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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 181 records · Page 10
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NASA NTRS2019

Demonstration Testing for Ground Servicing of the Commercial Crew Vehicle Emergency Breathing Air Assembly

The new Commercial crew vehicle (CCV) Emergency Breathing Air Assembly (CEBAA) is a Composite Overwrapped Pressure Vessel (COPV) filled with high-pressure air, which is designed to provide portable emergency breathing air for up to five crew in the event of an ammonia leak aboard the International Space Station (ISS). Industrially, several common methods of delivering breathing air exist; however, ground processing constraints and flight requirements necessitate the more unusual approach of servicing a COPV with high purity gaseous nitrogen and oxygen serially to achieve a specific mixture of breathing air at approximately 4000 PSIA. A dwell period allows the gases to mix before sampling for composition verification. The novelty of this approach led to concerns about acceptable gas mixing and the ability to deliver accurate gas compositions. Tests examining mixing rate over a series of post-servicing dwell periods were conducted to determine the optimal time for achieving a homogeneous mixture. Further testing was conducted to examine process accuracy using temperature-pressure load criteria to target a specific concentration of oxygen and nitrogen. Test results show that while some stratification of nitrogen and oxygen was observed, a seven-day dwell is adequate time to achieve an acceptable level of mixing, and that existing ground support equipment can accurately service CEBAA COPVs to the required temperature, pressure and composition for flight.

Active Thermal↗
NASA NTRS2019

Computational Non-Destructive Evaluation Improving Ultrasonic Interrogation of Complex Geometry Composite Parts

Finite element simulation was employed in modeling the ultrasound (UT) pressure pulse propagation through a coupled liquid-composite medium to reproduce experimental data. From the simulation point of view, the proposed approach is challenging when there is a large simulation domain. For example, it is shown that a sub-micron wavelength of an ultrasonic wave requires a mesh size of several microns and this in turn requires significant computational resources, as well as special care in modeling. Some of the simulation results are presented considering that such modeling should reproduce experimental data for a healthy and faulty composite structure with complex geometry. Many possible experimental setups are simulated to demonstrate the non-destructive testing technique. This setup includes the generation of pressure pulse propagating through the tested composite plate and possible scattering by discontinuities (area of different impedance) that may be present in the panel. This scattered pulse together with the baseline pressure pulse generates a signature on the probe element which can be used to locate the position of defects in the structures.

modeling↗
NASA NTRS1974

Stress-rupture strength and microstructural stability of W-HF-C wire-reinforced superalloy composites

W-Hf-C superalloy composites were found to be potentially useful for turbine-blade applications on the basis of stress-rupture strength. The 100- and 1000-hour rupture strengths obtained for 70 volume percent fiber composites tested at 1090 C were 420 and 280 MN/sq m. The investigation indicated that with better quality fibers, composites having 100- and 1000-hour rupture strengths of 570 and 370 MN/sq m may be obtained. Metallographic studies indicated sufficient fiber-matrix compatibility for long-term applications at 1090 C for 1000 hours or more.

Petrasek, D. W.↗
NASA NTRS1989

High-temperature testing of glass/ceramic matrix composites

Recent advances in ceramic and other high-temperature composites have created a need for test methods that can be used at 1000 C and above. Present test methods usually require adhesively bonded tabs that cannot be used at high temperatures. This paper discusses some of the difficulties with high-temperature test development and describes several promising test methods. Stress-strain data are given for Nicalon ceramic fiber reinforced glass and glass-ceramic matrix composites tested in air at temperatures up to 1000 C.

