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NASA NTRS1991

Indigenous lunar construction materials

The utilization of local resources for the construction and operation of a lunar base can significantly reduce the cost of transporting materials and supplies from Earth. The feasibility of processing lunar regolith to form construction materials and structural components is investigated. A preliminary review of potential processing methods such as sintering, hot-pressing, liquification, and cast basalt techniques, was completed. The processing method proposed is a variation on the cast basalt technique. It involves liquification of the regolith at 1200-1300 C, casting the liquid into a form, and controlled cooling. While the process temperature is higher than that for sintering or hot-pressing (1000-1100 C), this method is expected to yield a true engineering material with low variability in properties, high strength, and the potential to form large structural components. A scenario for this processing method was integrated with a design for a representative lunar base structure and potential construction techniques. The lunar shelter design is for a modular, segmented, pressurized, hemispherical dome which could serve as habitation and laboratory space. Based on this design, estimates of requirements for power, processing equipment, and construction equipment were made. This proposed combination of material processing method, structural design, and support requirements will help to establish the feasibility of lunar base construction using indigenous materials. Future work will refine the steps of the processing method. Specific areas where more information is needed are: furnace characteristics in vacuum; heat transfer during liquification; viscosity, pouring and forming behavior of molten regolith; design of high temperature forms; heat transfer during cooling; recrystallization of basalt; and refinement of estimates of elastic moduli, compressive and tensile strength, thermal expansion coefficient, thermal conductivity, and heat capacity. The preliminary design of the lunar shelter showed us that joining is a critical technology needed for building a structure from large segments. The problem of joining is important to the design of any structure that is not completely prefabricated. It is especially important when the structure is subjected to tensile loading by an internal pressure. For a lunar shelter constructed from large segments the joints between these large segments must be strong, and they must permit automated construction. With a cast basalt building material which is brittle, there is the additional problem of connecting the joint with the material and avoiding stress concentration that would cause failure. Thus, a well-defined project which we intend to pursue during this coming year is the design of joints for cast basalt structural elements.

Rogers, Wayne P.↗

NASA NTRS1992

Axisymmetric spherical shell models of mantle convection with variable properties and free and rigid lids

Axisymmetric spherical shell numerical simulations of mantle convection were carried out to investigate the influence of two end-member surface stress conditions: stress-free and rigid. These correspond approximately to a subducting or a rigid lithosphere and can be seen as end-member models of the surface of Venus. Our model assumed an effective Rayleigh number of 3 x 10 exp 6, similar to that for earth, and included uniform internal heating and depth-dependent thermal expansivity and thermal conductivity. The simulations utilized a Newtonian viscosity which was constant or varied with depth and/or temperature. We show how the temperature, speed, and vorticity fields change qualitatively and quantitatively with surface temperature, surface stress condition, internal heating and viscosity distribution. We find that a rigid lid and viscosity which increases with depth both promote steady large-scale circulation with smaller-scale circulation in the upper mantle.

Leitch, A. M.↗

NASA NTRS1991

Computational characterization of high temperature composites via METCAN

The computer code 'METCAN' (METal matrix Composite ANalyzer) developed at NASA Lewis Research Center can be used to predict the high temperature behavior of metal matrix composites using the room temperature constituent properties. A reference manual that characterizes some common composites is being developed from METCAN generated data. Typical plots found in the manual are shown for graphite/copper. These include plots of stress-strain, elastic and shear moduli, Poisson's ratio, thermal expansion, and thermal conductivity. This manual can be used in the preliminary design of structures and as a guideline for the behavior of other composite systems.

