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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development of fiber orientation in injection molding: Comparison of glass fiber, carbon fiber and their hybrid composites

Fiber orientation distribution (FOD) in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for glass fiber (GF), carbon fiber (CF), and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varied with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design and Production for Maximum Structural Efficiency With Respect to Fiber Orientation With Increased Understanding of Hybrid Fiber Flow Behavior

Discontinuous fiber-reinforced thermoplastic composites have gained considerable attention in automotive, aerospace, and other industries, due to their high-rate of production combined with their ability to attain complex and intricate shapes. Among other high-rate thermoplastic manufacturing processes, injection-molding is one of the most common manufacturing methods due to fast production and high surface finishing of complex geometries. Fiber orientation in discontinuous fiber composites plays a pivotal role in determining the mechanical, electrical, and thermomechanical properties, underscoring the necessity to comprehend fiber orientation in injection molded parts. Among different fiber types, glass and carbon fibers are most common in the composite industries. The recent trend of hybrid composites comprising both glass fiber (GF) and carbon fiber (CF) is also gaining importance in the automotive industry. Hybrid fiber options allow designers to optimize the balance between glass and carbon fibers by leveraging the high durability and low cost of GF while the strength and lightweight properties of CF. Consequently, comparing the fiber oriented distribution (FOD) of injection molded composites containing GF, CF, and a hybrid of GF/CF is critical to investigating the local mechanical properties of intricate structures for high-end applications. In Phase I of this project, FOD in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for GF, CF, and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varies with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Further development of chemical vapor deposition process for production of large diameter carbon-base monofilaments

The development of large diameter carbon-base monofilament in the 50 micron to 250 micron diameter range using the chemical vapor deposition process is described. The object of this program was to determine the critical process variables which control monofilament strength, monofilament modulus, and monofilament diameter. It was confirmed that wide scatter in the carbon substrate strength is primarily responsible for the scatter in the monofilament strength. It was also shown through etching experiments that defective substrate surface conditions which can induce low strength modular growth in the monofilament layers are best controlled by processing improvements during the synthesis of the substrate. Modulus was found to be linearily proportional to monofilament boron content. Filament modulus was increased to above 27.8MN/sq cm but only by a considerable increase in monofilament boron content to 60 wt. % or more. Monofilament diameter depended upon dwell time in the synthesis apparatus. A monofilament was prepared using these findings which had the combined properties of a mean U.T.S. of 398,000 N/sq cm, a modulus of 18.9 MN/sq cm (24,000,000 psi), and a diameter of 145 microns. Highest measured strength for this fiber was 451,000 N/sq cm (645,000 psi).

Hough, R. L.↗
NASA NTRS1974

Physical property measurements of doped cesium iodide crystals

Mechanical and thermal property values are reported for crystalline cesium iodide doped with sodium and thallium. Young's modulus, bulk modulus, shear modulus, and Poisson's ratio were obtained from ultrasonic measurements. Young's modulus and the samples' elastic and plastic behavior were also measured under tension and compression. Thermal expansion and thermal conductivity were the temperature dependent measurements that were made.

Synder, R. S.↗
NASA NTRS1975

Early detection of fatigue damage in composite materials

Early detection of fatigue damage in composite materials by nondestructive inspection (NDI) techniques has been demonstrated for glass/epoxy, graphite/glass/epoxy, and graphite/epoxy composites. Modulus and temperature were monitored and a correlation between them observed. Axial modulus and torsional modulus changes were a function of the laminate orientation. Torsional modulus measurements and coin tap tests were performed at 0, 1 million, 5 million, and 10 million cycles, on axial fatigue specimens. Three distinct regions were noted. In the primary region a small but rapid change in stiffness was noted in the first few thousand cycles. This was followed by a secondary region of little or no stiffness change. The tertiary region was characterized by an increasing rate of stiffness change leading to fracture. NDI procedures including holographic interferometry, ultrasonics, penetrant, and X-ray radiography were evaluated for fatigue damage detection.

