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Sang-Hyon Chu

Publications and source records attributed to Sang-Hyon Chu.

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Manufacturing and Scale-Up of Natural Fiber Composite eVTOL Propeller Skin and C-Channel

This report presents the manufacturing and scale-up of natural fiber composites for aerospace applications, conducted within NASA’s Convergent Aeronautics Solutions portfolio to advance aircraft capabilities and efficiency. The effort focused on the development and demonstration of two proof-of-concept articles, an Electric Vertical Take-off and Landing (eVTOL) propeller skin and a C-channel, produced through an iterative design and process optimization approach. Best practices and guidance on addressing key challenges with bio-based composite materials and manufacturing is provided. Ideally suited for non-load-bearing structural components, these emerging materials offer potential for weight reduction, vibration damping, noise mitigation, interference-free communication, and cost savings, without compromising the performance of safety-critical primary structures.

Natural fibers↗
NASA NTRS2025

Erosion Behavior of Ti-hBN Multifunctional Coatings in A Custom-Made Planetary Test Rig at Extreme Lunar Temperatures

Spacecraft landings and takeoffs on the lunar surface, along with extreme temperature variations between day and night (-196 to 150° C), cause high-velocity dust impacts and erosion, resulting in the premature failure of structures. Ti/2 vol% hBN coatings were deposited using atmospheric (APS) and vacuum plasma spray (VPS) using cryo-milled powder feedstock to protect the structural components. The erosion performance of coatings at extreme lunar temperature regimes (-150 to 150° C) was evaluated in a custom-made planetary erosion test rig (PETR) at low (50 mph) and high impact velocities (250 mph). The mass loss of VPS coatings was reduced by 50% compared to the APS coatings and 40% compared to the Ti6Al4V substrate. The cryogenic temperature induces brittleness in the material, rendering it susceptible to extreme conditions of material loss. The particle impact-deformation behavior was captured using a high-speed camera to study the erosion mechanism. This analysis revealed chipping in substrates and brittle APS coatings, while particles rebounding and embedding were observed in VPS coatings. Energy calculations, aided by particle trajectory tracking from the high-speed camera, have conclusively shown that VPS coatings absorb 5–10% more energy than APS coatings during erosion tests. A modified erosion index was developed incorporating the fracture toughness and temperatures. New erosion models for brittle and ductile target materials are proposed for developing erosion-resistant material systems.

Abhijith Kunneparambil Sukumaran↗
NASA NTRS2025

Radiation-Resistant Ti/BN Coatings: Insights From 171 Days Exposure to Space Radiation and Atomic Oxygen in Low Orbit

Atmospheric Plasma Spray (APS) and Vacuum Plasma Spray (VPS) techniques were used to develop Ti/2 vol.% hBN coatings, for extreme space environments and tested aboard the International Space Station as part of the MISSE-17 (Materials International Space Station Experiments) program. The coatings were exposed to atomic oxygen, space radiation, and low-orbit thermal cycling. VPS coatings showed a 56% increase in microhardness, a 26% rise in elastic modulus, minimal porosity and crack density changes compared to APS coatings. The change in mechanical properties is attributed to the formation of TiO, TiO₂ and TiN from nitrogen retention, alongside radiation-induced dislocations, which enhanced surface hardening. The oxidation of titanium led to the formation of TiO and TiO₂, while boron nitride was retained and underwent transmutation in VPS coatings. XPS and EDS analyses confirmed the enhanced space-environment resistance of VPS coatings, making them ideal for long-term spacecraft protection in lunar and Martian conditions.

Abhijith Kunneparambil Sukumaran↗
NASA NTRS2024

Dynamic Mechanical Analysis of Post-Cured Bismaleimide Resins for Composite-Overwrapped Combustion Chambers Cycled From Cryogenic to High Temperatures

In support of the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project, samples made of polybismaleimide (BMI) resin were made and tested under cryogenic conditions. Neat resin samples were tested for multiple cycles, from high temperature (300°C) to cryogenic temperature (-150°C), to replicate the conditions a rocket engine assembly would experience in a test campaign and in operation. To increase the glass transition temperature (and thus mechanical stability), samples were exposed to different post-cure temperatures and were tested using a dynamic mechanical analysis (DMA) instrument. Consistent with expectations, the BMI samples post-cured at higher temperatures generally resulted in higher storage modulus under high temperature test conditions but at the expense of storage modulus values at low temperature test conditions.