Brown, H. C.↗

NASA NTRS1996

A Thermostructural Analysis of a Diboride Composite Leading Edge

In an effort to support the design of zirconium diboride composite leading edges for hypersonic vehicles, a finite element model (FEM) of a prototype leading edge was created and finite element analysis (FEA) was employed to assess its thermal and structural response to aerothermal boundary conditions. Unidirectional material properties for the structural components of the leading edge, a continuous fiber reinforced diboride composite, were computed with COSTAR. These properties agree well with those experimentally measured. To verify the analytical approach taken with COSMOS/M, an independent FEA of one of the leading edge assembly components was also done with COSTAR. Good agreement was obtained between the two codes. Both showed that a unidirectional lay-up had the best margin of safety for a simple loading case. Both located the maximum stress in the same region and ply. The magnitudes agreed within 4 percent. Trajectory based aerothermal heating was then applied to the leading edge assembly FEM created with COSMOS/M to determine steady state temperature response, displacement, stresses, and contact forces due to thermal expansion and thermal strains. Results show that the leading edge stagnation line temperature reached 4700 F. The maximum computed failure index for the laminated composite components peaks at 4.2, and is located at the bolt flange in layer 2 of the side bracket. The temperature gradient in the tip causes a compressive stress of 279 ksi along its width and substantial tensile stresses within its depth.

Kowalski, Tom↗

NASA NTRS1997

Probabilistic Micromechanics and Macromechanics for Ceramic Matrix Composites

The properties of ceramic matrix composites (CMC's) are known to display a considerable amount of scatter due to variations in fiber/matrix properties, interphase properties, interphase bonding, amount of matrix voids, and many geometry- or fabrication-related parameters, such as ply thickness and ply orientation. This paper summarizes preliminary studies in which formal probabilistic descriptions of the material-behavior- and fabrication-related parameters were incorporated into micromechanics and macromechanics for CMC'S. In this process two existing methodologies, namely CMC micromechanics and macromechanics analysis and a fast probability integration (FPI) technique are synergistically coupled to obtain the probabilistic composite behavior or response. Preliminary results in the form of cumulative probability distributions and information on the probability sensitivities of the response to primitive variables for a unidirectional silicon carbide/reaction-bonded silicon nitride (SiC/RBSN) CMC are presented. The cumulative distribution functions are computed for composite moduli, thermal expansion coefficients, thermal conductivities, and longitudinal tensile strength at room temperature. The variations in the constituent properties that directly affect these composite properties are accounted for via assumed probabilistic distributions. Collectively, the results show that the present technique provides valuable information about the composite properties and sensitivity factors, which is useful to design or test engineers. Furthermore, the present methodology is computationally more efficient than a standard Monte-Carlo simulation technique; and the agreement between the two solutions is excellent, as shown via select examples.

Murthy, Pappu L. N.↗

NASA NTRS1998

Surface Micromachined Silicon Carbide Accelerometers for Gas Turbine Applications

A finite-element analysis of possible silicon carbide (SIC) folded-beam, lateral-resonating accelerometers is presented. Results include stiffness coefficients, acceleration sensitivities, resonant frequency versus temperature, and proof-mass displacements due to centripetal acceleration of a blade-mounted sensor. The surface micromachined devices, which are similar to the Analog Devices Inc., (Norwood, MA) air-bag crash detector, are etched from 2-pm thick, 3C-SiC films grown at 1600 K using atmospheric pressure chemical vapor deposition (APCVD). The substrate is a 500 gm-thick, (100) silicon wafer. Polysilicon or silicon dioxide is used as a sacrificial layer. The finite element analysis includes temperature-dependent properties, shape change due to volume expansion, and thermal stress caused by differential thermal expansion of the materials. The finite-element results are compared to experimental results for a SiC device of similar, but not identical, geometry. Along with changes in mechanical design, blade-mounted sensors would require on-chip circuitry to cancel displacements due to centripetal acceleration and improve sensitivity and bandwidth. These findings may result in better accelerometer designs for this application.

