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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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Topics include a lab overview, testing and processing equipment, hemochromic hydrogen sensors, antimicrobial materials, wire system materials, CNT ink formulations, CNT ink dust screens, CNT ink printed circuitry, cryogenic materials development, fire and polymers, the importance of lighting, electric lighting systems, LED for plant growth, and carbon nanotube fiber filaments.
The development of techniques for the preparation of glass and ceramic starting materials that will result in homogeneous glasses or ceramic products when melted and cooled in a containerless environment is described. Metal-organic starting materials were used to make compounds or mixtures which were then decomposed by hydrolysis reactions to the corresponding oxides. The sodium tungstate system was chosen as a model for a glass with a relatively low melting temperature. The alkoxide tungstates also have interesting optical properties. For all the compositions studied, comparison samples were prepared from inorganic starting materials and submitted to the same analyses.
The harsh conditions to which the Space Shuttles are exposed during flight required the development and use of many unique materials. These materials were specially designed to withstand extreme temperatures, in some cases over 1600 C, while other material must withstand the cryogenic conditions of -253 C, and others must operate while under extreme loads. All of these materials must not only operate in the harsh condition but they must be light weight as well. The Space Shuttle is composed of three major components when configured for launch, Figure 1; the Shuttle, solid rocket boosters, and external tank (ET). The different heat shields of the Shuttle make up the thermal protection system (TPS); this system consists of many different types of components designed to operate on various parts of the vehicle. The body of the Shuttle and ET are composed mainly of aluminum alloy and graphite epoxy. The TPS consists of reinforced carbon-carbon (RCC) used on the wing leading edges and nose cap areas while the upper forward fuselage areas, the entire underside of the Shuttle, the Orbiter maneuvering system, and reaction control system utilize blacc high temperature reusable surface insulation (HRSI) tiles, Figure 2. Other areas of the Orbiter are protected by fibrous refractory composite insulation (FRCI) tiles. Areas where the temperature stays below 649 C, such as the forward fuselage, mid-fuselage, aft fuselage, vertical tail, and upper wing, are protected by other material such as, white low temperature reusable surface insulation (LRSI) tiles, advanced flexible reusable surface insulation (AFRSI) blankets, and felt reusable surface insulation (FRSI) white blankets. The RCC is a pyrolized laminated carbon with the outer surface converted to silicon carbide to prevent oxidation. The FiRST tiles are made of a low-density, high purity silica 99.8-percent amorphous fiber insulation that is made rigid by ceramic bonding resulting in 90-percent void and 10-percent materials. The RCC and HRSI are used in areas where the temperature rises above 1260 T. The FRCI tiles are high strength tiles derived by adding alumina-bososilicate fiber to the pure silica tile slurry that welds the micron-sizes fibers of pure silica into a rigid structure during sintering. The FRCI is composed of 20-percent alumina-borosilicate fibers and 80-percent silica fibers, and provided improved strength, durability and resistance to coating cracking and weight reduction than HRSI.
Mechanical, thermal, and physical property test data was generated for as-fabricated advanced composite materials at room temperature (RT), -150 and 250 F. The results are documented of mechanical and thermophysical property tests of IM7/PEEK and discontinuous SiC/Al (particulate (p) and whisker (w) reinforced) composites which were tested at three different temperatures to determine the effect of temperature on material properties. The specific material systems tested were IM7/PEEK (0)8, (0, + or - 45, 90)s, (+ or - 30, 04)s, 25 vol. pct. (v/o) SiCp/Al, and 25 v/o SiCw/Al. RT material property results of IM7/PEEK were in good agreement with the predicted values, providing a measure of consolidation integrity attained during fabrication. Results of mechanical property tests indicated that modulus values at each test temperature were identical, whereas the strength (e.g., tensile, compressive, flexural, and shear) values were the same at -150 F, and RT, and gradually decreased as the test temperature was increased to 250 F. Similar trends in the strength values was also observed in discontinuous SiC/Al composites. These results indicate that the effect of temperature was more pronounced on the strength values than modulus values.