Salkind, M. J.↗
NASA NTRS1976

Diamagnetic studies on as-processed carbon fibers

The Faraday method has been used to measure the diamagnetic susceptibilities of small bundles of aligned carbon fibers of different types at room temperature. It was found that the tensor trace susceptibility of the fibers varies systematically over the range 0.8-20 (in units of -10 to the -6th emu/g) as a function of precursor type and processing history. The susceptibility increases, in general, with increasing nominal treatment temperature and hot stretching, and with increasing tensile elastic modulus. The anisotropy ratio of fibers increases approximately linearly with tensile elastic modulus for all fibers from about 1 for a modulus of about 70 GN/sq m to about 22 for a modulus of 700 GN/sq m in air, and is quantitatively consistent with the layer-plane orientation textures determined by X-ray diffraction when appropriate values of the crystallite principal susceptibilities are used.

Scott, C. B.↗
NASA NTRS1979

Dynamic response of damaged angleplied fiber composites

The effects of low level damage induced by monotonic load, cyclic load and/or residual stresses on the vibration frequencies and damping factors of fiber composite angleplied laminates were investigated. Two different composite systems were studied - low modulus fiber and ultra high modulus fiber composites. The results obtained show that the frequencies and damping factors of angleplied laminates made from low modulus fiber composites are sensitive to low level damage while those made from ultra high modulus composites are not. Vibration tests may not be sufficiently sensitive to assess concentrated local damage in angleplied laminates. Dynamic response determined from low-velocity impact coupled with the Fast Fourier Transform and packaged in a minicomputer can be a convenient procedure for assessing low-level damage.

Chamis, C. C.↗
NASA NTRS1979

Dynamic response of damaged angleplied fiber composites

An investigation was conducted to determine the effects of low level damage induced by monotonic load, cyclic load and/or residual stresses on the vibration frequencies and damping factors of fiber composite angleplied laminates. Two different composite systems were studied - low modulus fiber and ultra high modulus fiber composites. The results obtained showed that the frequencies and damping factors of angleplied laminates made from low modulus fiber composites are sensitive to low level damage while those made from ultra high modulus composites are not. Also, vibration tests may not be sufficiently sensitive to assess concentrated local damage in angleplied laminates. And furthermore, dynamic response determined from low-velocity impact coupled with the Fast Fourier Transform and packaged in a minicomputer can be a convenient procedure for assessing low-level damage in fiber composite angleplied laminates.

Chamis, C. C.↗
NASA NTRS1983

Stiffness Properties for Dynamic Modeling of Composite Graphite-Epoxy Cylindrical Orthotropic Shells

Traditional composite lamination theory was used to predict composite graphite-epoxy laminate stiffnesses for comparison to quasi-experimental stiffnesses developed from cylindrical bottle pressure testing. Stiffness sensitivities were examined for variations in constituent materials and geometric properties. The material component interactions examined were the fiber longitudinal and transverse Young's modulus, the fiber shear modulus and primary Poisson's ratio, the resin Young's modulus, shear modulus, and Poisson's ratio. The geometric variation of the helical winding angle was also examined. Two computer programs were written to generate the data used to demonstrate the stiffness variations.

Tolbert, R. N.↗
NASA NTRS1983

Producibility of fibrous refractory composite insulation, FRCI 40-20

Fibrous Refractory Composite Insulation (FRCI) is a NASA-developed, second generation, reusable heat-shield material that comprises a mixture of aluminoborosilicate fibers, silica fibers, and silicon carbide. Under NASA contract, a program was conducted to demonstrate the capability for manufacturing FRCI 40-20 billets. A detailed fabrication procedure was written and validated by testing specimens from the first two billets. The material conformed to NASA requirements for density, tensile strength, modulus of rupture, thermal expansion, cristobalite content, and uniformity. Twenty-four billets were prepared to provide 20 deliverable articles. Production billets were checked for density, modulus of rupture, cristobalite content, and uniformity. Billet density ranged from 309.48 to 332.22 kg/cu m (19.32 to 20.74 lb/cu ft) and modulus of rupture from 4690 to 10,140 kPa (680 to 1470 psi). Cristobalite content was less than 1 percent. A Weibull analysis of modulus-of-rupture data indicated a 1.5 percent probability for failure below the specified strength of 4480 kPa (650 psi).

