SEARCH · Search NASA

Results for “REINFORCED PLASTIC”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 181 records · Page 10

All sources NASA NTRS DOE OSTI

NASA NTRS2009

Mitigation of EMU Glove Cut Hazard by MMOD Impact Craters on Exposed ISS Handrails

Recent cut damages to crewmember extravehicular mobility unit (EMU) gloves during extravehicular activity (EVA) onboard the International Space Station (ISS) has been found to result from contact with sharp edges or pinch points rather than general wear or abrasion. One possible source of cut-hazards are protruding sharp edged crater lips from impact of micrometeoroid and orbital debris (MMOD) particles on external metallic handrails along EVA translation paths. During impact of MMOD particles at hypervelocity an evacuation flow develops behind the shock wave, resulting in the formation of crater lips that can protrude above the target surface. In this study, two methods were evaluated to limit EMU glove cut-hazards due to MMOD impact craters. In the first phase, four flexible overwrap configurations are evaluated: a felt-reusable surface insulation (FRSI), polyurethane polyether foam with beta-cloth cover, double-layer polyurethane polyether foam with beta-cloth cover, and multi-layer beta-cloth with intermediate Dacron netting spacers. These overwraps are suitable for retrofitting ground equipment that has yet to be flown, and are not intended to protect the handrail from impact of MMOD particles, rather to act as a spacer between hazardous impact profiles and crewmember gloves. At the impact conditions considered, all four overwrap configurations evaluated were effective in limiting contact between EMU gloves and impact crater profiles. The multi-layer beta-cloth configuration was the most effective in reducing the height of potentially hazardous profiles in handrail-representative targets. In the second phase of the study, four material alternatives to current aluminum and stainless steel alloys were evaluated: a metal matrix composite, carbon fiber reinforced plastic (CFRP), fiberglass, and a fiber metal laminate. Alternative material handrails are intended to prevent the formation of hazardous damage profiles during MMOD impact and are suitable for flight hardware yet to be constructed. Of the four materials evaluated, only the fiberglass formed a less hazardous damage profile than the baseline metallic target. Although the CFRP laminate did not form any noticeable crater lip, brittle protruding fibers are considered a puncture risk. In parallel with EMU glove redesign efforts, modifications to metallic ISS handrails such as those evaluated in this study provide the means to significantly reduce cut-hazards from MMOD impact craters.

Christiansen, Eric L.↗

NASA NTRS2010

Laser Surface Preparation and Bonding of Aerospace Structural Composites

Adhesive bonds are critical to the integrity of built-up structures. Disbonds can often be detected but the strength of adhesion between surfaces in contact is not obtainable without destructive testing. Typically the number one problem in a bonded structure is surface contamination, and by extension, surface preparation. Standard surface preparation techniques, including grit blasting, manual abrasion, and peel ply, are not ideal because of variations in their application. Etching of carbon fiber reinforced plastic (CFRP) panels using a neodymium-doped yttrium aluminum garnet (Nd:YAG) laser appears to be a highly precise and promising way to both clean a composite surface prior to bonding and provide a bond-promoting patterned surface akin to peel ply without the inherent drawbacks from the same (i.e., debris and curvature). CFRP surfaces prepared using laser patterns conducive to adhesive bonding were compared to typical prebonding surface treatments through optical microscopy, contact angle goniometry, and post-bonding mechanical testing.

Belcher, M. A.↗

NASA NTRS2010

Laser Surface Preparation for Adhesive Bonding of Aerospace Structural Composites

Adhesive bonds are critical to the integrity of built-up structures. Disbonds can often be detected but the strength of adhesion between surfaces in contact is not obtainable without destructive testing. Typically the number one problem in a bonded structure is surface contamination, and by extension, surface preparation. Standard surface preparation techniques, including grit blasting, manual abrasion, and peel ply, are not ideal because of variations in their application. Etching of carbon fiber reinforced plastic (CFRP) panels using a neodymium-doped yttrium aluminum garnet (Nd:YAG) laser appears to be a highly precise and promising way to both clean a composite surface prior to bonding and provide a bond-promoting patterned surface akin to peel ply without the inherent drawbacks from the same (i.e., debris and curvature). CFRP surfaces prepared using laser patterns conducive to adhesive bonding were compared to typical pre-bonding surface treatments through optical microscopy, contact angle goniometry, and post-bonding mechanical testing.

