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NASA NTRS2024

Direct Ink Write 3D Printing of Fully Dense and Functionally Graded Liquid Metal Elastomer Foams

Liquid metal (LM) elastomer composites offer promising potential in soft robotics, wearable electronics, and human-machine interfaces. Direct ink write (DIW) 3D printing offers a versatile manufacturing technique capable of precise control over LM microstructures, yet challenges such as interfilament void formation in multilayer structures impact material performance. Here, a DIW strategy is introduced to control both LM microstructure and material architecture. Investigating three key process parameters–nozzle height, extrusion rate, and nondimensionalized nozzle velocity–it is found that nozzle height and velocity predominantly influence filament geometry. The nozzle height primarily dictates the aspect ratio of the filament and the formation of voids. A threshold print height based on filament geometry is identified; below the height, significant surface roughness occurs, and above the ink fractures, which facilitates the creation of porous structures with tunable stiffness and programmable LM microstructure. These porous architectures exhibit reduced density and enhanced thermal conductivity compared to cast samples. When used as a dielectric in a soft capacitive sensor, they display high sensitivity (gauge factor = 9.0), as permittivity increases with compressive strain. These results demonstrate the capability to simultaneously manipulate LM microstructure and geometric architecture in LM elastomer composites through precise control of print parameters, while maintaining geometric fidelity in the printed design.

Spencer Pak↗

NASA NTRS1990

Out of plane analysis for composite structures

Simple two dimensional analysis techniques were developed to aid in the design of strong joints for integrally stiffened/bonded composite structures subjected to out of plane loads. It was found that most out of plane failures were due to induced stresses arising from rapid changes in load path direction or geometry, induced stresses due to changes in geometry caused by buckling, or direct stresses produced by fuel pressure or bearing loads. While the analysis techniques were developed to address a great variety of out of plane loading conditions, they were primarily derived to address the conditions described above. The methods were developed and verified using existing element test data. The methods were demonstrated using the data from a test failure of a high strain wingbox that was designed, built, and tested under a previous program. Subsequently, a set of design guidelines were assembled to assist in the design of safe, strong integral composite structures using the analysis techniques developed.

Paul, P. C.↗

NASA NTRS2019

Viscoelastic Characterization of Polymers for Deployable Composite Booms

Deployable space structures have been built from thin-walled fiber-reinforced polymer composite materials due to their high specific strength, high specific stiffness, and bistability. However, the inherent viscoelastic behavior of the resin matrix can cause dimensional instability when parts are stored under strain. The extended time of stowage between assembly and deployment in space can result in performance degradation and in the worst case, mission failure. In this study, the viscoelastic properties of candidate commercial polymers for deployable boom structures of solar sails were evaluated. Stress relaxation master curves of the candidate polymers were used to predict the relaxation that would occur in 1 year at room temperature under relatively low strains of ~0.1%. A bismaleimide (BMI) showed less stress relaxation (about 20%) than the baseline Novolac epoxy (about 50%). Carbon fiber composites fabricated with the BMI resin showed a 44% improvement in relaxation compared to the baseline epoxy composite. Other difunctional and tetrafunctional epoxies, thermoplastic, and thermosetting polyimides were also evaluated.

Kang, Jin Ho↗

NASA NTRS1993

The impact of LDEF results on the space application of metal matrix composites

Over 200 graphite/aluminum and graphite/magnesium composites were flown on the leading and trailing edges of LDEF on the Advanced Composites Experiment. The performance of these composites was evaluated by performing scanning electron microscopy and x-ray photoelectron spectroscopy of exposed surfaces, optical microscopy of cross sections, and on-orbit and postflight thermal expansion measurements. Graphite/aluminum and graphite/magnesium were found to be superior to graphite/polymer matrix composites in that they are inherently resistant to atomic oxygen and are less susceptible to thermal cycling induced microcracking. The surface foils on graphite/aluminum and graphite/magnesium protect the graphite fibers from atomic oxygen and from impact damage from small micrometeoroid or space debris particles. However, the surface foils were found to be susceptible to thermal fatigue cracking arising from contamination embrittlement, surface oxidation, or stress risers. Thus, the experiment reinforced requirements for carefully protecting these composites from prelaunch oxidation or corrosion, avoiding spacecraft contamination, and designing composite structures to minimize stress concentrations. On-orbit strain measurements demonstrated the importance of through-thickness thermal conductivity in composites to minimize thermal distortions arising from thermal gradients. Because of the high thermal conductivity of aluminum, thermal distortions were greatly reduced in the LDEF thermal environment for graphite/aluminum as compared to graphite/magnesium and graphite/polymer composites. The thermal expansion behavior of graphite/aluminum and graphite/magnesium was stabilized by on-orbit thermal cycling in the same manner as observed in laboratory tests.