Christopher Stelter↗
NASA NTRS2024

Wear and Neutron Shielding Resilience of Titanium-Hexagonal Boron Nitride Coatings Against Extreme Lunar Radiation and Thermal Cycles

Ti6Al4V and Al6061 are aerospace alloys used in lunar structural components and rovers owing to their high specific strength. However, they deteriorate rapidly when subjected to demanding conditions of the lunar environment, such as extreme thermal cycles, solar particle radiation, and abrasive regolith. Cryo-milled powders were employed to deposit hBN-reinforced protective titanium coatings through plasma spray (atmospheric APS and vacuum-VPS) with 2 and 10 vol% of hBN on Ti6Al4V and Al6061 substrates. These coatings were evaluated for durability under extreme lunar-like conditions, including thermal cycling, electron radiation, and synergistic (electron radiation-thermal cycle) exposure. The coatings exhibited radiation-induced hardening, resulting in a substantial increase in their microhardness ~20–40% compared to virgin condition. Bright-field transmission electron microscopy (TEM) analysis reveals the presence of high dislocation densities, black dot defects, and dislocation clusters, providing evidence of the severe impact of synergistic environmental stresses. Ball-on-disk tribological tests were conducted in the presence of JSC-1 A lunar regolith simulant to evaluate the wear performance of coatings. Compared to conventional Ti6Al4V substrate, 50%, 90%, and 70% reductions in wear volume were observed in the Ti/2 vol% hBN coatings in thermal-only, radiation-only, and synergistic environments. Neutron shielding tests indicate that the synergistic coatings offer higher neutron shielding performance by up to 28% compared to virgin coatings, attributed to improved neutron capture by 10B isotopes. Upon a comprehensive assessment and ranking of multiple coatings under varying conditions, the VPS Ti/2 vol% hBN coating emerges as the top choice for protection against extreme radiation and thermal cycles for future lunar explorations.

Boron nitride↗
NASA NTRS2024

Foam With Direction: Unraveling the Anisotropic Radiation Shielding Properties of 2D Boron Nitride Nanoplatelet Foams

Neutron radiation exposure is one of the main challenges faced during space missions. There is a critical need for advanced lightweight radiation shielding materials. Two-dimensional (2D) boron nitride nanoplatelets (BNNP) are excellent candidates for polymer matrix nanofillers due to their superior neutron shielding and thermal and mechanical properties. Furthermore, the 2D material anisotropic behavior unlocks the potential for composite property tailoring. This study fabricated ultra- lightweight lamellar BNNP foams (density 0.05 g cm –3 and 97.5% porous) via freeze-drying processing. The neutron shielding effectiveness or mass absorption coefficient of the BNNP foams with walls perpendicular to the direction of the radiation source was 14.47 cm 2 g –1 , while that of the foam with parallel configuration was only 8.51 cm 2 g –1 . The orientation-dependent neutron radiation shielding properties were modeled using the Beer-Lambert law for porous composite materials. The BNNP foam in this study has the potential to benefit advanced tailorable radiation shielding technologies for future aerospace missions.

Radiation shielding↗
NASA NTRS2024

Correlations of Additive Manufacturing Model-Based Process Metrics With Spatter-Induced Porosity in the Powder Bed Fusion-Laser Beam/Metallic Process

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Qualifying materials for components in critical applications requires a thorough understanding of pertinent processing-microstructure-property relationships. Porosity defects have a strong adverse effect on the mechanical properties of a material. The morphology of porosity defects created by lack of fusion in PBF-LB/M often exhibit high aspect ratios that can act as stress concentrators and become crack initiation sites. The occurrence of spatter induced porosity is studied using synchronized AM model-based process metrics and porosity measured by high-resolution X-ray computed tomography. A novel AM process metric is introduced to quantify the relative exposure to spatter ejecta impacts and incorporation throughout the sequence of the PBF-LB/M process. Further characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated statistically with the spatter ejecta impact field of the PBF-LB/M process. Both keyhole and lack of fusion porosity can be predicted by the spatter exposure process metric, which can be exploited to control the fusion sequence.