Belcher, M. A.↗

NASA NTRS2011

Improved, Low-Stress Economical Submerged Pipeline

A preliminary study has shown that the use of a high-strength composite fiber cloth material may greatly reduce fabrication and deployment costs of a subsea offshore pipeline. The problem is to develop an inexpensive submerged pipeline that can safely and economically transport large quantities of fresh water, oil, and natural gas underwater for long distances. Above-water pipelines are often not feasible due to safety, cost, and environmental problems, and present, fixed-wall, submerged pipelines are often very expensive. The solution is to have a submerged, compliant-walled tube that when filled, is lighter than the surrounding medium. Some examples include compliant tubes for transporting fresh water under the ocean, for transporting crude oil underneath salt or fresh water, and for transporting high-pressure natural gas from offshore to onshore. In each case, the fluid transported is lighter than its surrounding fluid, and thus the flexible tube will tend to float. The tube should be ballasted to the ocean floor so as to limit the motion of the tube in the horizontal and vertical directions. The tube should be placed below 100-m depth to minimize biofouling and turbulence from surface storms. The tube may also have periodic pumps to maintain flow without over-pressurizing, or it can have a single pump at the beginning. The tube may have periodic valves that allow sections of the tube to be repaired or maintained. Some examples of tube materials that may be particularly suited for these applications are non-porous composite tubes made of high-performance fibers such as Kevlar, Spectra, PBO, Aramid, carbon fibers, or high-strength glass. Above-ground pipes for transporting water, oil, and natural gas have typically been fabricated from fiber-reinforced plastic or from more costly high-strength steel. Also, previous suggested subsea pipeline designs have only included heavy fixed-wall pipes that can be very expensive initially, and can be difficult and expensive to deploy for long distances. A much less expensive Kevlar pipeline can be coiled up on a ship s deck and deployed in the water as the ship moves. Support ships can be used to drop sand into conduits below the uninflated tube, so that the tube remains in place when more buoyant fresh water later fills the tubes.

Jones, Jack A.↗

NASA NTRS2012

Composite Laminate With Coefficient of Thermal Expansion Matching D263 Glass

The International X-ray Observatory project seeks to make an X-ray telescope assembly with 14,000 flexible glass segments. The glass used is commercially available SCHOTT D263 glass. Thermal expansion causes the mirror to distort out of alignment. A housing material is needed that has a matching coefficient of thermal expansion (CTE) so that when temperatures change in the X-ray mirror assembly, the glass and housing pieces expand equally, thus reducing or eliminating distortion. Desirable characteristics of this material include a high stiffness/weight ratio, and low density. Some metal alloys show promise in matching the CTE of D263 glass, but their density is high compared to aluminum, and their stiffness/weight ratio is not favorable. A laminate made from carbon fiber reinforced plastic (CFRP) should provide more favorable characteristics, but there has not been any made with the CTE matching D263 Glass. It is common to create CFRP laminates of various CTEs by stacking layers of prepreg material at various angles. However, the CTE of D263 glass is 6.3 ppm/ C at 20 C, which is quite high, and actually unachievable solely with carbon fiber and resin. A composite laminate has been developed that has a coefficient of thermal expansion identical to that of SCHOTT D263 glass. The laminate is made of a combination of T300 carbon fiber, Eglass, and RS3C resin. The laminate has 50% uni-T300 plies and 50% uni-E-glass plies, with each fiber-layer type laid up in a quasi-isotropic laminate for a total of 16 plies. The fiber volume (percent of fiber compared to the resin) controls the CTE to a great extent. Tests have confirmed that a fiber volume around 48% gives a CTE of 6.3 ppm/ C. This is a fairly simple composite laminate, following well established industry procedures. The unique feature of this laminate is a somewhat unusual combination of carbon fiber with E-glass (fiberglass). The advantage is that the resulting CTE comes out to 6.3 ppm/ C at 20 C, which matches D263 glass. The trick with this laminate is to establish the proper fiber volume to get the desired CTE. Laminates were made with several different fiber volumes and coupons were tested to establish the relationship between fiber volume and CTE. Testing proved that fiber volume should be about 48%.

