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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
NASA NTRS1985

Metallic Foams

The formation of metallic foams by use of a blowing agent in the melt was investigated. It was attempted to produce a metallic foam by melting a mixture of Cu powder and graphite in a SPAR rocket. The graphite combines with the oxide on the copper to form Co and acts as a blowing agent. No foam was formed, and it could not be determined whether the foam fails to form, forms but was lost to surface tension instabilities, or is destroyed by incomplete solidification before reentry.

Pond, R. B.↗
NASA NTRS1991

Holographic study of conventional and negative Poisson's ratio metallic foams - Elasticity, yield and micro-deformation

An experimental study by holographic interferometry is reported of the following material properties of conventional and negative Poisson's ratio copper foams: Young's moduli, Poisson's ratios, yield strengths and characteristic lengths associated with inhomogeneous deformation. The Young's modulus and yield strength of the conventional copper foam were comparable to those predicted by microstructural modeling on the basis of cellular rib bending. The reentrant copper foam exhibited a negative Poisson's ratio, as indicated by the elliptical contour fringes on the specimen surface in the bending tests. Inhomogeneous, non-affine deformation was observed holographically in both foam materials.

Chen, C. P.↗
NASA NTRS1993

Development of spray guns for the application of rigid foam insulation

The paper describes the activities initiated to improve the existing spray gun system used for spraying insulating foam on the External Tank of the Space Shuttle, due to the quality variations of the applied foam noted in the past. Consideration is given to the two tasks of the project: (1) investigations of possible improvements, as an interim measure, to the spray gun currently used to apply the large acreage spray-on-foam insulation and the evaluation of other commercial equipment; and (2) the design and fabrication of a new automatic spray gun. The design and operation of the currently used Binks 43 PA spray gun are described together with several new breadboard spray guns designed and fabricated and the testing procedures developed. These new guns include the Modular Automatic Foam spray gun, the Ball Valve spray gun, and the Tapered Plug Valve (TPV) gun. As a result of tests, the TPV spray gun is recommended to replace the currently used automatic spray gun.

Allen, Peter B.↗
NASA NTRS1994

Plasma-Spray Metal Coating On Foam

Molds, forms, and other substrates made of foams coated with metals by plasma spraying. Foam might be ceramic, carbon, metallic, organic, or inorganic. After coat applied by plasma spraying, foam left intact or removed by acid leaching, conventional machining, water-jet cutting, or another suitable technique. Cores or vessels made of various foam materials plasma-coated with metals according to method useful as thermally insulating containers for foods, liquids, or gases, or as mandrels for making composite-material (matrix/fiber) parts, or making thermally insulating firewalls in automobiles.

Cranston, J.↗
NASA NTRS1994

Improved construction materials for polar regions using microcellular thermoplastic foams

Microcellular polymer foams (MCF) are thermoplastic foams with very small cell diameters, less than 10 microns, and very large cell densities, 10(exp 9) to 10(exp 15) cells per cubic centimeter of unfoamed material. The concept of foaming polymers with microcellular voids was conceived to reduce the amount of material used for mass-produced items without compromising the mechanical properties. The reasoning behind this concept was that if voids smaller than the critical flaw size pre-existing in polymers were introduced into the matrix, they would not affect the overall strength of the product. MCF polycarbonate (PC), polystyrene (PS), and polyvinyl chloride (PVC) were examined to determine the effects of the microstructure towards the mechanical properties of the materials at room and arctic temperatures. Batch process parameters were discovered for these materials and foamed samples of three densities were produced for each material. To quantify the toughness and strength of these polymers, the tensile yield strength, tensile toughness, and impact resistance were measured at room and arctic temperatures. The feasibility of MCF polymers has been demonstrated by the consistent and repeatable MCF microstructures formed, but the improvements in the mechanical properties were not conclusive. Therefore the usefulness of the MCF polymers to replace other materials in arctic environments is questionable.

Cunningham, Daniel J.↗
NASA NTRS1996

Effective Thermal Conductivity of an Aluminum Foam + Water Two Phase System

This study examined the effect of volume fraction and pore size on the effective thermal conductivity of an aluminum foam and water system. Nine specimens of aluminum foam representing a matrix of three volume fractions (4-8% by vol.) and three pore sizes (2-4 mm) were tested with water to determine relationships to the effective thermal conductivity. It was determined that increases in volume fraction of the aluminum phase were correlated to increases in the effective thermal conductivity. It was not statistically possible to prove that changes in pore size of the aluminum foam correlated to changes in the effective thermal conductivity. However, interaction effects between the volume fraction and pore size of the foam were statistically significant. Ten theoretical models were selected from the published literature to compare against the experimental data. Models by Asaad, Hadley, and de Vries provided effective thermal conductivity predictions within a 95% confidence interval.