Mandell, John F.↗
NASA NTRS1986

Mass spectrometric gas composition measurements associated with jet interaction tests in a high-enthalpy wind tunnel

Knowledge of test gas composition is important in wind-tunnel experiments measuring aerothermodynamic interactions. This paper describes measurements made by sampling the top of the test section during runs of the Langley 7-Inch High-Temperature Tunnel. The tests were conducted to determine the mixing of gas injected from a flat-plate model into a combustion-heated hypervelocity test stream and to monitor the CO2 produced in the combustion. The Mass Spectrometric (MS) measurements yield the mole fraction of N2 or He and CO2 reaching the sample inlets. The data obtained for several tunnel run conditions are related to the pressures measured in the tunnel test section and at the MS ionizer inlet. The apparent distributions of injected gas species and tunnel gas (CO2) are discussed relative to the sampling techniques. The measurements provided significant real-time data for the distribution of injected gases in the test section. The jet N2 diffused readily from the test stream, but the jet He was mostly entrained. The amounts of CO2 and Ar diffusing upward in the test section for several run conditions indicated the variability of the combustion-gas test-stream composition.

Lewis, B. W.↗
NASA NTRS1997

Analysis of Impact Induced Damage and its Effect on Structural Integrity of Space Flight Composite Overwrapped Pressure Vessels

The objective of this research work has been to provide analytical background and support to the ongoing experimental program at NASA, White Sands Test Facility, involving testing composite overwrapped pressure vessels (COPV) for impact damage and cyclic pressurization. Preliminary theoretical basis, including the governing equations for a shallow shell subjected to internal pressure, has been established. Effects of the Griffith type cracks on the structural integrity of the cylindrical vessel were evaluated by methods of Fracture Mechanics. The results indicate that the effective mass of the pressure vessel is an important factor influencing the response to impact events. We also have found that the material properties of the target, contained in the constitutive equations of the composite attached to the Aluminum liner, dominate the impact event in the low velocity range, the material properties become less important, while the target mass distribution and the impactor mass become more significant as the velocity of the impactor increases. Therefore, at high-velocity impact it is not only the kinetic energy of the impactor but also its mass which has a significant effect on the dynamics of the event, and consequently on the induced damage. This work also suggests a methodology for an assessment of the rate of loading effects on the degradation of the material toughness associated with a high-velocity impact where the rate effects become significant. To model the rate dependence of the material response a viscoelastic-plastic constitutive equations were assumed, and on this basis predictions are made regarding the rate dependent material resistance curve. Other dynamic phenomena associated with the impact event have been treated in the framework of the Computational Mechanics using the courtesy of Prof. P. Guebelle and his graduate student at University of Illinois at Urbana-Champaign who have an access to a super-fast computer located on their campus. Finally, the guidelines for a follow-up research program are provided in the body of this report. They address three major areas: theoretical research, numerical studies, and further experimental work.

Wnuk, Michael P.↗
NASA NTRS1985

Mixed-mode cyclic debonding of adhesively bonded composite joints

A combined experimental-analytical investigation to characterize the cyclic failure mechanism of a simple composite-to-composite bonded joint is conducted. The cracked lap shear (CLS) specimens of graphite/epoxy adherend bonded with EC-3445 adhesive are tested under combined mode 1 and 2 loading. In all specimens tested, fatigue failure occurs in the form of cyclic debonding. The cyclic debond growth rates are measured. The finite element analysis is employed to compute the mode 1, mode 2, and total strain energy release rates (i.e., GI, GII, and GT). A wide range of mixed-mode loading, i.e., GI/GII ranging from 0.03 to 0.38, is obtained. The total strain energy release rate, G sub T, appeared to be the driving parameter for cyclic debonding in the tested composite bonded system.

Rezaizadeh, M. A.↗
NASA NTRS1989

Sensor technology for smart structures

Advanced aerospace structures are discussed that will very likely be fabricated with integral sensors, actuators, and microprocessors for monitoring and dynamic control of configuration. The concept of 'smart structures' integrates fiber-optic sensor technology with advanced composite materials, whereby the optical fibers are embedded in a composite material and provide internal sensing capability for monitoring parameters which are important for the safety, performance, and reliability of the material and the structure. Along with other research facilities, NASA has initiated a cooperative program to design, fabricate, and test composite trusses, tubes, and flat panels with embedded optical fibers for testing and developing prototype smart structures. It is shown that fiber-optic sensor technology can be combined with advanced material and structure concepts to produce a new class of materials with internal sensors for health monitoring of structures.

