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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Interlaminar R-Curve Effects in Thermoplastic Composites: Experiments and Model Correlations

The interlaminar fracture behavior of thermoplastic composites under Mode-I and Mode-II static loading is investigated in this research. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK)†. Characterization experiments were conducted to measure the load-displacement response, peak load, and propagation of delamination from a pre-implanted Kapton® insert. The Mode-I response was characterized using a double cantilever beam (DCB) test according to the ASTM D5528-22 standard. It was observed that the propagation exhibited significant resistance to delamination growth, i.e., an R-Curve effect. The test data indicated that the steady-state fracture toughness, G SS I , was approximately twice the mean initiation fracture toughness, G Ic . The Mode-II response of an end notch flexure (ENF) specimen tested according to the ASTM D7905-19 standard exhibited an unexpected stable behavior upon attaining peak load. Prior to attaining peak load, the Mode-II response exhibited some non-linearity, which may be attributed to nonlinear bulk material response, e.g., hyper-elasticity, viscoelasticity, plasticity, etc., and potentially friction at the load/support rollers and R-Curve effects. Finite element models based on the Cohesive Zone Method (CZM) and the Virtual Crack Closure Technique (VCCT) were used to predict the DCB and ENF specimen responses. DCB analysis results obtained using G SS I predicted propagation consistent with experimental data. However, results obtained with the as characterized G Ic were inaccurate in predicting delamination growth onset and peak load. ENF analysis results obtained with the as-characterized Mode-II fracture toughness, G IIc , were inaccurate in predicting the peak load and propagation. Hence, R-Curve effects were included in both DCB and ENF simulations, which enabled improved predictions. The experimentally determined Mode-I R-Curve was used for the DCB simulations, whereas an R-Curve was derived for Mode-II assuming that the change in compliance of the specimen was associated with crack growth only.

Prabhakar Rao↗
NASA NTRSDate not supplied

Thermoplastic Composite Lunar Tower Truss Structure: Design Development and Verification Plans

The National Aeronautics and Space Administration (NASA) Space Technology and Mission Directorate (STMD) is advancing thermoplastic composite (TPC) technologies for exploration missions. The Technology Development for Exploration Applications (TDEA) project goals are to develop and mature TPC materials, designs, analyses tools and techniques, and mature manufacturing processes. This includes development of manufacturing and joining approaches relevant to space environments. To these ends TDEA endeavors toward demonstrating a TPC truss structure for a lunar tower configuration. The design, predicated on robotic assembly, uses open section truss elements fused to a joint splice plate, without a structural adhesive. This presentation details the TDEA lunar truss structure design development approach including design heritage, the requirements established, the mechanical design and analyses, and thermal analyses demonstrating structural requirements conformance, as well as planned building block verification efforts either underway or planned. The mechanical analyses show the most severe environment is a moon-quake the truss dynamic responses. The thermal analyses show the extreme cold for on-orbit welding, the window for less severe on-orbit welding, as well as the large thermal gradients on the truss. The building block approach shown includes ultrasonic welding and lap shear coupon testing on various truss element thicknesses and layups. Knockdown factor determinations due to lunar dust contamination (simulated) and effects of welding in a vacuum are presented. The most highly loaded truss joint configuration sub-element verification test matrix is outlined. Lastly, plans to build, inspect, and test a 2-bay truss representative unit cell that is 1.5 meters by 1.5 meters by 3.0 meters tall are detailed.

Lunar Tower↗
NASA NTRSDate not supplied

Modeling of Response of Thermoplastic Composites Under High Energy Impact

This work investigates the response of thermoplastic composites under impact loading. Panels fabricated with the material system under consideration – carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK) – were subject to impact with an Aluminum projectile, at low and high velocities. At lower velocities, the projectile rebounded from the panel after impact and caused damage e.g. delaminations. Finite element models were developed to model this test using LS-DYNA®, with material model MAT299, a continuum damage model based on the LaRC04 criteria, to capture the dynamic response and damage modes in the T700/LMPAEK panels. Interlaminar delaminations were modeled using the cohesive contact formulation available within LS-DYNA. Previous work by the authors showed that delaminations were consistently underpredicted in size, relative to the test. It was surmised that this was due to effects of strain rate on intralaminar and interlaminar response of the T700/LMPAEK material system. Therefore, the current work is focused on incorporating strain rate effects in modeling the interlaminar response. Rate dependence was incorporated using ‘one-way tie-break contact’ in LS-DYNA, wherein, the Mode-II fracture toughness of the LMPAEK resin, G IIc , was assumed to be an exponential function of the strain rate. In particular, G IIc , was modeled to exponentially decrease at higher strain rates. Models with this form of rate dependence favorably correlated with experimental data regarding delamination extent and rebound velocity, relative to prior models without strain rate effects.