Moskito, John↗
NASA NTRS1998

Prototype Aerogel Insulation for Melamine-Foam Substitute: Critical Space Station Express Rack Technology

There is a current lack of environmentally acceptable foams to insulate Long-Duration Human Spaceflight Missions, including the experimental Express Rack for the Space Station. A recent 60-day manned test in a sealed chamber at Johnson Space Center (JSC) was nearly aborted, because of persistently high formaldehyde concentrations in the chamber. Subsequent investigation showed that the source was melamine foam (used extensively for acoustic insulation). The thermal and acoustic potential for melamine-foam substitutes is evaluated for scale-up to a silica-based foam and aerogel, which is environmentally benign for long duration space flight. These features will be discussed in reference to an aerogel prototype to: 1) assemble material strength data for various formulated aerogels, both silica and organic carbon aerogels; 2) assemble the aerogel into panels of mylar/vacuum-encapsulated rigid boards which can be molded in various shapes and rigidities; and 3) describe a process for space applications for formaldehyde-free, long duration thermal and acoustic insulators.

Noever, David A.↗
NASA NTRS2002

Finite Element Modeling of Deployment, and Foam Rigidization of Struts and Quarter Scale Shooting Star Experiment

Inflated cylindrical struts constructed of kapton polyimide film and rigidized with foam have considerable practical application and potential for use as components of inflatable concentrator assemblies, antenna structures and space power systems, Because of their importance, it is of great interest to characterize the dynamic behavior of these components and structures both experimentally and analytically. It is very helpful to take a building-block approach to modeling and understanding inflatable assemblies by first investigating in detail the behavior of the components such as the struts. The foam material used for rigidization of such cylinders has varying modulus, which is a function of different factors, such as density of the foam. Thus, the primary motivation of the tests and analytical modeling efforts was to determine and understand the response of foam-rigidized cylinders for different densities, sizes, and construction methods. In recent years, inflatable structures have been the subject of renewed interest for space applications such as communications antennae, solar thermal propulsion, and space solar power. A major advantage of using inflatable structures in space is that they are extremely lightweight. This makes inflatables a perfect match for solar thermal propulsion because of the low thrust levels available. An obvious second advantage is on-orbit deployability and subsequent space savings in launch configuration. It can be seen that inflatable cylindrical struts and torus are critical components of structural assemblies. In view of this importance, structural dynamic and static behaviors of typical rigidized polyimide struts are investigated in this paper. The paper will focus on the finite element models that were used to model the behavior of the complete solar collector structure, and the results that they provided, as compared to test data.

Larry Leigh, Jr.↗
NASA NTRS2003

Synthesis, Microstructure and Properties of Nickel Aluminide Foams

Two Ph.D. students were involved in the project: Mr. Christopher Schuh (part-time, graduated in Spring 2001) and Ms. Andrea Hodge (full-time, graduated Summer 2002). One post-doctoral fellow, Dr. Heeman Choe, worked full-time on the project from July to December 2002. A new process to aluminize and chromize nickel foams was created. A kinetic aluminization model was developed. Creep testing was conducted on the foams. A finite-element model and a simplified analytical model for foam creep were produced. Four articles were written: one is published, two are accepted for publication, and one is in preparation. Ms. Hodge spent four months at NASA Glenn Research Center (9-12/2001 and 2-3/2002) under the supervision of Dr. Nathal. She conducted research on NiAl foam fabrication, mechanical testing and numerical modeling. She gave a talk at the ASM annual conference in November 2001 and presented her results at NASA in December 2001.

Dunand, David C.↗
NASA NTRS2003

Ceramic Foams for TPS Applications

Ceramic foams have potential in many areas of Thermal Protection Systems (TPS) including acreage and tile leading edges as well as being suitable as a repair approach for re-entry vehicles. NASA Ames is conducting ongoing research in developing lower-density foams from pre-ceramic polymer routes. One of the key factors to investigate, when developing new materials for re-entry applications, is their oxidation behavior in the appropriate re-entry environment which can be simulated using ground based arc jet (plasma jet) testing. Arc jet testing is required to provide the appropriate conditions (stagnation pressures, heat fluxes, enthalpies, heat loads and atmospheres) encountered during flight. This work looks at the response of ceramic foams (Si systems) exposed to simulated reentry environments and investigates the influence of microstructure and composition on the material? response. Other foam properties (mechanical and thermal) will also be presented.