Additive Manufacturing↗
NASA NTRS2023

Tribological and Radiation Shielding Response of Novel Titanium-Boron Nitride Coatings for Lunar Structural Components

Aluminum (Al) and titanium (Ti) lightweight alloys play a crucial role in space systems due to their exceptional strength-to-weight ratio. However, their premature failure in the presence of lunar regolith and their lack of neutron shielding ability are significant challenges. To address these issues, we have developed air and vacuum plasma-sprayed hBN (hexagonal Boron Nitride) -reinforced titanium coatings with 2 and 10 vol% of hBN. Tribological studies conducted with JSC-1 A lunar regolith simulant revealed a 90 % reduction in wear volume for the Ti/2 vol% hBN coatings compared to conventional materials due to the synergistic action of harder secondary phases and solid lubrication effect of hBN. Additionally, a 27 % enhancement in radiation shielding is obtained based on the mass absorption coefficient (radiation absorbed per sample density and thickness) for VPS Ti/2 vol% hBN coatings.

Wear↗
NASA NTRS2023

B 4 C-Al Metal Matrix Composites for Extreme Space Environments

Extreme space environments such as space vacuum, radiation, thermal extremes and cycles, jagged lunar dust, microgravity, micrometeoroids and orbit debris (MMOD), thrust plume ejecta, and their synergistically-adverse effects are difficult challenges for safe and sustainable space exploration to outer planets and satellites. Prolonged space radiation exposure embrittles materials and structures and abrasive jagged dust particles aggressively wear and erode moving parts leading to premature failure. To counter or even alleviate such potential failures, robust and exceptional materials are needed to make NASA missions including Artemis program sustainable with minimum service and repair needs. This study reports that boron-containing inclusion, B 4 C, can improve wear resistance and radiation shielding/resistance of aluminum alloy (Al6061) significantly to extend the service life in extreme space environments. With increasing B 4 C inclusions, the tensile strength increased up to 20 vol% at both room temperature and an elevated temperature (200˚C) while thermal conductivity decreased gradually as a function of B 4 C concentration. The neutron shielding effectiveness increased more than 110 times when 50 vol% B 4 C is incorporated in Al6061 when compared with the pristine Al6061. The shielding effectiveness under galactic cosmic rays (GCR) and solar particle events (SPE) was also studied computationally using on-line tool for the assessment of radiation in space (OLTARIS). By adding B 4 C, the adverse effect caused by secondary radiation through the Al6061 matrix was effectively suppressed to improve the shielding effectiveness against GCR and SPE. The presence of boron in B 4 C was the main reason for the enhanced radiation shielding capability against neutron, GCR, and SPE environments.

Sang-Hyon Chu↗
NASA NTRSDate not supplied

TPSAS-NF1676L-33911-DND

Future NASA missions for space exploration require key technological elements that must provide sustainability, survivability and operational envelope in extreme environments, such as the high and low extremes in pressures and temperatures, ionizing radiations, chemical and/or physical corrosion, and hypervelocity particles. Advanced multifunctional materials enable revolutionary design schemes for future aerospace vehicles and structures for the extreme environments of NASA missions. Recent studies of nanocomposite materials have shown the potential for both structural integrity and multifunctional capabilities, such as sensing, actuating, health monitoring, radiation shielding, energy harvesting, thermal management, and thermal protection in extreme environments. After the advent of carbon nanotube (CNT) in 1991, scientists predicted that boron and nitrogen, carbons immediate neighbors on the periodic chart, might also form perfect nanotubes, namely boron nitride nanotubes (BNNTs). The discovery and progress of a new catalyst-free method for synthesizing highly crystalline, very long, and small diameter BNNTs under a high temperature and pressure (HTP) environment have enabled new applications for multifunctional materials. The white color BNNTs offer extraordinary properties including neutron radiation shielding, piezoelectricity, electrostriction, high thermal oxidative stability (>800?C in air), not present in CNTs, as well as excellent mechanical strength and toughness, equivalent to CNTs. The characteristics of the novel BNNTs and their composites along with CNT composites are discussed in this presentation along with their potential aerospace applications in extreme environments.