DeAnna, Russell G.↗

NASA NTRS1996

Shape-Memory-Alloy-Based Deicing System Developed

Ice buildup on aircraft leading edge surfaces has historically been a problem. Most conventional deicing systems rely either on surface heating to melt the accreted ice or pneumatic surface inflation to mechanically debond the ice. Deicers that rely solely on surface heating require large amounts of power. Pneumatic deicers usually cannot remove thin layers of ice and lack durability. Thus, there is a need for an advanced, low-power ice protection system. As part of the NASA Small Business and Innovation Research (SBIR) program, Innovative Dynamics, Inc., developed an aircraft deicing system that utilizes the properties of Shape Memory Alloys (SMA). The SMA-based system has achieved promising improvements in energy efficiency and durability over more conventional deicers. When they are thermally activated, SMA materials change shape; this is analogous to a conventional thermal expansion. The thermal input is currently applied via conventional technology, but there are plans to implement a passive thermal input that is supplied from the energy transfer due to the formation of the ice itself. The actively powered deicer was tested in the NASA Lewis Icing Research Tunnel on a powered rotating rig in early 1995. The system showed promise, deicing both rime and glaze ice shapes as thin as 1/8 in. The first prototype SMA deicer reduced power usage by 45 percent over existing electrothermal systems. This prototype system was targeted for rotorcraft system development. However, there are current plans underway to develop a fixed-wing version of the deicer.

Source record↗

NASA NTRS2000

Constituent-Based Life Models Being Developed for SiC/SiC Composites

For the successful utilization of ceramic matrix composites (CMC) as hot-section components in advanced aeropropulsion engines, the CMC constituents will need to be tailored and optimized to meet all the critical property demands of each component. Under the High-Speed Research (HSR) and Advanced High-Temperature Engine Materials Technology (HITEMP) Programs, the NASA Glenn Research Center at Lewis Field initiated research to develop mechanistic models for key CMC thermostructural properties. These models would describe the effects of different constituent factors (composition, geometry, and volume fraction) and of potential application conditions (stress, time, temperature, and environment) on these properties. Particular focus was placed on both analytical and numerical modeling of state-of-the-art SiC/SiC composites where the primary load-bearing constituents are stoichiometric SiC fibers in a complex multiphase SiC matrix produced by chemical vapor infiltration and melt infiltration. Recent studies have resulted in computer-based numerical models for the elastic modulus, thermal expansion, and thermal conductivity properties of the SiC/SiC system. Additional studies have generated analytical and empirical models for the time dependence of composite rupture strength at temperatures above 2200 F (1200 C), where CMC's have an important thermostructural advantage over current nickel-based superalloys. These life models utilize thermal activation theory and fiber stress-rupture results measured at Glenn to generate Larson-Miller (L M) plots of fiber rupture strength versus q, a single time- and temperature-dependent parameter. Assuming a worse case in which the SiC matrix is cracked, rupture is then controlled by the time-dependent fracture characteristics of the fiber bundles bridging the matrix cracks. With this as the controlling mechanism, one can then use simple composite theory and the fiber L M plots to predict CMC rupture strength versus the q parameter. The dashed line shows the predicted rupture strength of a SiC/SiC composite that is reinforced by a state-of-the-art stoichiometric SiC fiber. For the q parameter, time is in hours and temperature in degrees kelvin. To generate these predictions, a two-dimensional 0 /90 composite with approximately 16 percent fiber in the applied stress direction and an air test environment were assumed. As such, it is possible to compare the model predictions against limited stress-rupture data for this CMC as shown by the data points. The good agreement confirms the rupture model at least for the selected CMC and test conditions. Thus for this particular SiC/SiC composite, one can estimate a 1000-hr rupture strength of approximately 12 ksi at 2400 F (T = 1588 K and q = 39 700 K). At lower CMC application stresses, the SiC matrix is typically uncracked, so both the fiber and matrix constituents share the composite load. In this case, CMC rupture is controlled by the constituent with the longest rupture time based on the creep rate of the composite. Measured Monkman-Grant plots of rupture time versus creep rate for the two SiC constituents have been used to develop CMC life models for this important application condition. NASA and DOD are currently using this information to establish application and material goals for more advanced CMC's that can be used at even higher temperatures.

DiCarlo, James A.↗

NASA NTRS2005

Flexible Metallic Overwrap Concept Developed for On-Orbit Repair of Space Shuttle Orbiter Leading Edges