Robinson, David↗

NASA NTRS2013

LSP Composite Susbtrate Manufacturing Processing Guide

This document is intended to define Carbon Fiber Reinforced Plastic (CFRP) test panel configurations that can be employed for the purposes of evaluating the protection capabilities of Lightning Strike Protection (LSP) materials developed by the Aerospace Industry. The configurations are intended to provide consistent behavior in their response to simulated lightning strikes at pre-defined levels when tested by a capable vendor according to a test procedure written to enable consistent results (ref section 2.1.2). In response to an attachment of a simulated lightning strike on a CFRP panel, one can expect to see various levels of ablation and delamination, both through the thickness of the panel and with respect to the amount of panel surface area that exhibits damage. Panel configurations defined in this document include: An "unprotected" configuration 128694-1 (ref section 4.1), consisting of a cured CFRP laminate stackup of tape and fabric prepregs, coated with a typical aerospace primer and paint finishing scheme, attached to aluminum grounding bars intended to draw electrical current from the lightning attachment point to the panel edges and thus to ground. A "protected" configuration 128694-2 (ref section 4.1), wherein a layer of an LSP material form often used in the Aerospace Industry is included in the laminate stackup prior to cure. The CFRP materials, finishes and grounding arrangement for ths configuration are the same as for the "unprotected" configuration.

Kovach, Daniel J.↗

NASA NTRS2013

Common Practice Lightning Strike Protection Characterization Technique to Quantify Damage Mechanisms on Composite Substrates

To support FAA certification airworthiness standards, composite substrates are subjected to lightning direct-effect electrical waveforms to determine performance characteristics of the lightning strike protection (LSP) conductive layers used to protect composite substrates. Test results collected from independent LSP studies are often incomparable due to variability in test procedures & applied practices at different organizations, which impairs performance correlations between different LSP data sets. Under a NASA supported contract, The Boeing Company developed technical procedures and documentation as guidance in order to facilitate a test method for conducting universal common practice lightning strike protection test procedures. The procedures obtain conformity in future lightning strike protection evaluations to allow meaningful performance correlations across data sets. This universal common practice guidance provides the manufacturing specifications to fabricate carbon fiber reinforced plastic (CFRP) test panels, including finish, grounding configuration, and acceptable methods for pretest nondestructive inspection (NDI) and posttest destructive inspection. The test operations guidance elaborates on the provisions contained in SAE ARP5416 to address inconsistencies in the generation of damage protection performance data, so as to provide for maximum achievable correlation across capable lab facilities. In addition, the guidance details a direct effects test bed design to aid in quantification of the multi-physical phenomena surrounding a lightning direct attachment supporting validation data requirements for the development of predictive computational modeling. The lightning test bed is designed to accommodate a repeatable installation procedure to secure the test panel and eliminate test installation uncertainty. It also facilitates a means to capture the electrical waveform parameters in 2 dimensions, along with the mechanical displacement and thermal heating parameters which occur during lightning attachment. Following guidance defined in the universal common practice LSP test documents, protected and unprotected CFRP panels were evaluated at 20, 40 and 100KAmps. This report presents analyzed data demonstrating the scientific usefulness of the common practice approach. Descriptions of the common practice CFRP test articles, LSP test bed fixture, and monitoring techniques to capture the electrical, mechanical and thermal parameters during lightning attachment are presented here. Two methods of measuring the electrical currents were evaluated, inductive current probes and a newly developed fiberoptic sensor. Two mechanical displacement methods were also examined, optical laser measurement sensors and a digital imaging correlation camera system. Recommendations are provided to help users implement the common practice test approach and obtain LSP test characterizations comparable across data sets.

