the cell faces by regular polygons, where the number of cell faces measured varied between 207 and 745. The present observations revealed that 50 to 57 percent of the cell faces were pentagonal while 24 to 28 percent were quadrilateral and 15 to 22 percent were hexagonal. The present measurements are shown to be in excellent agreement with literature data. It is demonstrated that the Kelvin model, as well as other proposed theoretical models, cannot accurately describe the FeCrAlY foam cell structure. Instead, it is suggested that the ideal foam cell geometry consists of 11 faces with three quadrilateral, six pentagonal faces and two hexagonal faces consistent with the 3-6-2 Matzke cell. A compilation of 90 years of experimental data reveals that the average number of cell faces decreases linearly with the increasing ratio of quadrilateral to pentagonal faces. It is concluded that the Kelvin model is not supported by these experimental data.

Raj, S. V.↗
NASA NTRS2011

Corrigendum to "Microstructural Characterization of Metal Foams: An Examination of the Applicability of the Theoretical Models for Modeling Foams"

Establishing the geometry of foam cells is useful in developing microstructure-based acoustic and structural models. Since experimental data on the geometry of the foam cells are limited, most modeling efforts use an idealized three-dimensional, space-filling Kelvin tetrakaidecahedron. The validity of this assumption is investigated in the present paper. Several FeCrAlY foams with relative densities varying between 3 and 15% and cells per mm (c.p.mm.) varying between 0.2 and 3.9 c.p.mm. were microstructurally evaluated. The number of edges per face for each foam specimen was counted by approximating the cell faces by regular polygons, where the number of cell faces measured varied between 207 and 745. The present observations revealed that 50-57% of the cell faces were pentagonal while 24-28% were quadrilateral and 15-22% were hexagonal. The present measurements are shown to be in excellent agreement with literature data. It is demonstrated that the Kelvin model, as well as other proposed theoretical models, cannot accurately describe the FeCrAlY foam cell structure. Instead, it is suggested that the ideal foam cell geometry consists of 11 faces with 3 quadrilateral, 6 pentagonal faces and 2 hexagonal faces consistent with the 3-6-2 Matzke cell

Raj. Sai V.↗
NASA NTRS1947

Foaming volume and foam stability

A method of measuring foaming volume is described and investigated to establish the critical factors in its operation. Data on foaming volumes and foam stabilities are given for a series of hydrocarbons and for a range of concentrations of aqueous ethylene-glycol solutions. It is shown that the amount of foam formed depends on the machinery of its production as well as on properties of the liquid, whereas the stability of the foam produced, within specified mechanical limitations, is primarily a function of the liquid.

Ross, Sydney↗
NASA NTRS2015

Determination of Acreage Thermal Protection Foam Loss From Ice and Foam Impacts

A parametric study was conducted to establish Thermal Protection System (TPS) loss from foam and ice impact conditions similar to what might occur on the Space Launch System. This study was based upon the large amount of testing and analysis that was conducted with both ice and foam debris impacts on TPS acreage foam for the Space Shuttle Project External Tank. Test verified material models and modeling techniques that resulted from Space Shuttle related testing were utilized for this parametric study. Parameters varied include projectile mass, impact velocity and impact angle (5 degree and 10 degree impacts). The amount of TPS acreage foam loss as a result of the various impact conditions is presented.

Thermal Protection System↗
DOE OSTI2025

Examining astrophysical gas cloud collapse using an optical depth-scaled, x-ray-irradiated, carbon-foam sphere

