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NASA NTRS2004

Hybrid Tank Technology

Researchers have accomplished great advances in pressure vessel technology by applying high-performance composite materials as an over-wrap to metal-lined pressure vessels. These composite over-wrapped pressure vessels (COPVs) are used in many areas, from air tanks for firefighters and compressed natural gas tanks for automobiles, to pressurant tanks for aerospace launch vehicles and propellant tanks for satellites and deep-space exploration vehicles. NASA and commercial industry are continually striving to find new ways to make high-performance pressure vessels safer and more reliable. While COPVs are much lighter than all-metal pressure vessels, the composite material, typically graphite fibers with an epoxy matrix resin, is vulnerable to impact damage. Carbon fiber is most frequently used for the high-performance COPV applications because of its high strength-to-weight characteristics. Other fibers have been used, but with limitations. For example, fiberglass is inexpensive but much heavier than carbon. Aramid fibers are impact resistant but have less strength than carbon and their performance tends to deteriorate.

Source record↗

NASA NTRS2010

Nitrous Oxide/Paraffin Hybrid Rocket Engines

Nitrous oxide/paraffin (N2OP) hybrid rocket engines have been invented as alternatives to other rocket engines especially those that burn granular, rubbery solid fuels consisting largely of hydroxyl- terminated polybutadiene (HTPB). Originally intended for use in launching spacecraft, these engines would also be suitable for terrestrial use in rocket-assisted takeoff of small airplanes. The main novel features of these engines are (1) the use of reinforced paraffin as the fuel and (2) the use of nitrous oxide as the oxidizer. Hybrid (solid-fuel/fluid-oxidizer) rocket engines offer advantages of safety and simplicity over fluid-bipropellant (fluid-fuel/fluid-oxidizer) rocket en - gines, but the thrusts of HTPB-based hybrid rocket engines are limited by the low regression rates of the fuel grains. Paraffin used as a solid fuel has a regression rate about 4 times that of HTPB, but pure paraffin fuel grains soften when heated; hence, paraffin fuel grains can, potentially, slump during firing. In a hybrid engine of the present type, the paraffin is molded into a 3-volume-percent graphite sponge or similar carbon matrix, which supports the paraffin against slumping during firing. In addition, because the carbon matrix material burns along with the paraffin, engine performance is not appreciably degraded by use of the matrix.

Zubrin, Robert↗

NASA NTRS1990

Microcracking mechanisms and interface toughening of semi-IPN polyimide matrix composites

A new research program was initiated as a preliminary phase. The following three objectives are being pursued for the overall program: to elucidate the mechanisms of microcracking for graphite fiber-reinforced semi-IPN polyimide matrix composites under mechanical and thermal cyclic loading; to devise material engineering solutions for possible improvement of fatigue damage resistance (or the increase of fatigue endurance strength) of semi-IPN matrix composites by tailoring of modulus and toughness of fiber-resin interface region; and to assess processing characteristics of the composites and their roles in controlling the resistance of composites to microcracking and the effectiveness of interface toughening. The main emphasis was placed upon the initial screening of material systems and optimization of processing conditions for semi-IPN matrix composites with tailored interface. As a first set of control material systems to study, the composites were prepared with unsized Celion 6000 graphite fiber reinforcement and the following resin matrices of varied fracture toughness: PMR-15 thermoset polyimide, semi-IPN of PNR-15 thermoset polyimide and NR150B2 thermoplastic polyimide in 75/25 ratio, and semi-IPN of PMR-15 and NR150B2 in 50/50 ratio. For the composites with the resin matrix of semi-IPN in 75/25 ratio, interface tailoring was attempted by using graphite fibers coated with the resins of systematically varied fracture toughness. In the continuing work, a broad range of interlayer toughness will be achieved by coating the fibers with reactants of semi-IPN having lower or higher content of thermoplastic constituent in comparison with the composition of surrounding resin matrix. In pursuing the objectives of the overall research program, the respective roles and interaction of critical parameters were defined.