Szatkowski, George N.↗

NASA NTRS2016

Design of Superconducting Gravity Gradiometer Cryogenic System for Mars Mission

Measurement of a planet's gravity field provides fundamental information about the planet's mass properties. The static gravity field reveals information about the internal structure of the planet, including crustal density variations that provide information on the planet's geological history and evolution. The time variations of gravity result from the movement of mass inside the planet, on the surface, and in the atmosphere. NASA is interested in a Superconducting Gravity Gradiometer (SGG) with which to measure the gravity field of a planet from orbit. An SGG instrument is under development with the NASA PICASSO program, which will be able to resolve the Mars static gravity field to degree 200 in spherical harmonics, and the time-varying field on a monthly basis to degree 20 from a 255 x 320 km orbit. The SGG has a precision two orders of magnitude better than the electrostatic gravity gradiometer that was used on the ESA's GOCE mission. The SGG operates at the superconducting temperature lower than 6 K. This study developed a cryogenic thermal system to maintain the SGG at the design temperature in Mars orbit. The system includes fixed radiation shields, a low thermal conductivity support structure and a two-stage cryocooler. The fixed radiation shields use double aluminized polyimide to emit heat from the warm spacecraft into the deep space. The support structure uses carbon fiber reinforced plastic, which has low thermal conductivity at cryogenic temperature and very high stress. The low vibration cryocooler has two stages, of which the high temperature stage operates at 65 K and the low temperature stage works at 6 K, and the heat rejection radiator works at 300 K. The study also designed a second option with a 4-K adiabatic demagnetization refrigerator (ADR) and two-stage 10-K turbo-Brayton cooler.

Gradiometer↗

NASA NTRS2016

Design of Superconducting Gravity Gradiometer Cryogenic System for Mars Mission

Measurement of a planets gravity field provides fundamental information about the planets mass properties. The static gravity field reveals information about the internal structure of the planet, including crustal density variations that provide information on the planets geological history and evolution. The time variations of gravity result from the movement of mass inside the planet, on the surface, and in the atmosphere. NASA is interested in a Superconducting Gravity Gradiometer (SGG) with which to measure the gravity field of a planet from orbit. An SGG instrument is under development with the NASA PICASSO program, which will be able to resolve the Mars static gravity field to degree 200 in spherical harmonics, and the time-varying field on a monthly basis to degree 20 from a 255 x 320 km orbit. The SGG has a precision two orders of magnitude better than the electrostatic gravity gradiometer that was used on the ESAs GOCE mission. The SGG operates at the superconducting temperature lower than 6 K. This study developed a cryogenic thermal system to maintain the SGG at the design temperature in Mars orbit. The system includes fixed radiation shields, a low thermal conductivity support structure and a two-stage cryocooler. The fixed radiation shields use double aluminized polyimide to emit heat from the warm spacecraft into the deep space. The support structure uses carbon fiber reinforced plastic, which has low thermal conductivity at cryogenic temperature and very high stress. The low vibration cryocooler has two stages, of which the high temperature stage operates at 65 K and the low temperature stage works at 6 K, and the heat rejection radiator works at 300 K. The study also designed a second option with a 4-K adiabatic demagnetization refrigerator (ADR) and two-stage 10-K turbo-Brayton cooler.

Li, X.↗

NASA NTRS2017

Picosecond Pulsed Laser Ablation for the Surface Preparation of Epoxy Composites

As part of a technical challenge under the Advanced Composites Program, methods for improving pre-bond process control for aerospace composite surface treatments and inspections, in conjunction with Federal Aviation Administration guidelines, are under investigation. The overall goal is to demonstrate high fidelity, rapid and reproducible surface treatment and surface characterization methods to reduce uncertainty associated with the bonding process. The desired outcomes are reliable bonded airframe structure, and reduced timeline to certification. In this work, laser ablation was conducted using a q-switched Nd:YVO4 laser capable of nominal pulse durations of 8 picoseconds (ps). Aerospace structural carbon fiber reinforced composites with an epoxy resin matrix were laser treated, characterized, processed into bonded assemblies and mechanically tested. The characterization of ablated surfaces were conducted using scanning electron microscopy (SEM), water contact angle (WCA) goniometry, micro laser induced breakdown spectroscopy (uLIBS), and electron spin resonance (ESR). The bond performance was assessed using a double cantilever beam (DCB) test with an epoxy adhesive. The surface characteristics and bond performance obtained from picosecond ablated carbon fiber reinforced plastics (CFRPs) are presented herein.