Rogowski, R. S.↗
NASA NTRS2018

Polymer Matrix Composites Fabrication and Testing

This project involves two separate processes for fabricating carbon fiber composite parts using Hexcel’s RTM6 resin system and Kaneka’s IR-6070 toughened resin system to impregnate carbon fiber tow and weave. These two resins were chosen to model microcracking in parts using RTM6 compared to parts using IR-6070. Plies of the composites were made by painting resin onto 8 harness satin weave or impregnating IM7 12k tow in a prepregging machine. Plies were consolidated using an out-of-autoclave oven or a heat press. Fabrication of the composite parts were conducted with the end goal of sending the composites to be tested and modeled for microcracking. The data will be used for computer modeling in the future.

Miller, Sandi↗
NASA NTRS1981

An evaluation of the sandwich beam compression test method for composites

The sandwich beam in a four-point bending compressive test method for advanced composites is evaluated. Young's modulus and Poisson's ratio were obtained for graphite/polyimide beam specimens tested at 117 K, room temperature, and 589 K. Tensile elastic properties obtained from the specimens were assumed to be equal to the compressive elastic properties and were used in the analysis. Strain gages were used to record strain data. A three-dimensional finite-element model was used to examine the effects of the honeycomb core on measured composite mechanical properties. Results of the analysis led to the following conclusions: (1) a near uniaxial compressive stress state existed in the top cover and essentially all the compressive load was carried by the top cover; (2) laminate orientation, test temperature, and type of honeycomb core material were shown to affect the type of beam failure; and (3) the test method can be used to obtain compressive elastic constants over the temperature range 117 to 589 K.

Shuart, M. J.↗
NASA NTRS1988

Laminate behavior for SiC fiber-reinforced reaction-bonded silicon nitride matrix composites

The room temperature mechanical properties of SiC fiber reinforced reaction-bonded silicon nitride matrix composite laminates (SiC/RBSN) have been measured. The laminates contained approx 30 volume fraction of aligned 142-micron diameter SiC fiber in a porous RBSN matrix. Three types of laminate studied were unidirectional: (1) (0) sub 8, (2) (10) sub 8, and (3) (45) sub 8, and (90) sub 8; cross plied laminates (0 sub 2/90 sub 2); and angle plied laminates: (+45 sub 2/-45 sub 2). Each laminate contained eight fiber plies. Results of the unidirectionally reinforced composites tested at various angles to the reinforcement direction indicate large anisotropy in in-plane properties. In addition, strength properties of these composites along the fiber direction were independent of specimen gage length and were unaffected by notches normal to the fiber direction. Splitting parallel to the fiber at the notch tip appears to be the dominant crack blunting mechanism responsible for notch insensitive behavior of these composites. In-plane properties of the composites can be improved by 2-D laminate construction. Mechanical property results for (0 sub 2/90 sub 2)sub s and (+45/-45 sub 2) sub s laminates showed that their matrix failure strains were similar to that for (0) sub 8 laminates, but their primary elastic moduli, matrix cracking strengths, and ultimate composite strengths were lower. The elastic properties of unidirectional, cross-ply, and angle-ply composites can be predicted from modified constitutive equations and laminate theory. Further improvements in laminate properties may be achieved by reducing the matrix porosity and by optimizing the bond strength between the SiC fiber and RBSN matrix.