Steckel, Gary L.↗

NASA NTRS2003

Matrix Cracking in Four Different 2D SiC/SiC Composite Systems

Silicon carbide fiber reinforced, silicon carbide matrix composites are some of the most advanced composite systems for high-temperature, high-stress applications in oxidizing environments. A basic area that needs to be understood for the purpose of material behavior modeling and optimization is the architectural, constituent, and mechanistic factors that contribute to non-linear stress-strain behavior. The mechanism that causes non-linear stress-strain in dense-matrix composites is the formation and propagation of bridged matrix cracks. In addition, the occurrence and propagation of matrix cracks controls the time-dependent strength-properties of these materials in oxidizing environments at elevated temperatures. A modal acoustic emission technique has been used to monitor and estimate the stress-dependent matrix cracking. Two different SiC matrix systems, chemical vapor infiltrated (CVI) and melt-infiltrated (MI), with two different SiC fiber reinforcement, Hi-Nicalon (trademark) and Sylramic (trademark) were compared. Even though the averages of the range where matrix cracking occurred for the composites varied by more than 0.1% in strain and almost 200 MPa in stress, the range or distribution for matrix cracking could be reduced to a narrow band of stress for CVI SiC and MI SiC composites if it were assumed that all matrix cracks emanate outside of the load-bearing fiber, interphase, CVI preform minicomposite. A simple relationship was determined to describe stress-dependent matrix cracking which can then be used to estimate the onset of large, bridged matrix cracks or for material behavior models.

Morscher, Gregory N.↗

NASA NTRS1998

Thin Film Sensors for Minimally-Intrusive Measurements in Harsh High Temperature Environment

Advanced thin film sensors are being developed to provide accurate surface temperature, heat flux and strain measurements for components used in hostile propulsion environments. These sensors are sputter deposited and microfabricated directly onto the test articles with no additional bonding agent. The thickness of the sensors is only a few micrometers which creates minimal disturbance of the gas flow over the test surface. Thus thin film sensors have the advantage over conventional wire- based sensors by providing minimally intrusive measurement and having a faster response. These thin film sensors are being developed for characterization of advanced materials and structures in hostile, high-temperature environments, and for validation of design codes. This paper presents the advances of three high temperature thin film sensor technologies developed at NASA Lewis Research Center: thermocouples, heat-flux gages and strain gages. The fabrication techniques of these thin film sensors which include physical vapor deposition, photolithography patterning and lead Wire attachment are described. Sensors demonstrations on a variety of engine materials, including superalloys, ceramics and advanced ceramic matrix composites, in several hostile, high-temperature test environments are presented. The advantages and limitations of thin film sensor technology are also discussed.

Lei, Jih-Fen↗

NASA NTRS1986

Response of symmetric rectangular composite laminates with nonlinear damping subjected to acoustic loading

Effects of both nonlinear damping and large-deflection are included in the analysis in an attempt to explain the experimental phenomena of aircraft panels excited at high sound pressure levels; that is the broadening and flattening out of the strain response peaks and the increasing of the response frequency. A nonlinear damping model is considered in the analysis using a single-mode approach. Root-mean-square (RMS) maximum deflection, RMS strains, spectral density functions of strain, and equivalent linear frequency are obtained for clamped and simply supported rectangular symmetric laminated composite plates. It is demonstrated that nonlinear damping is the one which causes the broadening of the response peaks, and it has great influence on RMS panel deflection, RMS strains, and frequency.

Mei, C.↗

NASA NTRS1977

Mechanical behavior and fracture characteristics of off-axis fiber composites. 1: Experimental investigation

The mechanical behavior, fracture surfaces, and fracture modes of unidirectional high-modulus graphite-fiber/epoxy composites subjected to off-axis tensile loads were investigated experimentally. The investigation included the generation of stress-strain-to-fracture data and scanning electron microscope studies of the fractured surfaces. The results led to the identification of fracture modes and distinct fracture surface characteristics for off-axis tensile loading. The results also led to the formulation of critical for identifying and characterizing these fracture modes and their associated fracture surfaces. The results presented and discussed herein were used in the theoretical investigation and comparisons described in Part 2. These results should also provide a good foundation for identifying, characterizing, and quantifying fracture modes in both off-axis and angle-plied laminates.