Lee, Byung L.↗

NASA NTRS2005

Graphite Nanoreinforcements for Aerospace Nanocomposites

New advances in the reinforcement of polymer matrix composite materials are critical for advancement of the aerospace industry. Reinforcements are required to have good mechanical and thermal properties, large aspect ratio, excellent adhesion to the matrix, and cost effectiveness. To fulfill the requirements, nanocomposites in which the matrix is filled with nanoscopic reinforcing phases having dimensions typically in the range of 1nm to 100 nm show considerably higher strength and modulus with far lower reinforcement content than their conventional counterparts. Graphite is a layered material whose layers have dimensions in the nanometer range and are held together by weak Van der Waals forces. Once these layers are exfoliated and dispersed in a polymer matrix as nano platelets, they have large aspect ratios. Graphite has an elastic modulus that is equal to the stiffest carbon fiber and 10-15 times that of other inorganic reinforcements, and it is also electrically and thermally conductive. If the appropriate surface treatment can be found for graphite, its exfoliation and dispersion in a polymer matrix will result in a composite with excellent mechanical properties, superior thermal stability, and very good electrical and thermal properties at very low reinforcement loadings.

Drzal, Lawrence T.↗

NASA NTRS1985

Bismaleimides and related maleimido polymers as matrix resins

Significant processing and property improvements can be achieved by copolymerization of state-of-the-art bisimides with various vinyl stilbazole derivatives to give both fire resistance and high-temperature properties from hot-melt compositions. Significant improvement in mechanical properties is achieved through these modifications, which may make these new matrix resins ideal candidates for fireworthy secondary graphite composite structures. Phosphorous modifications of maleimido polymers through phosphonate structure and tricyclophosphazene derivatives provide families of new matrix resins for short-time applications in severe thermo-oxidative environments. With further research these may provide matrix resins for long-term thermo-oxidative stability of advanced composites at temperatures up to 400 to 500 C.

Parker, J. A.↗

NASA NTRS1988

Space structures concepts and materials

An extension is preseted of the evaluation of graphite/aluminum metal matrix composites (MMC) for space structures application. A tubular DWG graphite/aluminum truss assembly was fabricated having the structural integrity and thermal stability needed for space application. DWG is a proprietary thin ply continuous graphite reinforced aluminum composite. The truss end fittings were constructed using the discontinuous ceramic particulate reinforced MMC DWAl 20 (trademark). Thermal stability was incorporated in the truss by utilizing high stiffness, negative coefficient of thermal expansion (CTE) P100 graphite fibers in a 6061 aluminum matrix, crossplied to provide minimized CTE in the assembled truss. Tube CTE was designed to be slightly negative to offset the effects of the end fitting and sleeve, CTE values of which are approx. 1/2 that of aluminum. In the design of the truss configuration, the CTE contribution of each component was evaluated to establish the component dimension and layup configuration required to provide a net zero CTE in the subassemblies which would then translate to a zero CTE for the entire truss bay produced.

Nowitzky, A. M.↗

NASA NTRS1989

Fiber-matrix interface failures

Interface fractures of aluminum-graphite composites under transverse loading are expected to occur within the graphite fibers, but very near the interface. Residual stresses in aluminum, reinforced with the new high modulus pitch-based fibers, are much lower than would be expected based on simple elasticity calculations. The excess stress may be relaxed by shearing internal to the fibers or at the interface rather than by plastic flow of the matrix. The internal shearing also occurs during repeated thermal cycling of these composites; the fibers are repeatedly intruded, then extruded, during repeated temperature excursions.

Rabenberg, Lew↗

NASA NTRS1990

High-temperature polymer matrix composites

Polymers research at the NASA Lewis Research Center has produced high-temperature, easily processable resin systems, such as PMR-15. In addition, the Polymers Branch has investigated ways to improve the mechanical properties of polymers and the microcracking resistance of polymer matrix composites in response to industry need for new and improved aeropropulsion materials. Current and future research in the Polymers Branch is aimed at advancing the upper use temperature of polymer matrix composites to 700 F and beyond by developing new resins, by examining the use of fiber reinforcements other than graphite, and by developing coatings for polymer matrix composites to increase their oxidation resistance.