Rhatt, R. T.↗
NASA NTRS1990

Laminate behavior for SiC fiber-reinforced reaction-bonded silicon nitride matrix composites

The room temperature mechanical properties of SiC fiber reinforced reaction-bonded silicon nitride matrix composite laminates (SiC/RBSN) have been measured. The laminates contained approx 30 volume fraction of aligned 142-micron diameter SiC fiber in a porous RBSN matrix. Three types of laminate studied were unidirectional: (1) (0) sub 8, (2) (10) sub 8, and (3) (45) sub 8, and (90) sub 8; cross plied laminates (0 sub 2/90 sub 2); and angle plied laminates: (+45 sub 2/-45 sub 2). Each laminate contained eight fiber plies. Results of the unidirectionally reinforced composites tested at various angles to the reinforcement direction indicate large anisotropy in in-plane properties. In addition, strength properties of these composites along the fiber direction were independent of specimen gage length and were unaffected by notches normal to the fiber direction. Splitting parallel to the fiber at the notch tip appears to be the dominant crack blunting mechanism responsible for notch insensitive behavior of these composites. In-plane properties of the composites can be improved by 2-D laminate construction. Mechanical property results for (0 sub 2/90 sub 2) sub s and (+45/-45 sub 2) sub s laminates showed that their matrix failure strains were similar to that for (0) sub 8 laminates, but their primary elastic moduli, matrix cracking strengths, and ultimate composite strengths were lower. The elastic properties of unidirectional, cross-ply, and angle-ply composites can be predicted from modified constitutive equations and laminate theory. Further improvements in laminate properties may be achieved by reducing the matrix porosity and by optimizing the bond strength between the SiC fiber and RBSN matrix.

Bhatt, Ramakrishna T.↗
NASA NTRS1998

Fabrication and Resistivity of IBr Intercalated Vapor-Grown Carbon Fiber Composites

Composites using vapor-crown carbon fibers (VGCF), the most conductive of the carbon fiber types, are attractive for applications where low density, high strength, and at least moderate conductivity are required, such as electromagnetic interference shielding covers for spacecraft. The conductivity can be enhanced another order of magnitude by intercalation of the VGCF. If a high Z intercalate is used, the protection of components from ionizing radiation can be enhanced also. Thus, the intercalation of VGCF with IBr is reported. Since composite testing is required to verify properties, the intercalation reaction optimization, stability of the intercalation compound, scale-up of the intercalation reaction, composite fabrication, and resistivity of the resulting composites is also reported. The optimum conditions for low resistivity and uniformity for the scaled up reaction (20-30 g of product) were 114 C for at least 72 hr, yielding a fiber with a resistivity of 8.7+/-2 micro-Omega-cm. The thermal stability of these fibers was poor, with degradation occurring at temperatures as low as 40 C in air, though they were insensitive to water vapor. Composite resistivity was 20-30 micro-Omega-cm, as measured by contactless conductivity measurements, about a factor of five higher than would be expected from a simple rule of mixtures. The addition of 1.0 percent Br2, intercalated microfibers increased the resistivity of the composites by more than 20 percent.

Gaier, James R.↗
NASA NTRS2003

Oxidation of Carbon Fibers in a Cracked Ceramic Matrix Composite Modeled as a Function of Temperature

The oxidation model simulates the oxidation of the reinforcing carbon fibers within a ceramic matrix composite material containing as-fabricated microcracks. The physics-based oxidation model uses theoretically and experimentally determined variables as input for the model. The model simulates the ingress of oxygen through microcracks into a two-dimensional plane within the composite material. Model input includes temperature, oxygen concentration, the reaction rate constant, the diffusion coefficient, and the crack opening width as a function of the mechanical and thermal loads. The model is run in an iterative process for a two-dimensional grid system in which oxygen diffuses through the porous and cracked regions of the material and reacts with carbon in short time steps. The model allows the local oxygen concentrations and carbon volumes from the edge to the interior of the composite to be determined over time. Oxidation damage predicted by the model was compared with that observed from microstructural analysis of experimentally tested composite material to validate the model for two temperatures of interest. When the model is run for low-temperature conditions, the kinetics are reaction controlled. Carbon and oxygen reactions occur relatively slowly. Therefore, oxygen can bypass the carbon near the outer edge and diffuse into the interior so that it saturates the entire composite at relatively high concentrations. The kinetics are limited by the reaction rate between carbon and oxygen. This results in an interior that has high local concentrations of oxygen and a similar amount of consumed carbon throughout the cross section. When the model is run for high-temperature conditions, the kinetics are diffusion controlled. Carbon and oxygen reactions occur very quickly. The carbon consumes oxygen as soon as it is supplied. The kinetics are limited by the relatively slow rate at which oxygen is supplied in comparison to the relatively fast rate at which carbon and oxygen reactions occur. This results in a sharp gradient in oxygen concentration from the edge where it is supplied to the nearest source of carbon, which is where the oxygen is quickly consumed. A moving reaction front is seen in which the outlaying carbon is consumed before the next inner layer of carbon begins to react.

