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NASA NTRS2019

Evaluation of an Alternate Method for Determining Yield Strength Offset Values for Selective Laser Sintered Polymeric Materials

Due to the unique characteristics of Additively Manufactured (AM) polymeric materials, typical mechanical strength characterization methods such as those commonly used for traditionally-processed polymers or composite materials can produce results that do not accurately represent material capabilities. In order to characterize mechanical properties of these materials, new test and analysis methods are required. As part of the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP), Boeing has evaluated true yield testing as an alternative or complimentary test to 0.2% offset yield testing for determining appropriate yield strength values of polymer materials. Previous testing has shown high strain, low modulus polymer materials such as selective laser sintered (SLS) Nylon 11 at elevated temperatures produce large variations in yield strength. The true yield test method was successful in finding the applied strain level when yield commences and appears to offer an increase in data robustness.

Henry, Chelsey↗

NASA NTRSDate not supplied

Surface-Enhanced Raman Spectroscopy (SERS) for Venus Atmospheric Characterization and Trace Organics Identification

The chemical composition of Venus’ clouds has attracted considerable attention since the first atmospheric probes entered the planet in the early 1980s. We know from these early studies that cloud aerosols consist of micron and submicron droplets of sulfuric acid (~85%) and water (~15%), but outstanding questions still exist regarding their trace chemical composition, especially the identity of the unknown UV absorber(s) and the possible presence of organic material (Spacek & Benner, 2021). Veritas and DaVinci will launch at the end of the decade to advance our understanding of Venus’ surface and atmosphere, however these missions are not designed to sample and analyze cloud aerosols at trace levels. Raman spectroscopy is an ideal candidate for characterizing aerosols and has a track record in studies of Earth’s atmosphere. Raman provides broad chemical screening of organic and inorganic molecules within seconds, and Raman instrumentation can be miniaturized to meet the stringent size, weight, and power (SWaP) constraints of an atmospheric probe while retaining sensitivity and specificity that allow spectral fingerprinting of compounds and functional groups. Raman alone is insufficient to characterize trace constituents however, as limits of detection are typically in the 10s to 100s of ppm at best for planetary Raman spectrometers. Surface-Enhanced Raman Spectroscopy (SERS), a method that utilizes nanoscale materials interacting with a sample to enhance weak Raman signals by orders of magnitude when probed by a laser, has the potential to drastically improve the sensitivity of a Raman instrument while adding little-to-no SWaP nor complexity to a scientific payload. We aim to de-risk SERS technology for rapid infusion in future planetary science missions by developing custom SERS substrates tailored towards Venus atmospheric exploration. We have developed SERS substrates consisting of nanotextured silver films and tested them on potential Venus-relevant organic compounds, with preliminary results indicating sub-ppm sensitivity. Additionally, we have planned tests to investigate durability, longevity, and other key characteristics that impact SERS substrate performance to prepare SERS technology for flight.

Venus↗

NASA NTRS2001

Characterization of Ceramic Matrix Composite Combustor Components: Pre and Post Exposure

The pursuit of lower emissions and higher performance from gas turbine engines requires the development of innovative concepts and the use of advanced materials for key engine components. One key engine component is the combustor, where innovative design and material improvements have the potential to lower emissions. Efforts to develop a High Speed Civil Transport with low emissions were focused on the evaluation of combustor concepts with liners fabricated from a ceramic matrix composite of silicon carbide fibers in a silicon carbide matrix (SiC/SiC). The evaluation of SiC/SiC composites progressed from simple coupons (to establish a first-order database and identify operant failure mechanisms and damage accumulation processes), to feature-based subelements (to assess fabricability and in situ material response), to actual components (to assess structural integrity, dimensional, and compositional fidelity) tested under simulated engine conditions. As in the case of all evolutionary material and process work, a key element to resolving fabrication issues is the evaluation of witness areas taken from fabricated components before testing the actual component. The witness material from these components allowed microstructural and mechanical testing to be performed and compared to the ideal, flat panel, conditions and data that are typical of basic characterization. This also allowed samples of similar design to be taken from components after 115 hours of combustion exposure. Testing consisted of tensile, double notch shear, ring burst, and thermal conductivity that sampled various regions of the components. The evaluation of the witness material allowed an understanding of the fabrication process, highlighting critical issues, in an early phase of the learning curve development of these configuration and material unique parts. Residual property testing, after exposure, showed if degradation of the material under actual service conditions was occurring. This paper will present the results of this critical testing. Evaluations that consider the degree of complexity of the fabricated part were established to relate in situ performance to that of flat panel based coupons. Nondestructive evaluation was used throughout the evaluation process. These results will also be discussed as an aid in understanding the test results.