Stockpoole, Mairead↗
NASA NTRS2001

Effect of convection on osteoblastic cell growth and function in biodegradable polymer foam scaffolds

Culture of seeded osteoblastic cells in three-dimensional osteoconductive scaffolds in vitro is a promising approach to produce an osteoinductive material for repair of bone defects. However, culture of cells in scaffolds sufficiently large to bridge critical-sized defects is a challenge for tissue engineers. Diffusion may not be sufficient to supply nutrients into large scaffolds and consequently cells may grow preferentially at the periphery under static culture conditions. Three alternative culturing schemes that convect media were considered: a spinner flask, a rotary vessel, and a perfusion flow system. Poly(DL-lactic-co-glycolic acid) (PLGA) foam discs (12.7 mm diameter, 6.0 mm thick, 78.8% porous) were seeded with osteoblastic marrow stromal cells and cultured in the presence of dexamethasone and L-ascorbic acid for 7 and 14 days. Cell numbers per foam were found to be similar with all culturing schemes indicating that cell growth could not be enhanced by convection, but histological analysis indicated that the rotary vessel and flow system produced a more uniform distribution of cells throughout the foams. Alkaline phosphatase (ALP) activity per cell was higher with culture in the flow system and spinner flask after 7 days, while no differences in osteocalcin (OC) activity per cell were observed among culturing methods after 14 days in culture. Based on the higher ALP activity and better cell uniformity throughout the cultured foams, the flow system appears to be the superior culturing method, although equally important is the fact that in none of the tests did any of the alternative culturing techniques underperform the static controls. Thus, this study demonstrates that culturing techniques that utilize fluid flow, and in particular the flow perfusion system, improve the properties of the seeded cells over those maintained in static culture.

NASA Discipline Cell Biology↗
NASA NTRS2005

Nondestructive Evaluation of Space Shuttle External Tank Foam

During launch of Shuttle Columbia, mission STS-107, a large piece of spray on foam insulation (SOFI) separated from the external tank left bipod ramp area impacting the shuttle orbiter left wing leading edge. "Analysis showed that this large piece of foam struck Columbia on the underside of the left wing after launch. Later, analysis showed that the larger piece struck Columbia on the underside of the left wing, around Reinforced Carbon-Carbon (RCC) panels 5 through 9, at 81.9 seconds after launch. Further photographic analysis revealed that the large foam piece was approximately 21 to 27 inches long and 12 to 18 inches wide and was moving at a relative velocity to the Shuttle stack of 625 to 840 feet per second (416 to 573 miles per hour) at the time of impact." This impact damaged the wing leading edge resulting in loss of orbiter thermal protection. The piece of errant foam was part of a bipod ramp which was designed to meet thermal and aerodynamic requirements in that region of the external tank (ET).

Thom, Robert L.↗
NASA NTRS2005

Polyimide Foams

A fully imidized, solvent-free polyimide foam having excellent mechanical, acoustic, thermal, and flame resistant properties is produced. A first solution is provided, which includes one or more aromatic dianhydrides or derivatives of aromatic dianhydrides, and may include one or more aromatic diamines, dissolved in one or more polar solvents, along with an effective amount of one or more blowing agents. This first solution may also advantageously include effective amounts respectively of one or mores catalysts, one or more surfactants, and one or more fire retardants. A second solution is also provided which includes one or more isocyanates. The first and second solutions are rapidly and thoroughly mixed to produce an admixture, which is allowed to foam-in an open container, or in a closed mold-under ambient conditions to completion produce a foamed product. This foamed product is then cured by high frequency electromagnetic radiation, thermal energy, or a combination thereof. Alternatively, the process is adapted for spraying or extrusion.