Composite Materials↗
NASA NTRS2024

Impact Response of Thermoplastic Composites – Experiments and Modeling

This study investigates the impact response of thermoplastic composite materials. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK reinforced with T700G (T700/LMPAEK ). Several High Energy Dynamic Impact (HEDI) tests were performed wherein an aluminum projectile impacted T700/LMPAEK panels at different velocities. In the impact experiment studied herein, the projectile impacted the T700/LMAPEK panel at 73.2 m/s and rebounded. The ensuing damage to the T700/LMPAEK panel was characterized via ultrasonic C-scans, visualizing damage modes including matrix cracking and delaminations. Since the projectile rebounded, the fiber breakage damage mode was not evident. The impact event was modeled using a combined continuum damage mechanics and cohesive zone analysis approach with the commercially available hydrocode LS-DYNA®. The dynamic deformation and damage of the continuum, i.e., the plies in the T700/LMPAEK laminate, was modeled using a Deformation Gradient Decomposition (DGD) material model, i.e., MAT299 available within LS-DYNA. The interlaminar regions were treated as zero-thickness cohesive zones, wherein the dynamic delamination mechanics was modeled using a traction-separation formulation. Mixed-mode delamination growth was captured using the Benzegaggh-Kenane (B-K) traction-separation interpolation law. Strain-rate sensitivity of interlaminar fracture toughness was included using approximations based on published literature. The outcomes of the modeling effort are discussed herein which demonstrate good correlations with test data regarding panel deflection, panel-projectile interactions, damage modes and damage extent.

Impact modeling↗
NASA NTRSDate not supplied

In-Situ Scanning Electron Microscope Experiments for Microscale Mechanical Testing and Validated Modeling of Fiber Reinforced Thermoplastics

A novel, in-situ, scanning electron microscope (SEM) mechanical testing capability for materials at the microscale which provides experimental validation to a machine learning (ML) toolset for full-field validation of physics-based micromechanics models is being developed by researchers at NASA Glenn Research Center. These are enabling technologies for the integration of multiscale digital twins for materials into system level models which will result in the improved performance, material discovery, reduced production cost and time, rapid characterization, and prognostic structural health monitoring (SHM) for materials and structures for extreme environments in support of NASA space exploration missions. In order to bridge the material structure-to-system gap for digital twins, physics-based models must be experimentally validated at multiple length scales. Seminal microscale experiments, conducted at the Air Force Research Laboratory (AFRL), were limited to transverse compression of single-layer, unidirectional thermoset polymer matrix composite (PMC) micropillar specimens [1]. The early phases of the current project followed those initial results and setup to reproduce the compression testing of PMC material on the custom-built piezoelectric actuated micromechanical testing rig built by MicroTesting Solutions LLC. In this work, samples of thermoplastic PMC material were first machined into 3 mm cubes, and then further machining and final milling was done using a Focused Ion Beam (FIB). The initial experiment was done on a pillar roughly 20 µm x 20 µm x 40 µm tall. Additional pillars were milled with final sizes ranging from 20 µm x 20 µm x 40 µm tall to 40 µm x 40 µm x 65 µm tall. A speckle pattern for in-situ full-field measurements using Digital Image Correlation (DIC) was applied with platinum, which was coated on the surface, and then the FIB was used to mill away some of the coating to produce an irregular pattern of Pt on the pillar surface. The samples were loaded into the custom testing rig and placed into the SEM and loaded under compression until failure. Images were collected in the SEM during testing. Post-processing of the images was conducted using DIC to obtain full-field displacement and strain measurements elucidating the role of the matrix as well as fiber-fiber interaction at the microscale within the composite subjected to compression loading well into the non-linear regime of the material. Moreover, the evolution of fiber-matrix debonding and matrix cracking is observed in-situ at the microscale. This data, along with images segmented with a newly developed ML toolset [2], was used to create and validate physics-based micromechanics models. An image of the failed micropillar is shown in Figure 1. The techniques developed in the initial compression experiment was tailored to the validation needs of the models and expanded to include different sized samples as well as possibly tension and fatigue.