Meador, Michael A.↗

NASA NTRS1997

Mineralogy of Meteorite Groups

Approximately 275 mineral species have been identified in meteorites, reflecting diverse redox environments, and, in some cases, unusual nebular formation conditions. Anhydrous ordinary, carbonaceous and R chondrites contain major olivine, pyroxene and plagioclase; major opaque phases include metallic Fe-Ni, troilite and chromite. Primitive achondrites are mineralogically similar. The highly reduced enstatite chondrites and achondrites contain major enstatite, plagioclase, free silica and kamacite as well as nitrides, a silicide and Ca-, Mg-, Mn-, Na-, Cr-, K- and Ti-rich sulfides. Aqueously altered carbonaceous chondrites contain major amounts of hydrous phyllosilicates, complex organic compounds, magnetite, various sulfates and sulfides, and carbonates. In addition to kamacite and taenite, iron meteorites contain carbides, elemental C, nitrides, phosphates, phosphides, chromite and sulfides. Silicate inclusions in IAB/IIICD and lIE iron meteorites consist of mafic silicates, plagioclase and various sulfides, oxides and phosphates. Eucrites, howardites and diogenites have basaltic to orthopyroxenitic compositions and consist of major pyroxene and calcic plagioclase and several accessory oxides. Ureilttes .are made up mainly of calcic, chromian olivine and low-Ca clinopyroxene embedded in a carbonaceous matrix; accessory phases include the C polymorphs graphite, diamond, lonsdaleite and chaoite as well as metallic Fe-Ni, troilite and halides. Angrites are achondrites rich in fassaitic pyroxene (i.e. , AI-Ti diopside); minor olivine with included magnesian kirschsteinite is also present. Martian meteorites comprise basalts, Iherzolites, a dunite and an orthopyroxenite. Major phases include various pyroxenes and olivine; minor to accessory phases include various sulfides, magnetite, chromite and Ca-phosphates. Lunar meteorites comprise mare basalts with major augite and calcic plagioclase and anorthositic breccias with major calcic plagioclase. Several meteoritic phases were formed by shock metamorphism. Martensite (a2-fe,Ni) has a distorted body-centered-cubic structure and formed by a shear transformation from taenite during shock reheating and rapid cooling. The C polymorphs diamond, lonsdaleite and chaoite formed by shock from graphite. Suessite formed in the North Haig ureilite by reduction of Fe and Si (possibly from olivine) via reaction with carbonaceous matrix material. Ringwoodite, the spinel form of (Mg,Fe)2Si04, and majorite, a polymorph of (Mg,Fe)Si03 with the garnet structure, formed inside shock veins in highly shocked ordinary chondrites. Secondary minerals in meteorite finds that formed during terrestrial weathering include oxides and hy-. droxides formed directly from metallic Fe-Ni by oxidation, phosphates formed by the alteration of schreibersite, and sulfates formed by alteration of troilite.

Rubin, Alan E.↗

NASA NTRS1986

Effects of thermal cycling on graphie-fiber-reinforced 6061 aluminum

Graphite-reinforced aluminum alloy metal-matrix composites are among materials being considered for structural components in dimensionally stable space structures. This application requires materials with low values of thermal expansions and high specific stiffnesses. They must remain stable during exposures to the space environment for periods extending to 20 years. The effects of thermal cycling on the thermal expansion behavior and mechanical properties of Thornel P100 graphite 6061 aluminum composites, as fabricated and after thermal processing to eliminate thermal strain hysteresis, have been investigated. Two groups of composites were studied: one was fabricated by hot roll bonding and the other by diffusion bonding. Processing significantly reduced strain hysteresis during thermal cycling in both groups and improved the ultimate tensile strength and modulus in the diffusion-bonded composites. Thermal cycling stabilized the as-fabricated composites by reducing the residual fabrication stress and increased the matrix strength by metallurgical aging. Thermal expansion behavior of both groups after processing was insensitive to thermal cycling. Data scatter was too large to determine effects of thermal cycling on the mechanical properties. The primary effects of processing and thermal cycling can be attributed to changes in the metallurgical condition and stress state of the matrix.