Strauss, E. L.↗
NASA NTRS1989

Improved silicon carbide for advanced heat engines

The development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines is studied. Injection molding was the forming method selected for the program because it is capable of forming complex parts adaptable for mass production on an economically sound basis. The goals were to reach a Weibull characteristic strength of 550 MPa (80 ksi) and a Weibull modulus of 16 for bars tested in four-point loading. Statistically designed experiments were performed throughout the program and a fluid mixing process employing an attritor mixer was developed. Compositional improvements in the amounts and sources of boron and carbon used and a pressureless sintering cycle were developed which provided samples of about 99 percent of theoretical density. Strengths were found to improve significantly by annealing in air. Strengths in excess of 550 MPa (80 ksi) with Weibull modulus of about 9 were obtained. Further improvements in Weibull modulus to about 16 were realized by proof testing. This is an increase of 86 percent in strength and 100 percent in Weibull modulus over the baseline data generated at the beginning of the program. Molding yields were improved and flaw distributions were observed to follow a Poisson process. Magic angle spinning nuclear magnetic resonance spectra were found to be useful in characterizing the SiC powder and the sintered samples. Turbocharger rotors were molded and examined as an indication of the moldability of the mixes which were developed in this program.

Whalen, Thomas J.↗
NASA NTRS1991

Preliminary investigation of thin film polymers exposed to low Earth orbit

Preliminary results of thin film polymers exposed to low-Earth orbit aboard the Long Duration Exposure Facility (LDEF) are discussed. Dynamic testing of a 0.92/0.92 mil. polyester laminate film indicated that the modulus loss of the exposed specimens may be very small. When the storage modulus of the exposed specimen was compared to the storage modulus of a control specimen over a temperature range of minus 150 degrees to 100 degrees, there was very little change. Fourier Transform Spectroscopy performed on the same exposed material indicated crosslinking of the polyethylene, which was verified by an increase in the storage modulus above the glass transition temperature. Optical microscopy of the sample showed micrometeoroid strikes and contamination in spots by what is thought to be silicon outgassed from a nearby experiment.

Strganac, Thomas↗
NASA NTRS1991

Temperature dependence of the elastic moduli and damping for polycrystalline LiF-22 pct CaF2 eutectic salt

Young's and shear moduli and damping were measured for as-cast polycrystalline LiF-(22 mol pct)CaF2 eutectic specimens as a function of temperature using the piezoelectric ultrasonic composite oscillator technique. The shear modulus decreased with increasing temperature from about 40 GPa at 295 K to about 30 GPa at 1000 K, while the Young modulus decreased from about 115 GPa at 295 K to about 35 GPa at 900 K. These values are compared with those derived from the rule of mixtures using elastic moduli data for LiF and CaF2 single crystals. It is shown that, while the shear modulus data agree reasonably well with the predicted trend, there is a large discrepancy between the theoretical calculations and the Young modulus values, where this disagreement increases with increasing temperature.

Wolfenden, A.↗
NASA NTRS1991

Oxynitride glass fibers

Research at the Army Materials Technology Laboratory (AMTL) and elsewhere has shown that many glass properties including elastic modulus, hardness, and corrosion resistance are improved markedly by the substitution of nitrogen for oxygen in the glass structure. Oxynitride glasses, therefore, offer exciting opportunities for making high modulus, high strength fibers. Processes for making oxynitride glasses and fibers of glass compositions similar to commercial oxide glasses, but with considerable enhanced properties, are discussed. We have made glasses with elastic moduli as high as 140 GPa and fibers with moduli of 120 GPa and tensile strengths up to 2900 MPa. AMTL holds a U.S. patent on oxynitride glass fibers, and this presentation discusses a unique process for drawing small diameter oxynitride glass fibers at high drawing rates. Fibers are drawn through a nozzle from molten glass in a molybdenum crucible at 1550 C. The crucible is situated in a furnace chamber in flowing nitrogen, and the fiber is wound in air outside of the chamber, making the process straightforward and commercially feasible. Strengths were considerably improved by improving glass quality to minimize internal defects. Though the fiber strengths were comparable with oxide fibers, work is currently in progress to further improve the elastic modulus and strength of fibers. The high elastic modulus of oxynitride glasses indicate their potential for making fibers with tensile strengths surpassing any oxide glass fibers, and we hope to realize that potential in the near future.