Sinclair, J. H.↗

NASA NTRS1996

Characterization of SiGe/Ge heterostructures and graded layers using variable angle spectroscopic ellipsometry

Variable angle spectroscopic ellipsometry (VASE) has been used to characterize Si(x)Ge(1-x)/Ge superlattices (SLs) grown on Ge substrates and thick Si(x)Ge(1-x)/Ge heterostructures grown on Si substrates. Our VASE analysis yielded the thicknesses and alloy compositions of all layers within the optical penetration depth of the surface. In addition, strain effects were observed in the VASE results for layers under both compressive and tensile strain. Results for the SL structures were found to be in close agreement with high resolution x-ray diffraction measurements made on the same samples. The VASE analysis has been upgraded to characterize linearly graded Si(x)Ge(1-x) buffer layers. The algorithm has been used to determine the total thickness of the buffer layer along with the start and end alloy composition by breaking the total thickness into many (typically more than 20) equal layers. Our ellipsometric results for 1 (mu)m buffer layers graded in the ranges 0.7 less than or = x less than or = 1.0, and 0.5 less than or = x less than or = 1.0 are presented, and compare favorably with the nominal values.

Croke, E. T.↗

NASA NTRS1983

Large diameter astromast development, phase 1

Coilable-longeron lattice columns called Astromasts (trademark) were manufactured for a variety of spacecraft missions. These flight structures varied in diameter from 0.2 to 0.5 meter (9 to 19 in.), and the longest Astromast of this type deploys to a length of 30 meters (100 feet). A double-laced diagonal Astromast design referred to as the Supermast (trademark) which, because it has shorter baylengths than an Astromast, is approximately four times as strong. The longeron cross section and composite material selection for these structures are limited by the maximum strain associated with stowage and deployment. As a result, future requirements for deployable columns with high stiffness and strength require the development of both structures in larger diameters. The design, development, and manufacture of a 6.1-m-long (20-ft), 0.75-m-diameter (30-in.), double-laced diagonal version of the Astromast is described.

Preiswerk, P. R.↗

NASA NTRS2019

Fatigue Behavior of Coated Titanium Alloys

Advanced multi-component TiAlCrTaSiN-based multilayered coatings were developed and processed onto Ti-6Al-4V (Ti-6-4) and GammaMet PX (GMPX or TiAl) alloys by a magnetron-enhanced physical vapor deposition technique. The coatings have recently been in development with the goal of improving advanced titanium alloy, turbine engine component durability and oxidation-erosion resistance. In this work, the performance of the multi-component coating system (including the outer layer nitride based coating and inner TiAlCrSi oxidation barrier bond coat) was studied, and the coating's influence on the fatigue behavior of the titanium-based alloys were compared. Although the multi-component coating was initially optimized to improve the coating's high temperature oxidation and erosion resistance, the lower ductility nitride-based coating needs further work on microstructure or composition to improve its mechanical stress resistance and strain tolerance for use in cyclically loaded, turbine blade operating conditions. This is particularly true for GMPX and other γ-TiAl alloys because these intermetallic titanium alloys have limited ductility and are very sensitive to defects such as coating cracks. However, the inner layer TiAlCrSi-coating had better adhesion and ductility, and may be a suitable choice to improve the oxidation resistance of titanium alloys.

Oxidation Barrier Coatings↗

NASA NTRS2012

NDT and SHM of Carbon Fiber Composites using Linear Drive MWM-Arrays

Carbon fiber composites are used in a wide range of structural applications due to their excellent specific strength and stiffness. However, the anisotropic mechanical and electrical properties associated with the fibers within each composite layer present challenges, and opportunities, for Nondestructive Testing (NDT) methods used to characterize and assess the structure condition. This includes composite condition after manufacture (such as fiber orientation and density, porosity, delamination, and bond strength) and during usage (such as damage from impact, fiber breakage, thermal exposure or applied stress). Ultrasonic and thermographic methods can address some of these challenges, but eddy current methods provide an alternative method for composite structures that contain a conducting material, such as carbon fibers or a metallic liner. This presentation reviews recent advances in the development of eddy current sensors and arrays for carbon fiber composite NDT and Structural Health Monitoring (SHM) applications. The focus is on eddy current sensor constructs with linear drive windings, such as MWM -Arrays, that induce currents primarily within the linear fibers of the composite. By combining this type of sensor construct with micromechanical models that relate composite constituent properties to measurable sensor responses, insight is obtained into the volumetric distribution of electrical properties within the composite and the associated manufacturing, damage, or strain conditions. With knowledge of the fiber layup, this MWM-Array technology is able to detect damage and strain/stress as a function of depth and fiber orientation. This work has been funded by NASA, NA V AIR and the Army for applications ranging from composite overwrapped pressure vessels (COPVs) to aircraft structures and rotorcraft blades. This presentation will specifically present background on the MWM-Array technology, results from the micromechanical modeling effort, and results from ongoing efforts for high resolution imaging and volumetric strain sensing.