Ojard, G.↗

NASA NTRS2005

High-Power, High-Temperature Superconductor Technology Development

Since the first discovery of high-temperature superconductors (HTS) 10 years ago, the most promising areas for their applications in microwave systems have been as passive components for communication systems. Soon after the discovery, experiments showed that passive microwave circuits made from HTS material exceeded the performance of conventional devices for low-power applications and could be 10 times as small or smaller. However, for superconducting microwave components, high-power microwave applications have remained elusive until now. In 1996, DuPont and Com Dev Ltd. developed high-power superconducting materials and components for communication applications under a NASA Lewis Research Center cooperative agreement, NCC3-344 "High Power High Temperature Superconductor (HTS) Technology Development." The agreement was cost shared between the Defense Advanced Research Projects Agency's (DARPA) Technology Reinvestment Program Office and the two industrial partners. It has the following objectives: 1) Material development and characterization for high-power HTS applications; 2) Development and validation of generic high-power microwave components; 3) Development of a proof-of-concept model for a high-power six-channel HTS output multiplexer.

Bhasin, Kul B.↗

NASA NTRS2006

Floating the Ball: Advances in the Technology of Electrostatic Levitation

Electrostatic Levitation (ESL) is an emerging technology. The MSFC ESL is a NASA facility that supports investigations of refractory solids and melts. The facility can be used to process a wide variety of materials including metals, alloys, ceramics, glasses and semiconductors. Containerless processing via ESL provides a high-purity environment for the study of high temperature materials and access to metastable states. Scientific topics investigated in the facility include nucleation, undercooling, metastable state formation and metallic glass formation. Additionally, the MSFC ESL provides data for the determination of phase diagrams, time-temperature-transition diagrams, viscosity, surface tension, density, heat capacity and creep resistance. In order to support a diverse research community, the MSFC ESL facility has developed a number of technical capabilities, including a portable system for in situ studies of structural tran$hrmations during processing at the high-energy X-ray beamline at the Advanced Photon Source of Argonne National Laboratory. The capabilities of the MSFC ESL facilities will be discussed and selected results of materials processing and characterization studies will be presented.

Rogers, Jan R.↗

NASA NTRS2003

Characterization of Polyimide Foams for Ultra-Lightweight Space Structures

Ultra-lightweight materials have played a significant role in nearly every area of human activity ranging from magnetic tapes and artificial organs to atmospheric balloons and space inflatables. The application range of ultra-lightweight materials in past decades has expanded dramatically due to their unsurpassed efficiency in terms of low weight and high compliance properties. A new generation of ultra-lightweight materials involving advanced polymeric materials, such as TEEK (TM) polyimide foams, is beginning to emerge to produce novel performance from ultra-lightweight systems for space applications. As a result, they require that special conditions be fulfilled to ensure adequate structural performance, shape retention, and thermal stability. It is therefore important and essential to develop methodologies for predicting the complex properties of ultra-lightweight foams. To support NASA programs such as the Reusable Launch Vehicle (RLV), Clark Atlanta University, along with SORDAL, Inc., has initiated projects for commercial process development of polyimide foams for the proposed cryogenic tank integrated structure (see figure 1). Fabrication and characterization of high temperature, advanced aerospace-grade polyimide foams and filled foam sandwich composites for specified lifetimes in NASA space applications, as well as quantifying the lifetime of components, are immensely attractive goals. In order to improve the development, durability, safety, and life cycle performance of ultra-lightweight polymeric foams, test methods for the properties are constant concerns in terms of timeliness, reliability, and cost. A major challenge is to identify the mechanisms of failures (i.e., core failure, interfacial debonding, and crack development) that are reflected in the measured properties. The long-term goal of the this research is to develop the tools and capabilities necessary to successfully engineer ultra-lightweight polymeric foams. The desire is to reduce density at the material and structural levels, while at the same time maintaining or increasing mechanical and other properties.