Palmieri, Frank↗

NASA NTRS2018

Relevence of 3D Simulations and Sandwich Core Topology for the Modeling of Honeycomb Core Sandwich Panels Undergoing Mode I Delamination

A recently developed cohesive zone traction-separation law, which includes the effects of fiber bridging in a novel way, is extended from 2D to 3D. The proposed cohesive model is applied to low fidelity (i.e. homogenized core representation) and high fidelity (i.e. directly accounting for the core topology) finite element models of a composite panel comprised of carbon fiber reinforced plastic facesheets and a honeycomb sandwich core. This enables the investigation of 2D to 3D parameter transferability, width-dependent effects such as thumbnail-shaped crack growth, and the verification of plane strain / plane stress assumptions. A pronounced curvature of the initial interface-related crack front is observed, while the bridging-related crack front is straight. Furthermore, it is found that the cohesive parameters can easily be transferred from 2D to 3D under plane stress assumptions, but not under plane strain assumptions. The numerical predictions are compared to experimental load-displacement and R-curves.

Composites↗

NASA NTRS2019

Orbital Debris Quarterly News

Inside - NASA Technical Standard Process for Limiting Orbital Debris Revision Ratified - Testing and Modeling the Demisability of Fiber-Reinforced Plastics - An Extended Parametric Study of the Effects of Large Constellations on the Future Debris Environment - Meeting Reports - Abstracts from the NASA HVIT - Abstracts from the NASA ODPO - ODQN Vol. 23, Issue 1&2 Errata - Orbital Debris Analyst - Space Missions/Satellite Box Score

Phillip Anz-Meador↗

NASA NTRS2019

Operational and Technical Updates to the Object Reentry Survival Analysis Tool

The Object Reentry Survival Analysis Tool (ORSAT) has been used in the NASA Orbital Debris Program Office for over 25 years to estimate risk due to uncontrolled reentry of spacecraft and rocket bodies. Development over the last 3 years has included: a major change to the treatment of carbon fiber- and glass fiber-reinforced plastics (CFRP and GFRP, respectively); an updated atmospheric model; a new model for computing casualty area around an impacting debris object; and a newly-implemented scheme to determine the breakup altitude of a reentry object. Software also was written to automatically perform parameter sweeps in ORSAT to allow for uncertainty quantification and sensitivity analysis for components with borderline demisability. These updates have improved the speed and fidelity of the reentry analysis performed using ORSAT, and have allowed for improved engineering understanding by estimating the uncertainty for each component’s survivability. A statistical model for initial conditions captures the latitude bias in population density, a large improvement over the previous inclination-based latitude-averaged models. A sample spacecraft has been analyzed with standard techniques using ORSAT 6.2.1 and again using all the updated models; we will demonstrate the variation in the total debris casualty area and overall expectation of casualty.

Ostrom, C.↗

NASA NTRS2019

Characterization of Prepreg Tack for Composite Manufacturing by Automated Fiber Placement

Automated fiber placement (AFP) has become the industry standard for large-scale production of carbon fiber reinforced plastics (CFRP) to improve rate and reduce defects associated with manual layup. Still, defects generated during AFP processes require manual, painstaking inspection by technicians and rework of the part when substantial defects are found. Prepreg (carbon fiber infused with uncured epoxy resin) tack is one of the primary factors that influences the generation of defects that arise during auto-mated fiber placement (AFP). Tack, as it relates to AFP processes and defect formation, can be understood as a combination of two stages, cohesion and decohesion. During the cohesion phase, two pieces of prepreg are brought into contact under elevated temperature and pressure. Compaction of the resin within the contact area will result in a degree of intimate contact, I, between the mating prepreg surfaces. Defect formation, as a result of decohesion between prepreg surfaces, occurs after the cohesion phase and arises due to stress from events such as fiber placement over an existing defect, on a contoured path, etc. (Figure 1). Tack strength resists the displacement of prepreg on a surface due to stresses developed during deposition.