When stellar radiation interacts with a molecular cloud, the cloud's fate depends on the strength of the incident radiation and the radiation's mean-free-path within the cloud [F. Bertoldi, Astrophys. J. 346, 735–755 (1989)]. Under the right conditions, the radiation compresses the cloud and a star formation may occur. Where and when the stellar formation occurs in the cloud's collapse are open questions. Direct observation of the complete star–cloud lifecycle is nearly impossible due to the immense timescales and distances over which the interaction occurs. Laboratory astrophysics offers a way to investigate such a system by scaling the important astrophysical parameters to the laboratory. This work describes laboratory experiments to study the radiation-driven implosion of clouds, using x rays from a laser-irradiated, thin, gold foil as a surrogate star and a carbon-foam sphere as a surrogate cloud. An optically thick system, theoretically corresponding to a star-forming regime, was selected by choice of the foam density. Gold foil and sphere motions were imaged by x-ray radiography. Radiographic images show the formation of an interface between rarefied gold and carbon plasmas, a shock moving into the sphere, and a blunting of the initial sphere's shape. Measurements show that the shock moved linearly around 64 μm/ns into the sphere, and the gold–carbon interface formed by 2 ns at the sphere edge remained stationary. The deformation of the sphere was driven by the incident radiation and not by mechanical pressures applied by gold plasma. The blunting of the sphere was likely due to the geometric reduction of flux near the sphere's poles. Higher x-ray flux near the sphere's equator caused high compression and a faster shock, which flattened the sphere. We will discuss the results and implications of our observations.

VanDervort, R. W. [University of Michigan 1 , Ann ↗
NASA NTRS2001

Update: HFC 245fa Blown Foam Development with External Tank Spray Foams

The Marshall Space Flight Center (MSFC) Thermal Protection Systems (TPS) Materials Research Laboratory is currently investigating environmentally friendly blowing agents for use in the insulations of the Space Shuttle's External Tank. The original TPS foam materials of the External Tank were blown with chlorofluorocarbon 11, which is now regulated because of its high Ozone Depletion Potential (ODP). Hydrochlorofluorocarbons (HCFCs), with an ODP that is one tenth that of CFCs, have been widely adopted as an interim blowing agent in urethane insulations. In FY96, Lockheed Martin completed the production qualification and validation of HCFC 141b blown insulations. Because of the expected limited commercial lifetime of HCFC 141b, research efforts are underway to identify and develop alternatives with zero ODP. HFC245fa (1,1,1,3,3-pentaflouropropane) has been chosen by the manufacturer as a third-generation blowing agent to be marketed commercially. Preliminary work evaluating this third-generation candidate has demonstrated promising material mechanical property data. Favorable results from small-scale spray activities have justified evaluations using production foam processing spray parameters. With the scale-up of the spray equipment, however, additional processing issues have been identified. This paper will present data collected to date regarding the use of this blowing agent in External Tank spray foams.

Davis, S.↗
NASA NTRS2008

Shear Modulus for Nonisotropic, Open-Celled Foams Using a General Elongated Kelvin Foam Model

An equation for the shear modulus for nonisotropic, open-celled foams in the plane transverse to the elongation (rise) direction is derived using an elongated Kelvin foam model with the most general geometric description. The shear modulus was found to be a function of the unit cell dimensions, the solid material properties, and the cell edge cross-section properties. The shear modulus equation reduces to the relation derived by others for isotropic foams when the unit cell is equiaxed.

Sullivan, Roy M.↗
NASA NTRS2009

Shear Moduli for Non-Isotropic, Open Cell Foams Using a General Elongated Kelvin Foam Model

Equations for calculating the shear modulus of non-isotropic, open cell foams in the plane perpendicular to the rise direction and in a plane parallel to the rise direction are derived using an elongated Kelvin foam model. This Kelvin foam model is more general than that employed by previous authors as the size and shape of the unit cell are defined by specifying three independent cell dimensions. The equations for the shear compliances are derived as a function of three unit cell dimensions and the section properties of the cell edges. From the compliance equations, the shear modulus equations are obtained and written as a function of the relative density and two unit cell shape parameters. The dependence of the two shear moduli on the relative density and the two shape parameters is demonstrated.

Sullivan, Roy M.↗
NASA NTRS1978

Effect of foam age on toxicity of pyrolysis gases from polyurethane flexible foams

The toxicity of the pyrolysis gases from some samples of polyurethane flexible foams appears to have decreased with age, while other samples seem to exhibit no significant change with age in this respect. The changes observed were greater than could be accounted for by variations in the material, or test variations or artifacts.

Hilado, C. J.↗