Meador, Michael↗

NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗

NASA NTRS1996

A Method for Characterizing Thermoset Polyimides

Thermoset polyimides have great potential for successfully meeting tough stress and temperature challenges in the advanced aircraft development program. However, studies of structure-property relationships in these materials have not been very successful so far. Positron lifetime spectroscopy (PLS) has been used to investigate free volumes and associated parameters in a series of variable, segmental molecular weight samples. The free volume correlates well with the molecular weight M(sub c), the cross-link density v, and the coefficient of thermal expansion (CTE) of these materials. Currently, no other techniques are available for direct measurement of these parameters, particularly for polymers in solid phase. Experimental results and their interpretations are presented.

Ranganathaiah, C.↗

NASA NTRS2008

State of the Art Assessment of Simulation in Advanced Materials Development

Advances in both the underlying theory and in the practical implementation of molecular modeling techniques have increased their value in the advanced materials development process. The objective is to accelerate the maturation of emerging materials by tightly integrating modeling with the other critical processes: synthesis, processing, and characterization. The aims of this report are to summarize the state of the art of existing modeling tools and to highlight a number of areas in which additional development is required. In an effort to maintain focus and limit length, this survey is restricted to classical simulation techniques including molecular dynamics and Monte Carlo simulations.

Wise, Kristopher E.↗

NASA NTRSDate not supplied

REACTER 2.0: Quantum-Informed Reaction Constraints and Automated Interaction Typing

REACTER is a heuristic method for modeling chemical reactions in classical molecular dynamics simulations, implemented in LAMMPS as fix bond/react. The authors recently extended LAMMPS to support alphanumeric labels for atom types, bond types etc., which enables the pre- and post-reaction templates required by the REACTER protocol to be portable between different simulations and greatly simplifies the task of creating simulation-ready reaction templates. To further increase the generality of reaction templates, support for wildcard characters within atom types has been added, along with the automatic assignment of interaction types for new bonds, angles, etc. based on the involved atom types. In some cases, this feature can express a class of reactions with one pair of reaction templates, where previously dozens may have been required. Advanced reaction constraints have also been added, including an Arrhenius constraint to enforce an effective activation energy, a root-mean-square-deviation option for complex geometrical constraints, as well as a custom constraint that leverages LAMMPS’ powerful built-in variable framework. Other new features include variable support for various inputs (e.g., to allow reaction rates or cutoffs to be dependent on overall conversion), on-the-fly update of molecule IDs, and the ability to create new atoms positioned with respect to the reaction site. The new features are applied to modeling polymeric, thermosetting and composite materials, and advanced applications of the new reaction constraints are demonstrated. For example, REACTER is shown to accurately reproduce mechanically-induced bond breaking, as characterized by third-order DFT-based tight-binding (DFTB3) simulations, via a constraint on the total potential energy of the involved atoms.

polymer simulations↗

NASA NTRS1987

Chemical and spectroscopic characterization of a suite of Mars soil analogs

The National Aeronautics and Space Administration has begun preparations for the flight of the Mars Observer Mission in the early 1990s. An advanced ground-based study is being conducted on a usefully limited suite of Mars Soil Analog Materials (MarSAM) intended to simulate the aeolian material covering the surface of Mars. A series of variably proportioned iron/calcium smectite clays were prepared from a typical montmorillonite clay using the Banin method. The effect of increasing iron on a diverse set of chemical and spectroscopic properties of the suite of clays is discussed. In order to chemically characterize the MarSAM and compare them with the Martian soil studied by Viking, the clays were analyzed for their major and minor elemental compositions by X-ray fluorescence and ion-coupled plasma techniques. It was concluded that the surface iron has a complex and hitherto uninvestigated impact on the catalytic and spectroscopic properties of clays and on the ability of these material to store energy.