Patel, Parimal J.↗
NASA NTRS1992

Effect of heat treatment on the flexural properties of a titanium matrix composite

Titanium matrix composites (TMC) reinforced with carbon fibers are widely used in the aerospace industry due to their light weight, high strength and modulus and the retention of their strength and modulus at elevated temperatures. Liquid infiltration, a low cost technique for making TMCs, has been little used due to the extent of the reaction between titanium and carbon during fabrication. Rapid infrared processing (RIP) has been developed as a technique for reducing interfacial reaction during composite fabrication. The strength and modulus of composites produced using RIP were higher than or comparable to those for other composites. This paper examines the effect of heat treatment on the room temperature flexural strength and modulus of TMC produced using RIP. The experiments carried out are described and results are presented. Results showed increased flexural strength of the composites upon aging at temperatures of 800 and 900 degrees C. This increased strength may be due to increased strength of the matrix.

Warrier, S. G.↗
NASA NTRS1947

Elastic Properties in Tension and Shear of High Strength Nonferrous Metals and Stainless Steel - Effect of Previous Deformation and Heat Treatment

A resume is given of an investigation of the influence of plastic deformation and of annealing temperature on the tensile and shear elastic properties of high strength nonferrous metals and stainless steels in the form of rods and tubes. The data were obtained from earlier technical reports and notes, and from unpublished work in this investigation. There are also included data obtained from published and unpublished work performed on an independent investigation. The rod materials, namely, nickel, monel, inconel, copper, 13:2 Cr-Ni steel, and 18:8 Cr-Ni steel, were tested in tension; 18:8 Cr-Ni steel tubes were tested in shear, and nickel, monel, aluminum-monel, and Inconel tubes were tested in both tension and shear. There are first described experiments on the relationship between hysteresis and creep, as obtained with repeated cyclic stressing of annealed stainless steel specimens over a constant load range. These tests, which preceded the measurements of elastic properties, assisted in devising the loading time schedule used in such measurements. From corrected stress-set curves are derived the five proof stresses used as indices of elastic or yield strength. From corrected stress-strain curves are derived the secant modulus and its variation with stress. The relationship between the forms of the stress-set and stress-strain curves and the values of the properties derived is discussed. Curves of variation of proof stress and modulus with prior extension, as obtained with single rod specimens, consist in wavelike basic curves with superposed oscillations due to differences of rest interval and extension spacing; the effects of these differences are studied. Oscillations of proof stress and modulus are generally opposite in manner. The use of a series of tubular specimens corresponding to different amounts of prior extension of cold reduction gave curves almost devoid of oscillation since the effects of variation of rest interval and extension spacing were removed. Comparison is also obtained between the variation of the several properties, as measured in tension and in shear. The rise of proof stress with extension is studied, and the work-hardening rates of the various metals evaluated. The ratio between the tensile and shear proof stresses for the various annealed and cold-worked tubular metals is likewise calculated. The influence of annealing or tempering temperature on the proof stresses and moduli for the cold-worked metals and for air-hardened 13:2 Cr-Ni steel is investigated. An improvement of elastic strength generally is obtained, without important loss of yield strength, by annealing at suitable temperature. The variation of the proof stress and modulus of elasticity with plastic deformation or annealing temperature is explained in terms of the relative dominance of three important factors: namely, (a) internal stress, (b) lattice-expansion or work-hardening, and (c) crystal reorientation. Effective values of Poisson's ratio were computed from tensile and shear moduli obtained on tubular specimens. The variation of Poisson's ratio with plastic deformation and annealing temperature is explained in terms of the degree of anisotropy produced by changes of (a) internal stress and (b) crystal orientation.