Halbig, Michael C.↗
NASA NTRS2015

Analysis and Testing of a Composite Fuselage Shield for Open Rotor Engine Blade-Out Protection

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test predictions. This paper documents the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

safety↗
NASA NTRS2011

Approaches for Tensile Testing of Braided Composites

For angleply composites, lamina tension and compression strengths are commonly determined by applying classical lamination theory to test data obtained from testing of angleply composite specimens. For textile composites such as 2D triaxial braids, analysis is more complex and standard test methods do not always yield reliable strength measurements. This paper describes recent research focused on development of more reliable tensile test methods for braided composites and presents preliminary data for various approaches. The materials investigated in this work have 0deg+/-60 2D triaxial braid architecture with nearly equal fiber volume fraction in each of the three fiber directions. Flat composite panels are fabricated by resin transfer molding (RTM) using six layers of the braided preform aligned along the 0deg fiber direction. Various epoxy resins are used as matrix materials. Single layer panels are also fabricated in order to examine local variations in deformation related to the braid architecture. Specimens are cut from these panels in the shape of standard straight-sided coupons, an alternative bowtie geometry, and an alternative notched geometry. Axial tensile properties are measured using specimens loaded along the 0deg fiber direction. Transverse tensile properties are measured using specimens loaded perpendicular to the 0deg fibers. Composite tubes are also fabricated by RTM. These tubes are tested by internal pressurization using a soft rubbery material sealed between the inside diameter of the tube and the load fixtures. The ends of the tube are unconstrained, so the primary load is in the hoop direction. Tubes are fabricated with the 0deg fibers aligned along the tube axis by overbraiding the preform on a mandrel. Since the loading is in the hoop direction, testing of the overbraided tube provides a measure of transverse tensile strength. Previous work has indicated that straight-sided coupons yield a transverse tensile strength that is much lower than the expected material strength because of premature edge-initiated failure. Full-field strain measured during transverse tensile tests clearly showed accumulation of edge damage prior to failure. In the current work, high speed video and testing of single layer specimens are used to investigate potential failure mechanisms in more detail. High speed video clearly shows the edge initiation in six layer transverse tensile test coupons. Specimens with the bowtie geometry and the notched geometry minimize this edge effect and yield significantly higher transverse tensile strength values compared to the straight-sided coupons. However, bowtie and notched specimens geometries are not ideal because of the non-uniform stress and strain fields in the region of failure. Testing of tubes using internal pressurization eliminates edge-initiated failure and provides a more uniform state of stress and strain. Preliminary results indicate that bowtie, notched, and tube specimens yield comparable values for transverse tensile strength and that these values are much higher than the strength measured using a straight-sided coupon.

Roberts, Gary D.↗
NASA NTRS1974

Stress-rupture strength and microstructural stability of W-HF-C wire reinforced superalloy composites

W-Hf-C/superalloy composites were found to be potentially useful for turbine blade applications on the basis of stress-rupture strength. The 100-and 1000-hour rupture strengths obtained for 70 volume percent fiber composites tested at 1090 C were 420 and 280 MN/sq m (61,000 and 41,000 psi). The investigation indicated that with better quality fibers, composites having 100- and 1000-hour rupture strengths of 570 and 370 MN/sq m (82,000 and 54,000 psi) may be obtained. Metallographic studies indicated sufficient fiber-matrix compatibility for long time applications at 1090 C for 1000 hours or more.

Petrasek, D. W.↗