Coyne, L. M.↗

NASA NTRS1997

Electrochemical Characterization of Semiconductor Materials and Structures

For a period covering October 1, 1995 through August 12, 1996, the research group at CSU has conducted theoretical and experimental research on "Electrochemical Characterization of Semiconductor Materials and Structures. " The objective of this investigation was to demonstrate the applicability of electrochemical techniques for characterization of complex device structures based on InP and GaAs, Ge, InGaAs, InSb, InAs and InSb, including: (1) accurate EC-V net majority carrier concentration depth profiling, and (2) surface and bulk structural and electrical type defect densities. Our motivation for this R&D effort was as follows: "Advanced space solar cells and ThermoPhotoVoltaic (TPV) cells are fabricated using a large variety of III-V materials based on InP and GaAs for solar cells and low bandgap materials such as Ge, InGaAs, InAs and InSb for TPV applications. At the present time for complex device structures using these materials, however, there is no simple way to assess the quality of these structures prior to device fabrication. Therefore, process optimization is a very time consuming and a costly endeavor". Completion of this R&D effort would have had unquestionable benefits for space solar cell and TPV cells, since electrochemical characterization of the above cell structures, if properly designed can provide many useful structural and electrical material information virtually at any depth inside various layers and at the interfaces. This, could have been applied for step-by-step process optimization, which could have been used for fabrication of new generation high efficiency, low cost space PV and TPV cells.

Source record↗

NASA NTRSDate not supplied

Advancement of Metal Additive Manufacturing Processes and Alloys for Rocket Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗

NASA NTRS2017

Overview of the Mission Design Reference Trajectory for NASA's Asteroid Redirect Robotic Mission

The National Aeronautics and Space Administration's (NASA's) recently cancelled Asteroid Redirect Mission was proposed to rendezvous with and characterize a 100 m plus class near-Earth asteroid and provide the capability to capture and retrieve a boulder off of the surface of the asteroid and bring the asteroidal material back to cislunar space. Leveraging the best of NASA's science, technology, and human exploration efforts, this mission was originally conceived to support observation campaigns, advanced solar electric propulsion, and NASA's Space Launch System heavy-lift rocket and Orion crew vehicle. The asteroid characterization and capture portion of ARM was referred to as the Asteroid Redirect Robotic Mission (ARRM) and was focused on the robotic capture and then redirection of an asteroidal boulder mass from the reference target, asteroid 2008 EV5, into an orbit near the Moon, referred to as a Near Rectilinear Halo Orbit where astronauts would visit and study it. The purpose of this paper is to document the final reference trajectory of ARRM and the challenges and unique methods employed in the trajectory design of the mission.

low thrust↗

NASA NTRS2010

Copoly(Imide Siloxane) Abhesive Materials with Varied Siloxane Oligomer Length

Incorporation of PDMS moieties into a polyimide matrix lowered the surface energy resulting in enhanced adhesive interactions. Polyimide siloxane materials were generated using amine-terminated PDMS oligomers of different lengths to study changes in surface migration behavior, phase segregation, mechanical, thermal, and optical properties. These materials were characterized using contact angle goniometry, tensile testing, and differential scanning calorimetry. The surface migration behavior of the PDMS component depended upon the siloxane molecular weight as indicated by distinct relationships between PDMS chain length and advancing water contact angles. Similar correlations were observed for percent elongation values obtained from tensile testing, while the addition of PDMS reduced the modulus. High fidelity topographical modification via laser ablation patterning further reduced the polyimide siloxane surface energy. Initial particulate adhesion testing experiments demonstrated that polyimide siloxane materials exhibited greater abhesive interactions relative to their respective homopolyimides.