Dries, G. A.↗

NASA NTRS2002

Analysis of Graphite-Reinforced Cementitious Composites

Strategically embedding graphite meshes in a compliant cementitious matrix produces a composite material with relatively high tension and compressive properties as compared to steel-reinforced structures fabricated from a standard concrete mix. Although these composite systems are somewhat similar, the methods used to analyze steel-reinforced composites often fail to characterize the behavior of their more advanced graphite-reinforced counterparts. This Technical Memorandum describes some of the analytical methods being developed to determine the deflections and stresses in graphite-reinforced cementitious composites. It is initially demonstrated that the standard transform section method fails to provide accurate results when the elastic moduli ratio exceeds 20. An alternate approach is formulated by using the rule of mixtures to determine a set of effective material properties for the composite. Tensile tests are conducted on composite samples to verify this approach. When the effective material properties are used to characterize the deflections of composite beams subjected to pure bending, an excellent agreement is obtained. Laminated composite plate theory is investigated as a means for analyzing even more complex composites, consisting of multiple graphite layers oriented in different directions. In this case, composite beams are analyzed using the laminated composite plate theory with material properties established from tensile tests. Then, finite element modeling is used to verify the results. Considering the complexity of the samples, a very good agreement is obtained.

Vaughan, R. E.↗

NASA NTRS2005

Formation of TiC-core, Graphitic-mantle Grains from CO Gas

We demonstrate a new formation route for TiC-core, graphitic-mantle spherules that does not require c-atom addition and the very long timescales associated with such growth (Bernatowicz et al. 1996). Carbonaceous materials can also be formed from C2H2 and its derivatives, as well as from CO gas. In this paper, we will demonstrate that large cage structure carbon particles can be produced from CO gas by the Boudouard reaction. Since the sublimation temperature for such fullerenes is low, the large cages can be deposited onto previously-nucleated TiC and produce TiC-core, graphitic-mantle spherules. New constraints for the formation conditions and the timescale for the formation of TiC-core, graphitic-mantle spherules are suggested by the results of this study. In particular, TiC-core, graphitic-mantle grains found in primitive meteorites that have never experienced hydration could be mantled by fullerenes or carbon nanotubes rather than by graphite. In situ observations of these grains in primitive anhydrous meteoritic matrix could confirm or refute this prediction and would demonstrate that the graphitic mantle on such grains is a metamorphic feature due to interaction of the pre-solar fullerenes with water within the meteorite matrix.

Kimura, Yuki↗

NASA NTRS2011

Modifying Matrix Materials to Increase Wetting and Adhesion

In an alternative approach to increasing the degrees of wetting and adhesion between the fiber and matrix components of organic-fiber/polymer matrix composite materials, the matrix resins are modified. Heretofore, it has been common practice to modify the fibers rather than the matrices: The fibers are modified by chemical and/or physical surface treatments prior to combining the fibers with matrix resins - an approach that entails considerable expense and usually results in degradation (typically, weakening) of fibers. The alternative approach of modifying the matrix resins does not entail degradation of fibers, and affords opportunities for improving the mechanical properties of the fiber composites. The alternative approach is more cost-effective, not only because it eliminates expensive fiber-surface treatments but also because it does not entail changes in procedures for manufacturing conventional composite-material structures. The alternative approach is best described by citing an example of its application to a composite of ultra-high-molecular- weight polyethylene (UHMWPE) fibers in an epoxy matrix. The epoxy matrix was modified to a chemically reactive, polarized epoxy nano-matrix to increase the degrees of wetting and adhesion between the fibers and the matrix. The modification was effected by incorporating a small proportion (0.3 weight percent) of reactive graphitic nanofibers produced from functionalized nanofibers into the epoxy matrix resin prior to combining the resin with the UHMWPE fibers. The resulting increase in fiber/matrix adhesion manifested itself in several test results, notably including an increase of 25 percent in the maximum fiber pullout force and an increase of 60-65 percent in fiber pullout energy. In addition, it was conjectured that the functionalized nanofibers became involved in the cross linking reaction of the epoxy resin, with resultant enhancement of the mechanical properties and lower viscosity of the matrix.