Cheol Park↗
NASA NTRSDate not supplied

TPSAS-NF1676L-34417-DND

A boron nitride nanotube (BNNT), an electrically-insulating counterpart of a carbon nanotube (CNT), is a great nanofiller candidate for ferroelectric polymeric nanocomposites due to BNNT?s exceptional properties in piezoelectricity, thermal stability, mechanical strength, and radiation shielding capability. Fast and high-yield polar crystallization of polyvinylidene fluoride (PVDF) was accomplished by incorporating BNNTs as a nucleating agent. As-fabricated BNNT-PVDF nanocomposites were characterized by Fourier-transform infrared spectroscopy (FTIR), wide-angle X-ray diffraction (XRD), and differential scanning calorimetry (DSC) to identify and quantify chain conformations. Besides, piezoelectric constants, d33 of BNNT-PVDF nanocomposites were measured and compared with that of a mechanically drawn beta phase polar PVDF. The polar transformation due to BNNT incorporation has a great advantage over conventional beta or gamma transformation methods that require (1) mechanical drawing often resulting in defects or (2) high-temperature annealing for an extended time. In addition to the fast polar crystallization, BNNTs had a role of reinforcement of the polymer matrix. The improved Young?s modulus and electromechanical coupling coefficient of BNNT-PVDF nanocomposites indicated potential applications in energy harvesting under harsh environments such as large deformation, wide temperature cycles, and high radiation.

Dongwon Lee↗
NASA NTRSDate not supplied

TPSAS-NF1676L-35440-DND

Future NASA missions for space exploration require key technological elements that must provide sustainability, survivability and operational envelope in extreme environments, such as the high and low extremes in pressures and temperatures, ionizing radiations, chemical and/or physical corrosion, and hypervelocity particles. Advanced multifunctional materials enable revolutionary design schemes for future aerospace vehicles and structures for the extreme environments of NASA missions. Recent studies of nanocomposite materials have shown the potential for both structural integrity and multifunctional capabilities, such as sensing, actuating, health monitoring, radiation shielding, energy harvesting, thermal management, and thermal protection in extreme environments. After the advent of carbon nanotube (CNT) in 1991, scientists predicted that boron and nitrogen, carbon's immediate neighbors on the periodic chart, might also form perfect nanotubes, namely boron nitride nanotubes (BNNTs). The discovery and progress of a new catalyst-free method for synthesizing highly crystalline, very long, and small diameter BNNTs under a high temperature and pressure (HTP) environment have enabled new applications for multifunctional materials. The white color BNNTs offer extraordinary properties including neutron radiation shielding, piezoelectricity, electrostriction, high thermal oxidative stability(>800 C in air), not present in CNTs, as well as excellent mechanical strength and toughness, equivalent to CNTs. The characteristics of the BNNTs and their composites along with CNT composites are discussed in this presentation along with their potential aerospace applications in extreme environments.

Cheol Park↗
NASA NTRSDate not supplied

High Temperature Pressure (HTP) Boron Nitride Nanotube (BNNT): Discovery and Commercialization

Future NASA missions for space exploration require key technological elements that must provide sustainability, survivability and operational envelope in extreme environments, such as the high and low extremes in pressures and temperatures, ionizing radiations, chemical and/or physical corrosion, and hypervelocity particles. Advanced multifunctional materials enable revolutionary design schemes for future aerospace vehicles and structures for the extreme environments of NASA missions. Recent studies of nanocomposite materials have shown the potential for both structural integrity and multifunctional capabilities, such as sensing, actuating, health monitoring, radiation shielding, energy harvesting, thermal management, and thermal protection in extreme environments. After the advent of carbon nanotube (CNT) in 1991, scientists predicted that boron and nitrogen, carbons immediate neighbors on the periodic chart, might also form perfect nanotubes, namely boron nitride nanotubes (BNNTs). The discovery and progress of a new catalyst-free method for synthesizing highly crystalline, very long, and small diameter BNNTs under a high temperature and pressure (HTP) environment have enabled new applications for multifunctional materials. The white color BNNTs offer extraordinary properties including neutron radiation shielding, piezoelectricity, electrostriction, high thermal oxidative stability (>800C in air), not present in CNTs, as well as excellent mechanical strength and toughness, equivalent to CNTs. The characteristics of the BNNTs and their composites along with CNT composites are discussed in this presentation along with their potential aerospace applications in extreme environments.

Cheol Park↗