The Columbia accident has focused attention on the critical need for on-orbit repair concepts for leading edges in the event that damage is incurred during space shuttle orbiter flight. Damage that is considered as potentially catastrophic for orbiter leading edges ranges from simple cracks to holes as large as 16 in. in diameter. NASA is particularly interested in examining potential solutions for areas of larger damage since such a problem was identified as the cause for the Columbia disaster. One possible idea for the on-orbit repair of the reinforced carbon/carbon (RCC) leading edges is an overwrap concept that would use a metallic sheet flexible enough to conform to the contours of the orbiter and robust enough to protect any problem area from catastrophic failure during reentry. The simplified view of the application of a refractory metal sheet over a mockup of shuttle orbiter panel 9, which experiences the highest temperatures on the shuttle during reentry is shown. The metallic overwrap concept is attractive because of its versatility as well as the ease with which it can be included in an onboard repair kit. Reentry of the orbiter into Earth's atmosphere imposes extreme requirements on repair materials. Temperatures can exceed 1650 C for up to 15 min in the presence of an extremely oxidizing plasma environment. Several other factors are critical, including catalysity, emissivity, and vibrational and aerodynamic loads. Materials chosen for this application will need to be evaluated with respect to high-temperature capability, resistance to oxidation, strength, coefficient of thermal expansion, and thermal conductivity. The temperature profile across panel 9 during reentry as well as a schematic of the overwrap concept itself is shown.

Ritzert, Frank J.↗

NASA NTRS2021

Extended Stroke and Miniaturized Reverse-Operation DTE Thermal Switches

This paper describes two advanced thermal switches under development that are offshoots of the recently flight-qualified 2500:1 reverse-operation differential thermal expansion (DTE) thermal switch (ROD-TSW). The first is the extended stroke ROD-TSW (ES-ROD-TSW) while the second is the miniaturized ROD-TSW (mini-ROD-TSW). Each employs multiple diametrically nested DTE stages in contrast to the single-stage ROD-TSW. The ES-ROD-TSW employs two stages and a negative CTE material known as Allvar and its main purpose is to extend its stroke for use in non-vacuum planetary environments. The mini-ROD-TSW employs four stages to miniaturize its size for use in compact lunar instruments and rovers. The ES-ROD-TSW was TVAC tested at JPL and its ON/OFF ratio is 13000:1 based on a measured ON conductance of 6.89 W/K and a calculated OFF conductance of 0.00053 W/K. The mini-ROD-TSW is targeted to have an ON conductance of 1.5 W/K and an OFF conductance of 0.0015 W/K, both verified by analysis. Test verification of the mini-ROD-TSW remains to be carried out. The paper will provide design/performance details of each device.

Farmer, Jeffery T.↗

NASA NTRS2026

Polymer Composite Material Testing for a Cryotank Application

Composite cryotanks will play a key role in enabling the next generation of efficient aircraft. Carbon fiber reinforced polymer (CFRP) composites have the benefits of reduced weight and potentially higher structural strength compared to traditional metallic fuel tanks. A material screening study was conducted to inform material selection for liquid hydrogen (LH2) fuel storage. Three composite materials were considered because of their aerospace grade toughness, strength, and existing data to compare against. These materials were a thermoplastic low-melt polyaryletherketone (LM-PAEK)/carbon fiber (CF), thermoset/CF, and hybrid thermoset/thermoplastic polyurethane (TPU) veil/CF composite. Mechanical screening tests included tension, compression, in-plane shear (IPS), and tensile-tensile fatigue (TTF). Each material was tested at both a baseline (no liquid nitrogen/LN2 cycling) and 100 LN2-cycled conditions to determine the knockdown factor, if any, of each material when exposed to environmental loading effects in a cryotank. Results show minimal effects of the LN2-cycling compared against baseline values. The three materials behaved similarly in tension; however, the thermoplastic/CF had the highest IPS toughness. The hybrid thermoset/TPU/CF composite had the lowest IPS strength, compressive strength, and toughness. LN2-cycling had minimal effects on tensile-tensile fatigue performance of the thermoplastic/CF material. Mechanical data was captured to guide material down selection for future commercially viable hydrogen aircraft design. In its current state, there does not exist a consolidated, publicly available database for CFRP composite material performance data at cryogenic temperatures. The next step in this work is to test the thermoplastic and thermoset CFRP composites, as well as the neat resins, at LH2 relevant temperature (20 K) to capture this crucial material property data. These results are essential to inform cryotank design and modeling efforts. The process to start this next round of testing has begun. Planned mechanical tests include toughness (single-edge notched beam), tension (unidirectional and quasi-isotropic), thermal expansion, and thermal conductivity. Some tests will also be conducted at an intermediate temperature of 111 K relevant to liquid natural gas (LNG), another attractive fuel choice. The ultimate goal is to manufacture a sub-scale cryotank part that can pass relevant burst, fatigue, permeation, and thermal cycling tests. This work is a part of NASA’s Commercially viable Hydrogen Aircraft for Robust Growth in Efficiency (CHARGE) Project under the larger NASA Subsonic Vehicle Technologies and Tools (SVTT) Project.