Zhong, Katie↗

NASA NTRS2000

Enhancements of Nucleate Boiling Under Microgravity Conditions

This paper presents two means for enhancing nucleate boiling and critical heat flux under microgravity conditions: using micro-configured metal-graphite composites as the boiling surface and dilute aqueous solutions of long-chain alcohols as the working fluid. In the former, thermocapillary force induced by temperature difference between the graphite-fiber tips and the metal matrix plays an important role in bubble detachment. Thus boiling-heat transfer performance does not deteriorate in a reduced-gravity environment. In the latter cases, the surface tension-temperature gradient of the long-chain alcohol solutions turns positive as the temperature exceeds a certain value. Consequently, the Marangoni effect does not impede, but rather aids in bubble departure from the heating surface. This feature is most favorable in microgravity. As a result, the bubble size of departure is substantially reduced at higher frequencies. Based on the existing experimental data, and a two-tier theoretical model, correlation formulas are derived for nucleate boiling on the copper-graphite and aluminum-graphite composite surfaces, in both the isolated and coalesced bubble regimes. In addition, performance equations for nucleate boiling and critical heat flux in dilute aqueous solutions of long-chain alcohols are obtained.

Zhang, Nengli↗

NASA NTRS1979

Development and fabrication of bismaleimide-graphite composites

The successful fabrication of high temperature resistant composites depends mainly on the processability of the resin binder matrix. For two new bismaleimide type resins the processing of graphite fabric prepregs to composites is described. One resin coded M 751 has to be processed from N-Methylpyrrolidone, the other resin evaluated is a so-called hot melt solvent-less system. Commercial T300/3000 Graphite fabrics were used as reinforcement. The M 751 - Resin is a press grade material and laminates are therefore moulded in high pressure conditions (400 N/sq cm). The solvent-less resin system H 795 is an autoclave grade material and can be cured at 40 N/sq cm. The cure cycles for both the press grade and the autoclave grade material (Fiberite W 143 fabric prepregs) are provided and the mechanical properties of laminates at low (23 C) and high (232 C) temperatures were measured. For comparison, the neat resin flexural properties are also presented. The water absorption for the neat resins and the graphite fabric laminates after a 1000 hour period was evaluated.

Stenzenberger, H.↗

NASA NTRS1991

Probabilistic micromechanics and macromechanics of polymer matrix composites

A probabilistic evaluation of an eight ply graphite-epoxy quasi-isotropic laminate was completed using the Integrated Composite Analyzer (ICAN) in conjunction with Monte Carlo simulation and Fast Probability Integration (FPI) techniques. Probabilistic input included fiber and matrix properties, fiber misalignment, fiber volume ratio, void volume ratio, ply thickness and ply layup angle. Cumulative distribution functions (CDFs) for select laminate properties are given. To reduce the number of simulations, a Fast Probability Integration (FPI) technique was used to generate CDFs for the select properties in the absence of fiber misalignment. These CDFs were compared to a second Monte Carlo simulation done without fiber misalignment effects. It was found that FPI requires fewer simulations to obtain the cumulative distribution functions as opposed to Monte Carlo simulation techniques. Furthermore, FPI provides valuable information regarding the sensitivities of composite properties to the constituent properties, fiber volume ratio and void volume ratio.

Mase, G. T.↗

NASA NTRS1991

Probabilistic micromechanics and macromechanics of polymer matrix composites

Mase, G. T.↗

NASA NTRSDate not supplied

Hot Structure Concepts and Materials for Space Exploration Project

Hot structures are multifunctional material systems that integrate the functions of thermal protection systems (TPS) and primary structure to increase mass efficiency in aerospace vehicles. The goal of this project was to improve our capabilities for developing lightweight, reusable, and reliable hot structures concepts to enable advanced space exploration missions. Specifically, current hot structure carbon/carbon (C/C) composite material systems have low interlaminar strength, which can lead to material failures at low load levels, and large material property variability in as-fabricated parts. Two parallel paths were followed to address these shortcomings. First, analysis models were developed to identify the conditions under which excessive interlaminar stresses occur and to evaluate the potential of stitching the C/C laminae to improve the interlaminar thermal-structural response. This effort included the development of high-fidelity, fracture-based thermal-structural finite element analysis models to evaluate critical features needed to produce efficient hot structure concepts. The second path focused on developing atomistic and mesoscale simulation tools to model the fabrication process in an effort to reduce the time and cost of production while improving the quality of the resulting parts. Aspects of the process currently being investigated include the infusion of the matrix precursor into the fiber preform, the cure of the precursor molecules into their polymeric form, and the carbonization and graphitization of the polymer to form the carbon matrix material. Results of the 6-month study are presented herein.

thermal↗