Wohl, Christopher J↗

NASA NTRSDate not supplied

Recent Updates to the Object Reentry Survival Analysis Tool (ORSAT) Version 7.1

The Object Reentry Survival Analysis Tool (ORSAT) code is maintained and used by the NASA Orbital Debris Program Office (ODPO) and has been under continuous development and improvement since the mid-1990s. ORSAT is an object-oriented reentry simulation tool; it models a satellite as a collection of discrete components that follow independent trajectories upon the breakup of the parent object. Version 7.1 of the tool incorporates five years of new thermal and aerodynamic model development, multi-processor parametric study capability, codebase upgrades, and numerous bug-fixes. The thermal demise model was completely rewritten using a forward-time/central-space numerical stencil and incorporating a new pyrolysis model for fiber-reinforced plastic (FRP) materials. New aerodynamic and aeroheating models for hollow cylinders and hollow square prisms were developed using a combination of flow simulations in the direct simulation Monte Carlo (DSMC) Analysis Code (DAC) and Data Parallel Line Relaxation (DPLR) code and free-flight tests in the University of Texas at San Antonio’s Hypersonic Wind Tunnel. The latest version also incorporates a mechanical, strength-based demise model for FRP materials. Minor improvements include an update to the Fortran 2018 codebase; improved integration and speed with the Python-based, multi-core, parametric study tool, AutoORSAT; and fixes for many minor bugs. This new version of ORSAT will enable more accurate reentry risk assessments for modern satellites. This paper presents an overview of these changes and a summary of the verification and validation performed on the final code.

Benton R. Greene↗

NASA NTRSDate not supplied

Recent Updates to the Object Reentry Survival Analysis Tool (ORSAT) Version 7.1

Benton R. Greene↗

DOE OSTI2023

Developing a Roadmap for Bio-Derivable and Recyclable Composites: Re-Design and Scale-Up Considerations

Composites, often in the form of fiber reinforced plastics, are used in multiple facets of modern life from snowboards to vehicles, to wind turbines and beyond. Despite their prolific, and often renewable energy related uses, they are currently subject to a linear material economy from emission intensive precursors; thus, there is an opportunity to re-design these materials to be both bio-derivable and recyclable. In the present work, we provide a roadmap of what application considerations must be considered for vacuum assisted resin transfer molding (VARTM) processes for large composites materials at scale (e.g. infusible viscosities, moderate cure times, proper fiber adhesion, low cost, and maximum peak exotherm) when implementing bio-derivable and recyclable materials. We also provide illustrative concepts utilizing polyester covalently adaptable networks, from epoxy-anhydride chemistry, to achieve these goals. We further provide considerations when developing recycling process (e.g. maintenance of fiber sizing and orientation) and demonstrate these practices using low temperature methanolysis. Accompanying technoeconomic and life cycle analysis further illustrate the decarbonization benefits to bio-derivable and recyclable thermosets while informing future research and recycling processes. Finally, we provide a brief introduction to synergistic work within our team exploring how to further decarbonize the manufacturing of these materials.

BIOMASS FUELS,ENERGY CONSERVATION, CONSUMPTION, AN↗

DOE OSTI2023

Torrefaction of almond shell as a renewable reinforcing agent for plastics: techno-economic analyses and comparison to bioethanol process

Abstract In 2016, the US state of California alone produced nearly 3.5 billion kilograms of almonds, accounting for approximately 84% of the world’s almond production. This generated about 2.58 million metric tons (MTs) of almond residues. Almond shells are currently either burned to generate power or disposed of in landfill. Valorizing almond shells and hulls provides an opportunity to replace petroleum-derived products and divert organic material from landfill. Here we demonstrate a detailed techno-economic analysis (TEA) of an almond shell torrefaction process capable of utilizing the 520 000 MTs of almond shells produced annually in California. Our process also includes preprocessing the torrefied biomass to exploit it as a reinforcing agent for plastics. We further compared the revenue generated from the torrefied biomass and bioethanol derived from the same quantity of almond shells. We considered three different torrefaction facility scales to evaluate trade-offs between economies of scale at the facility and trucking costs to deliver almond shells. A facility that takes in 200 000 MT yr –1 of almond shells results in lower per-unit-output basis capital and operating cost relative to other smaller-scale torrefaction facilities, including 10 000 MT yr –1 and 50 000 MT yr –1 , considered for analysis in this study. The large-sale facility results in a minimum selling price (MSP) of the torrefied biomass of $311.4 MT –1 . An analogous TEA on converting almond residues into bioethanol is also investigated. The MSP of almond shell derived ethanol ($1.71 kg −1 ) is higher than that of corn ($0.48 kg −1 ) or cellulosic biomass ($0.88 kg −1 ) derived ethanol. Compared with the bioethanol route, the torrefied almond shells result in three times more revenue if utilized as a reinforcing agent for plastics.

Liu, Dupeng (ORCID:0000000269514064)↗