composites↗

NASA NTRS2000

Composite fastener for use in high temperature environments

A fastener includes a composite body and a metal coupling attached to the body. The metal coupling includes an attachment structure to connect the fastener to an external structure. An assembly of components includes a first metallic component having a first coefficient of thermal expansion, a second non-metallic component having a second coefficient of thermal expansion different from the first thermal expansion and having a groove that receives a fastener that extends between the groove and the second component, the fastener slidably engaging the groove to accommodate relative expansion between the components.

Miller, Robert J.↗

NASA NTRS2018

Advanced Protective Coatings for Gr-Based Nuclear Propulsion Fuel Elements

A protective coating for a graphite (Gr) containing fuel element used in a nuclear thermal propulsion system includes a first layer that is configured to resist hot hydrogen attacks. The first layer has a coefficient of thermal expansion that is higher than a coefficient of thermal expansion of the Gr containing substrate. The coating also includes a plurality of second layers located between the first layer and the substrate. The second layers are configured to mitigate the differences in coefficients of thermal expansion between the first layer and the substrate to minimize debonding and exposure of the substrate to hydrogen attack. Preferably, the protective coating can comprise an outermost first layer including zirconium carbide (ZrC), a second layer including niobium (Nb), a third layer including molybdenum (Mo), and a fourth layer including molybdenum carbide (Mo.sub.2C) located adjacent to the substrate.

Raj, Sai V.↗

NASA NTRS1990

Method of fabricating composite structures

A method of fabricating structures formed from composite materials by positioning the structure about a high coefficient of thermal expansion material, wrapping a graphite fiber overwrap about the structure, and thereafter heating the assembly to expand the high coefficient of thermal expansion material to forcibly compress the composite structure against the restraint provided by the graphite overwrap. The high coefficient of thermal expansion material is disposed about a mandrel with a release system therebetween, and with a release system between the material having the high coefficient of thermal expansion and the composite material, and between the graphite fibers and the composite structure. The heating may occur by inducing heat into the assembly by a magnetic field created by coils disposed about the assembly through which alternating current flows. The method permits structures to be formed without the use of an autoclave.

Sigur, W. A.↗

NASA NTRS1992

Method of fabricating composite structures

Sigur, Wanda A.↗

NASA NTRS2015

Hybrid Exhaust Component

An exhaust includes a wall that has a first composite material having a first coefficient of thermal expansion and a second composite material having a second coefficient of the thermal expansion that is less than the first coefficient of thermal expansion.

Pelletier, Gerard D.↗

NASA NTRS1988

Metal/Ceramic Bond Coatings For High Temperatures

Reduced-thermal-expansion bond coatings developed for use at high temperatures in thermal-barrier-coating systems. Bond coatings composed of low-pressure-plasma-sprayed metallic matrices dispersed with low-thermal-expansion high-bulk-modulus ceramic particles. New coatings and application lower thermal-expansion-mismatch strain while maintaining integrity at high temperatures.

Miller, Robert A.↗

NASA NTRS1983

Dimensional stability of Superinvar

Attention is called to new thermal expansion measurements on temporally stable Superinvar. The measurements indicate that its thermal expansivity vs temperature is more desirable than has been suggested by earlier measurements (Berthold et al., 1976). It is pointed out that at approximately 47 C, the thermal expansion coefficient is zero; however, the coefficient increases rapidly as the temperature departs from 47 C. A second zero-crossing of the expansivity is found at -21 C. The magnitude of negative expansivity between -21 C and 45 C remains bounded and small. No disruptive and reversible phase transition is found at temperatures down to -26 C.

Connors, C.↗