Juan M Vazquez↗
NASA NTRS2006

Noninvasive 3D Visualization of Defects and Crack Propagation in Layered Foam Structures by Phase Contrast Microimaging

Applications of polymeric foams in our modern society continue to grow because of their light weight, high strength, excellent thermal and mechanical insulation, and the ease of engineering. Among others, closed-cell foam has been structurally used for thermally insulating the shuttle external tank. However, internal defects of the foams were difficult to observe non-invasively due to limited sensitivity to the low-density structures possessed by traditional imaging tools such as computed X-ray tomography By combining phase contrast X-ray imaging with pressure loading, we succeeded in precisely mapping intact cellular structure and defects inside the bulk of layered foam and visualizing its subsequent response to the pressure in three-dimensional space. The work demonstrated a powerfir1 approach for yielding insight into underlying problems in lightweight cellular materials otherwise unobtainable.

Hu, Z. W.↗
NASA NTRS2007

NDE Methods for the External Tank Spray on Foam Insulation

The foam thermal protection system (TPS) of the space shuttle External Tank (ET) has provided some unique challenges to the nondestructive testing community. Three nondestructive evaluation methods have been developed to identify defects in the foam TPS of the ET. Terahertz imaging and backscatter radiography have been developed to identify voids in thick foam regions while shearography has been developed to identify shallow delaminations, shallow voids and crush damage in the foam. The basic theory of operation along with factors, determined from a series of designed experiments, affecting the results of these methods will be described. Results from both test panels and flight tank inspections will be provided, along with predicted probability of detection estimates to show the range in defect sizes and types that can be readily detected.

Walker, James L.↗
NASA NTRS2005

Polyimide foams

A fully imidized, solvent-free polyimide foam having excellent mechanical, acoustic, thermal, and flame resistant properties is produced. A first solution is provided, which includes one or more aromatic dianhydrides or derivatives of aromatic dianhydrides, and may include one or more aromatic diamines, dissolved in one or more polar solvents, along with an effective amount of one or more blowing agents. This first solution may also advantageously include effective amounts respectively of one or mores catalysts, one or more surfactants, and one or more fire retardants. A second solution is also provided which includes one or more isocyanates. The first and second solutions are rapidly and thoroughly mixed to produce an admixture, which is allowed to foam?in an open container, or in a closed mold?under ambient conditions to completion produce a foamed product. This foamed product is then cured by high frequency electromagnetic radiation, thermal energy, or a combination thereof. Alternatively, the process is adapted for spraying or extrusion.

Vazquez, Juan M.↗
NASA NTRS2008

Nano-Aramid Fiber Reinforced Polyurethane Foam

Closed cell polyurethane and, particularly, polyisocyanurate foams are a large family of flexible and rigid products the result of a reactive two part process wherein a urethane based polyol is combined with a foaming or "blowing" agent to create a cellular solid at room temperature. The ratio of reactive components, the constituency of the base materials, temperature, humidity, molding, pouring, spraying and many other processing techniques vary greatly. However, there is no known process for incorporating reinforcing fibers small enough to be integrally dispersed within the cell walls resulting in superior final products. The key differentiating aspect from the current state of art resides in the many processing technologies to be fully developed from the novel concept of milled nano pulp aramid fibers and their enabling entanglement capability fully enclosed within the cell walls of these closed cell urethane foams. The authors present the results of research and development of reinforced foam processing, equipment development, strength characteristics and the evolution of its many applications.

Semmes, Edmund B.↗
NASA NTRS2009

Assessment of Soft Vane and Metal Foam Engine Noise Reduction Concepts

Two innovative fan-noise reduction concepts developed by NASA are presented - soft vanes and over-the-rotor metal foam liners. Design methodologies are described for each concept. Soft vanes are outlet guide vanes with internal, resonant chambers that communicate with the exterior aeroacoustic environment via a porous surface. They provide acoustic absorption via viscous losses generated by interaction of unsteady flows with the internal solid structure. Over-the-rotor metal foam liners installed at or near the fan rotor axial plane provide rotor noise absorption. Both concepts also provide pressure-release surfaces that potentially inhibit noise generation. Several configurations for both concepts are evaluated with a normal incidence tube, and the results are used to guide designs for implementation in two NASA fan rigs. For soft vanes, approximately 1 to 2 dB of broadband inlet and aft-radiated fan noise reduction is achieved. For over-the-rotor metal foam liners, up to 3 dB of fan noise reduction is measured in the low-speed fan rig, but minimal reduction is measured in the high-speed fan rig. These metal foam liner results are compared with a static engine test, in which inlet sound power level reductions up to 5 dB were measured. Brief plans for further development are also provided.

Jones, Michael G.↗