Washabaugh, Andrew↗

NASA NTRS2003

Hydrogen Permeability of a Polymer Based Composite Tank Material Under Tetra-Axial Strain

In order to increase the performance of future expendable and reusable launch vehicles and reduce per-pound payload launch costs, weight reductions have been sought in vehicle components. Historically, the cryogenic propellant tanks for launch vehicles have been constructed from metal. These are some of the largest structural components in the vehicle and contribute significantly to the vehicles total dry weight. A successful replacement material will be conformable, have a high strength to weight ratio, and have a low gas-permeability to the cryogens being stored, i.e., oxygen and hydrogen. Polymer-based composites are likely candidates to fill this role. Polymer and polymer-based composites in general are known to have acceptable gas permeation properties in their as-cured state.1 The use of polymer-based composites for this application has been proposed for some time.2 Some successes have been reported with oxygen3, but other than the DC-XA experience, those with hydrogen have been limited. The primary reason for this has been the small molecular diameter of hydrogen, the lower temperatures of the liquid, and that the composite materials examined to date have all been susceptible to microcrack formation in response to the thermal-mechanical cycles experienced in the use-environment. There have been numerous accounts of composite materials with reported acceptable resistance to the formation of microcracks when exposed to various mechanical and/or thermal cycles. However, virtually all of these studies have employed uniaxial loads and there has been no discussion or empirical evidence pertaining to how these loads relate to the biaxial state of stress in the material in its use environment. Furthermore, many of these studies have suffered from a lack of instrument sensitivity in detecting hydrogen permeability, no standards, insufficient documentation of test conditions, testing of cycled materials in their unload state, and/or false assumptions about the nature of the microcracks in the material. This paper documents the results of hydrogen permeability testing on a Bismaleimide (BMI) based graphite fiber composite material under a variety of tetra-axial strain states.

Stokes, Eric H.↗

NASA NTRS1991

HITCAN for actively cooled hot-composite thermostructural analysis

A computer code, high temperature composite analyzer (HITCAN), was developed to analyze/design hot metal matrix composite structures. HITCAN is a general purpose code for predicting the global structural and local stress-strain response of multilayered (arbitrarily oriented) metal matrix structures both at the constituent (fiber, matrix, and interphase) and the structural level, including the fabrication process effects. The thermomechanical properties of the constituents are considered to be nonlinearly dependent on several parameters, including temperature, stress, and stress rate. The computational procedure employs an incremental iterative nonlinear approach utilizing a multifactor-interaction material behavior model, i.e., the material properties are expressed in terms of a product of several factors that affect the properties. HITCAN structural analysis capabilities (static, load stepping - a multistep static analysis with material properties updated at each step, modal, and buckling) for cooled hot structures are demonstrated through a specific example problem.

Chamis, C. C.↗

NASA NTRS1992

HITCAN for actively cooled hot-composite thermostructural analysis

Chamis, C. C.↗

NASA NTRS1996

Comparison Testings between Two High-temperature Strain Measurement Systems

An experimental evaluation was conducted at NASA Lewis Research Center to compare and contrast the performance of a newly developed resistance strain gage, the PdCr temperature-compensated wire strain gage, to that of a conventional high-temperature extensometry. The evaluation of the two strain measurement systems was conducted through the application of various thermal and mechanical loading spectra using a high-temperature thermomechanical uniaxial testing system equipped with quartz lamp heating. The purpose of the testing was not only to compare and contrast the two strain sensors but also to investigate the applicability of the PdCr strain gage to the testing environment typically employed when characterizing the high-temperature mechanical behavior of structural materials. Strain measurement capabilities to 8OO C were investigated with a nickel base superalloy IN100 substrate material, and application to titanium matrix composite (TMC) materials was examined with the SCS-6/Ti-15-3 08 system. PdCr strain gages installed by three attachment techniques, namely, flame spraying, spot welding and rapid infrared joining were investigated.

Lei, J.-F.↗

NASA NTRS1985

Moire interferometry for deformation and strain studies

Recent advances in high sensitivity more interferometry are described. In-plane displacement fields are shown for very challenging problem areas: adhesive joints in tension and in bending, flexure of quasi-isotropic composite laminates, and fatigue cracks in aluminum. Reference gratings with 2400 lines/mm (60,690 l/in) were used, providing a sensitivity of 0.417 micron/fringe order (16.4 microinch./fringe order). Excellent fringe contrast was obtained in all cases, even for gradients of 64 fringes/mm (1600 fringes/in.). A four-beam optical system to produce two orthogonal virtual reference gratings was employed. The question of unknown relative displacements in two-body problems was answered by use of a soft bridge between the bodies to provide a continous path for the fringe count.

Post, D.↗

NASA NTRS2014

Slow Strain Rate Tensile Testing to Assess the Ability of Superalloys to Resist Environment-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720, ATI 718Plus alloy, Haynes 282, and Inconel 740. Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

Heat resistant alloys↗