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The preparation of high-temperature superconducting ceramics in bulk form is a major challenge in materials science. The current status of both partial melting and melt quenching techniques, with or without an intermediate powder processing stage, is described in detail, and the problems associated with each of the methods are discussed. Results of studies performed on melt-processed materials are reported and discussed. The discussion places emphasis on magnetization and on other physical properties associated with it, such as critical current density, levitation force, and flux creep. The nature of structural features which give rise to flux pinning, including both small and large defects, is discussed with reference to theoretical considerations. The rates of flux creep and the factors involved in attempting to retard the decay of the magnetization are surveyed.
Study of passive temperature and humidity control systems for extravehicular space suits
The objectives of the program were to: generate mechanical, thermal, and physical property test data for as-fabricated advanced materials; design and fabricate an accelerated thermal cycling chamber; and determine the effect of thermal cycling on thermomechanical properties and dimensional stability of composites. In the current program, extensive mechanical and thermophysical property tests of various organic matrix, metal matrix, glass matrix, and carbon-carbon composites were conducted, and a reliable database was constructed for spacecraft material selection. Material property results for the majority of the as-fabricated composites were consistent with the predicted values, providing a measure of consolidation integrity attained during fabrication. To determine the effect of thermal cycling on mechanical properties, microcracking, and thermal expansion behavior, approximately 500 composite specimens were exposed to 10,000 cycles between -150 and +150 F. These specimens were placed in a large (18 cu ft work space) thermal cycling chamber that was specially designed and fabricated to simulate one year low earth orbital (LEO) thermal cycling in 20 days. With this rate of thermal cycling, this is the largest thermal cycling unit in the country. Material property measurements of the thermal cycled organic matrix composite laminate specimens exhibited less than 24 percent decrease in strength, whereas, the remaining materials exhibited less than 8 percent decrease in strength. The thermal expansion response of each of the thermal cycled specimens revealed significant reduction in hysteresis and residual strain, and the average CTE values were close to the predicted values.
Improvements to the monolayer woven pile concept were evaluated in terms of increased durability and thermal performance. Three varieties of the monolayer material were tested for thermal conductance under various conditions simulating those which occur in space. In addition, the tendency of the pile to unravel was subjectively evaluated.
A method was developed for predicting oxidation distribution through the thickness of reinforced carbon-carbon material in an earth atmospheric entry environment. A mathematical model was developed which describes oxygen diffusion and reaction rates within material pores. Pertinent rate constants were derived, and material mass loss was computed for a range of temperatures and pressures. Results indicate that both temperature and pressure have an important effect on mass loss distribution. Analytical results were quite consistent with results of ground oxidation tests.
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Task illumination has a major impact on human performance: What a person can perceive in his environment significantly affects his ability to perform tasks, especially in space's harsh environment. Training for lighting conditions in space has long depended on physical models and simulations to emulate the effect of lighting, but such tests are expensive and time-consuming. To evaluate lighting conditions not easily simulated on Earth, personnel at NASA Johnson Space Center's (JSC) Graphics Research and Analysis Facility (GRAF) have been developing computerized simulations of various illumination conditions using the ray-tracing program, Radiance, developed by Greg Ward at Lawrence Berkeley Laboratory. Because these computer simulations are only as accurate as the data used, accurate information about the reflectance properties of materials and light distributions is needed. JSC's Lighting Environment Test Facility (LETF) personnel gathered material reflectance properties for a large number of paints, metals, and cloths used in the Space Shuttle and Space Station programs, and processed these data into reflectance parameters needed for the computer simulations. They also gathered lamp distribution data for most of the light sources used, and validated the ability to accurately simulate lighting levels by comparing predictions with measurements for several ground-based tests. The result of this study is a database of material reflectance properties for a wide variety of materials, and lighting information for most of the standard light sources used in the Shuttle/Station programs. The combination of the Radiance program and GRAF's graphics capability form a validated computerized lighting simulation capability for NASA.