METALS - ELASTICITY↗
NASA NTRS1991

An Evaluation of the Iosipescu Specimen for Composite Materials Shear Property Measurement

A detailed evaluation of the suitability of the Iosipescu specimen tested in the modified Wyoming fixture is presented. An experimental investigation using conventional strain gage instrumentation and moire interferometry is performed. A finite element analysis of the Iosipescu shear test for unidirectional and cross-ply composites is used to assess the uniformity of the shear stress field in the vicinity of the notch, and demonstrate the effect of the nonuniform stress field upon the strain gage measurements used for the determination of composite shear moduli. From the test results for graphite-epoxy laminates, it is shown that the proximity of the load introduction point to the test section greatly influences the individual gage readings for certain fiber orientations but the effect upon shear modulus measurement is relatively unimportant. A numerical study of the load contact effect shows the sensitivity of some fiber configurations to the specimen/fixture contact mechanism and may account for the variations in the measured shear moduli. A comparison of the strain gage readings from one surface of a specimen with corresponding data from moire interferometry on the opposite face documented an extreme sensitivity of some fiber orientations to eccentric loading which induced twisting and yielded spurious shear stress-strain curves. In the numerical analysis, it is shown that the Iosipescu specimens for different fiber orientations have to be modeled differently in order to closely approximate the true loading conditions. Correction factors are needed to allow for the nonuniformity of the strain field and the use of the average shear stress in the shear modulus evaluation. The correction factors, which are determined for the region occupied by the strain gage rosette, are found to be dependent upon the material orthotropic ratio and the finite element models. Based upon the experimental and numerical results, recommendations for improving the reliability and accuracy of the shear modulus values are made, and the implications for shear strength measurement discussed. Further application of the Iosipescu shear test to woven fabric composites is presented. The limitations of the traditional strain gage instrumentation on the satin weave and high tow plain weave fabrics is discussed. Test results of a epoxy based aluminum particulate composite is also presented. A modification of the Iosipescu specimen is proposed and investigated experimentally and numerically. It is shown that the proposed new specimen design provides a more uniform shear stress field in the test section and greatly reduces the normal and shear stress concentrations in the vicinity of the notches. While the fabrication and the material cost of the proposed specimen is tremendously reduced, it is shown the accuracy of the shear modulus measurement is not sacrificed.

Ho, Henjen↗
NASA NTRS1996

Tensile Strength and Microstructural Characterization of Uncoated and Coated HPZ Ceramic Fibers

Tensile strengths of as-received HPZ fiber and those surface coated with BN, BN/SiC, and BN/Si3N4 have been determined at room temperature using a two-parameter Weibull distribution. Nominally approx. 0.4 micron BN and 0.2 micron SiC or Si3N4 coatings were deposited on the fibers by chemical vapor deposition using a continuous reactor. The average tensile strength of uncoated HPZ fiber was 2.0 +/- 0.56 GPa (290 +/- 81 ksi) with a Weibull modulus of 4.1. For the BN coated fibers, the average strength and the Weibull modulus increased to 2.39 +/- 0.44 GPa (346 +/- 64 ksi) and 6.5, respectively. The HPZ/BN/SiC fibers showed an average strength of 2.0 +/- 0.32 GPa (290 +/- 47 ksi) and Weibull modulus of 7.3. Average strength of the fibers having a dual BN/Si3N4 surface coating degraded to 1.15 +/- 0.26 GPa (166 +/- 38 ksi) with a Weibull modulus of 5.3. The chemical composition and thickness of the fiber coatings were determined using scanning Auger analysis. Microstructural analysis of the fibers and the coatings was carried out by scanning electron microscopy and transmission electron microscopy. A microporous silica-rich layer approx. 200 nm thick is present on the as-received HPZ fiber surface. The BN coatings on the fibers are amorphous to partly turbostratic and contaminated with carbon and oxygen. Silicon carbide coating was crystalline whereas the silicon nitride coating was amorphous. The silicon carbide and silicon nitride coatings are non-stoichiometric, non-uniform, and granular. Within a fiber tow, the fibers on the outside had thicker and more granular coatings than those on the inside.

Bansal, Narottam P.↗