Laura Wilson↗
DOE OSTI2022

Renewable low viscosity polyester-polyols for biodegradable thermoplastic polyurethanes

In the transition to renewably sourced, biodegradable polymers, the preparation of low viscosity polyester-polyols has posed a challenge for renewable polyurethane (PU) development. Low viscosity polyols not only reduce the requirement for high process temperatures but also decrease manufacturing time. In our efforts to incorporate increasing ratios of bio-based monomers into renewable PUs, we mixed diacids such as even carbon sebacic acid and odd carbon azelaic acid along with a renewable diol. This provided library of 2000 g/mol molecular weight polyester-polyols, and structures were established by 1 H and 13 C NMR analysis. The prepared polyester-polyols offered lower viscosity and enable lower fabrication temperatures to make TPUs, and their structure and material metrics were evaluated. The formation of TPUs is ascertained from FTIR and NMR analysis. The final TPUs displayed good physical and mechanical properties. Further, these TPUs exhibited T g in the range of -56.5 to -39.7°C, corresponding to TPU soft block structure, and T m between 98.3 and 105.1°C originating from the hard segment. Prepared TPUs exhibit excellent biodegradation under compost environmental conditions. These TPUs showed up to 57% decrease in molecular weight by GPC analysis after 9 weeks of biodegradation, and respirometer analysis displayed up to 97% biodegradation over 120 days.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRSDate not supplied

High Energy Dynamic Impact Testing of APC AS4/PEKK-FC and TC1225 LMPAEK T700G Thermoplastic Composite Materials

High energy dynamic impact tests were conducted on Solvay APC AS4D/PEKK-FC and Toray TC1225 LMPAEK T700Gthermoplastic composite laminates. The primary objective was to provide data for evaluation of computational composite impact models. Empirical results indicate an approximately 50% increase in penetration threshold velocity and over 100% increase in penetration energy threshold for the TC1225 LMPAEK T700Gcomposite compared to the APC AS4D/PEKK-FC composite. The velocity required to produce NDE-detectable delamination in the TC1225 LMPAEK T700Gcomposite was roughly twice that for the APC AS4D/PEKK-FC composite. Comparison of the normalized energy absorption showed similar results for the APC AS4D/PEKK-FC system compared to a previously studied IM7/8552 composite material. The TC1225 LMPAEK T700Gsystem absorbed approximately twice that of the other two systems when normalized by areal weight.

Impact↗
DOE OSTI2023

Effect of Molecular Weight on the Morphology of a Polymer Semiconductor–Thermoplastic Elastomer Blend

Abstract Polymer semiconductors (PSCs) are essential active materials in mechanically stretchable electronic devices. However, many exhibit low fracture strain due to their rigid chain conformation and the presence of large crystalline domains. Here, a PSC/elastomer blend, poly[((2,6‐bis(thiophen‐2‐yl)‐3,7‐bis(9‐octylnonadecyl)thieno[3,2‐b]thieno[2′,3′:4,5]thieno[2,3‐d]thiophene)‐5,5′‐diyl)(2,5‐bis(8‐octyloctadecyl)‐3,6‐di(thiophen‐2‐yl)pyrrolo[3,4‐c]pyrrole‐1,4‐dione)‐5,5′‐diyl]] (P2TDPP2TFT4) and polystyrene‐ block ‐poly(ethylene‐ran‐butylene)‐ block ‐polystyrene (SEBS) are systematically investigated. Specifically, the effects of molecular weight of both SEBS and P2TDPP2TFT4 on the resulting blend morphology, mechanical, and electrical properties are explored. In addition to commonly used techniques, atomic force microscopy‐based nanomechanical images are used to provide additional insights into the blend film morphology. Opposing trends in SEBS‐induced aggregation are observed for the different P2TDPP2TFT4 molecular weights upon increasing the SEBS molecular weight from 87 to 276 kDa. Furthermore, these trends are seen in device performance trends for both molecular weights of P2TDPP2TFT4. SEBS molecular weight also has a substantial influence on the mesoscale phase separation. Strain at fracture increases dramatically upon blending, reaching a maximum value of 640% ± 20% in the blended films measured with film‐on‐water method. These results highlight the importance of molecular weight for electronic devices. In addition, this study provides valuable insights into appropriate polymer selections for stretchable semiconducting thin films that simultaneously possess excellent mechanical and electrical properties.

36 MATERIALS SCIENCE↗