Future reusable space vehicles will be in service much more frequently than current space shuttles. Therefore, rapid reconditioning of spacecraft will be required. Currently, the waterproofing of space shuttles after each re-entry takes 72 hours and requires substantial labor. In addition, the currently used waterproofing reagent, DiMethylEthoxySilane (DMES), is considered toxic, and ethanol fumes are released during its hydrolytic activation. Consequently, a long time period, which is not acceptable for future operations, is needed to ensure that 0 the excess volatile compounds are removed before further maintenance of the space vehicle can be performed. The objective of this project was to assist NASA Ames in finding improved waterproofing systems by identifying suitable waterproofing agents that can be applied by vapor phase deposition and will be less toxic, bond more rapidly to the insulation material surface, and potentially have higher thermal stability than the DMES system. Several approaches to achieve faster waterproofing with less toxicity were assessed using the following alternatives: Reactive volatile compounds that are rapidly deposited by chemical bonding at the surface and leave no toxic volatiles. Reactive reagents that are the least toxic. Nonvolatile reagents that are very reactive and bond strongly to the insulating material surface. Three specific types of potential reagents were chosen for evaluation in this project: 1. Volatile reagents with Si-Cl functional groups for vapor deposition 2. Volatile reagents with Si-H functional groups for vapor deposition 3. Nonvolatile oligomeric or polymeric reactive siloxanes that are assumed to have higher thermal stability and/or strong bonding to the insulating material. The chemistry involved in the project was targeted at the generation of intermediates having reactive Si-OH bonds for the formation of either volatile species or polymeric species that bond rapidly to the surface and also cure rapidly. We focused on two chemical reactions@-hydrolysis of Si-Cl bonds and catalytic dehydrocoupling of Si-H bonds.
The test facility presented herein uses a groundbased rocket combustor to test the durability of new ceramic composite and metallic materials in a rocket engine thermal environment. A gaseous H2/02 rocket combustor (essentially a ground-based rocket engine) is used to generate a high temperature/high heat flux environment to which advanced ceramic and/or metallic materials are exposed. These materials can either be an integral part of the combustor (nozzle, thrust chamber etc) or can be mounted downstream of the combustor in the combustor exhaust plume. The test materials can be uncooled, water cooled or cooled with gaseous hydrogen.
In order to sustain life on the moon, and especially on Mars, the inhabitants must be self-sufficient. As on Earth, electronic and mechanical systems will break down and must be repaired. It is not realistic to "send" parts to the moon or Mars in an effort to replace failed ones or have spares for all components. It will be important to have spares on hand and even better would be to have the capability to fabricate parts in situ. The In Situ Fabrication and Repair (ISFR) team is working to develop the Arcam Electron Beam Melting (EBM) machine as the manufacturing process that will have the capability to produce repair parts, as well as new designs, and tooling on the lunar surface and eventually on Mars. What materials will be available for the inhabitants to use? What materials would be most useful? The EBM process is versatile and can handle a multitude of materials. These include titanium, stainless steels, aluminums, inconels, and copper alloys. Research has shown what parts have failed during past space missions and this data has been compiled and assessed. The EBM machine is fully capable of processing these materials of choice. Additionally, the long-term goal is to use the lunar regolith as a viable feedstock. Preliminary work has been performed to assess the feasibility of using raw lunar regolith as a material source or use a binder combined with the regolith to achieve a good melt.
Terrestrial industry consumes a wide range of elements in producing the outputs which support and make industrial societies possible. 'Demandite' is a conceptual or synthetic molecule which is composed of the weight fractions of the major elements consumed by industry. Demandite needed for mature industrial activities in space will differ from the terrestrial composition because solar energy must replace hydrocarbon-energy, lunar and asteroidal bulk compositions are different from mineral deposits on the earth, and the major bulk processing in space will be the creation of radiation shielding for human habitats to provide real estate in space complete with water, atmosphere and life-stock elements. Demandite cost may be dominated by earth to deep space transport cost of minor elemental constituents depleted in the lunar soils unless careful attention is given to substitution of materials, searches of the moon (polar regions) and asteroids for the depleted elements, and continuing lowering of earth to deep space transport costs.
A method was developed for predicting oxidation performance, in an earth atmospheric entry environment, of reinforced carbon-carbon material, coated for oxidation resistance. A model was developed which describes oxidation control mechanisms, and the equations defining these mechanisms were derived. These relations were used to correlate oxidation test data, and to infer pertinent rate constants. Predictions were made of material oxidation performance in a representative entry environment, and the predictions were compared with ground test data. Results indicate that the method can be successfully used for predicting material oxidation performance.
Polymeric materials in low earth orbit will be exposed to a harmful environment mainly due to atomic oxygen and ultraviolet radiation. In geosynchronous earth orbit, the major hazards to such materials are energetic charged particles and ultraviolet radiation. The progress of studies on the effects of these hazards on a polyetherimide, a polyimide, and an epoxy adhesive is presented.