Wohl, Christopher J.↗

NASA NTRSDate not supplied

Enhanced Quantification of 3D Woven Composites Via Fourier Analysis and Structure Tensors Applied to CT Scans

NASA's development of advanced 3D woven carbon composites, such as HEEET and 3MDCP, represents a significant leap in materials designed to endure extreme atmospheric entry conditions. However, the internal complexity of these materials introduces a variety of structures and novel defect types. Traditional characterization methods rely on labor-intensive, manual examination of X-ray CT scans, demanding considerable time and expertise. This process, while thorough, is not sustainable for large-scale analysis and defect tracking. Addressing this critical challenge, this presentation introduces an innovative suite of automated tools and analytical techniques, pioneered by the Mars Sample Return (MSR) Earth Entry System (EES) Thermal Protection System (TPS) project. These advancements offer a more efficient and accurate approach for quantifying CT data and characterizing the defects of 3D woven composites.

Magnus Haw↗

NASA NTRS1999

Nondestructive Evaluation Correlated with Finite Element Analysis

Advanced materials are being developed for use in high-temperature gas turbine applications. For these new materials to be fully utilized, their deformation properties, their nondestructive evaluation (NDE) quality and material durability, and their creep and fatigue fracture characteristics need to be determined by suitable experiments. The experimental findings must be analyzed, characterized, modeled and translated into constitutive equations for stress analysis and life prediction. Only when these ingredients - together with the appropriate computational tools - are available, can durability analysis be performed in the design stage, long before the component is built. One of the many structural components being evaluated by the NDE group at the NASA Lewis Research Center is the flywheel system. It is being considered as an energy storage device for advanced space vehicles. Such devices offer advantages over electrochemical batteries in situations demanding high power delivery and high energy storage per unit weight. In addition, flywheels have potentially higher efficiency and longer lifetimes with proper motor-generator and rotor design. Flywheels made of fiber-reinforced polymer composite material show great promise for energy applications because of the high energy and power densities that they can achieve along with a burst failure mode that is relatively benign in comparison to those of flywheels made of metallic materials Therefore, to help improve durability and reduce structural uncertainties, we are developing a comprehensive analytical approach to predict the reliability and life of these components under these harsh loading conditions. The combination of NDE and two- and three-dimensional finite element analyses (e.g., stress analyses and fracture mechanics) is expected to set a standardized procedure to accurately assess the applicability of using various composite materials to design a suitable rotor/flywheel assembly.

Abdul-Azid, Ali↗

NASA NTRSDate not supplied

An Overview of Research in Nondestructive Evaluation at the National Aeronautics and Space Administration’s Langley Research Center

The primary focus of the nondestructive evaluation (NDE) effort at Langley Research Center (LaRC) is to pioneer advances in NDE and structural health monitoring (SHM) through fundamental scientific research, technology development, and transferring these to the scientific and aerospace communities. This research supports a variety of NASA missions in space operations, exploration and aeronautics. The work presented will focus on the development of advanced inspection systems to detect critical flaws in both metallic and non-metallic materials and structures for aerospace applications. The emphasis is on increasing the performance of inspection systems to provide defect detection and quantitative characterization of the material state. LaRC NDE utilizes expertise in computational ultrasonic, thermal and eddy current simulations to reduce measured responses to size and locations of flaws, establish technique limitations and optimize performance. This presentation will highlight research into five strategic areas: (1) The development of novel solutions using state-of-the-art NDE technologies such as eddy current, ultrasound, thermography and x-ray computed tomography; (2) Research in the development of unique NDE technologies such as terahertz, wavefield imaging and nonlinear ultrasound; (3) The application of both computational and analytic models to NDE problems; (4) The development of advanced analytic methods to interpret large complex data sets; and (5) Advanced methods of applying and interrogating sensors for structural health monitoring.

K Elliott Cramer↗