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At least 325 records · Page 18

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NASA NTRS1994

High temperature polymer dielectric film-wire insulation

The highlights of the program are outlined including two major accomplishments. TRW identified and demonstrated the potential of two aromatic/heterocyclic polymers to have an outstanding and superior combination of electrical, thermal, and chemical resistance properties versus state-of-the-art Kapton for spacecraft and/or aircraft dielectric insulation applications. (Supporting data is provided in tables.) Feasibility was demonstrated for supporting/enabling technologies such as ceramic coatings, continuous film casting, and conductor wire wrapping, which are designed to accelerate qualification and deployment of the new wire insulation materials for USAF systems applications during the mid- to late-1990's.

Nairus, John G.↗

NASA NTRS2009

Recent Developments in Ultra High Temperature Ceramics at NASA Ames

NASA Ames is pursuing a variety of approaches to modify and control the microstructure of UHTCs with the goal of improving fracture toughness, oxidation resistance and controlling thermal conductivity. The overall goal is to produce materials that can perform reliably as sharp leading edges or nose tips in hypersonic reentry vehicles. Processing approaches include the use of preceramic polymers as the SiC source (as opposed to powder techniques), the addition of third phases to control grain growth and oxidation, and the use of processing techniques to produce high purity materials. Both hot pressing and field assisted sintering have been used to make UHTCs. Characterization of the mechanical and thermal properties of these materials is ongoing, as is arcjet testing to evaluate performance under simulated reentry conditions. The preceramic polymer approach has generated a microstructure in which elongated SiC grains grow in the form of an in-situ composite. This microstructure has the advantage of improving fracture toughness while potentially improving oxidation resistance by reducing the amount and interconnectivity of SiC in the material. Addition of third phases, such as Ir, results in a very fine-grained microstructure, even in hot-pressed samples. The results of processing and compositional changes on microstructure and properties are reported, along with selected arcjet results.

Johnson, Sylvia M.↗

NASA NTRS1975

Investigation of discrete component chip mounting technology for hybrid microelectronic circuits

The use of polymer adhesives for high reliability microcircuit applications is a radical deviation from past practices in electronic packaging. Bonding studies were performed using two gold-filled conductive adhesives, 10/90 tin/lead solder and Indalloy no. 7 solder. Various types of discrete components were mounted on ceramic substrates using both thick-film and thin-film metallization. Electrical and mechanical testing were performed on the samples before and after environmental exposure to MIL-STD-883 screening tests.

Caruso, S. V.↗

NASA NTRS2002

Rapid Prototyping of Continuous Fiber Reinforced Ceramic Matrix Composites

For ceramics to be used as structural components in high temperature applications, their fracture toughness is improved by embedding continuous ceramic fibers. Ceramic matrix composite (CMC) materials allow increasing the overall operating temperature, raising the temperature safety margins, avoiding the need for cooling, and improving the damping capacity, while reducing the weight at the same time. They also need to be reliable and available in large quantities as well. In this paper, an innovative rapid prototyping technique to fabricate continuous fiber reinforced ceramic matrix composites is described. The process is simple, robust and will be widely applicable to a number of high temperature material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The results of mechanical properties and microstructural characterization are presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts at an order of magnitude lower cost than current CVI and PIP processes.

Vaidyanathan, R.↗

NASA NTRS2003

Rapid Prototyping of Continuous Fiber Reinforced Ceramic Matrix Composites

Vaidyanathan, R.↗

NASA NTRS2011

PICA Variants with Improved Mechanical Properties

Phenolic Impregnated Carbon Ablator (PICA) is a member of the family of Lightweight Ceramic Ablators (LCAs) and was developed at NASA Ames Research Center as a thermal protection system (TPS) material for the Stardust mission probe that entered the Earth s atmosphere faster than any other probe or vehicle to date. PICA, carbon fiberform base and phenolic polymer, shows excellent thermal insulative properties at heating rates from about 250 W/sq cm to 1000 W/sq cm. The density of standard PICA - 0.26 g/cu cm to 0.28 g/cu cm - can be changed by changing the concentration of the phenolic resin. By adding polymers to the phenolic resin before curing it is possible to significantly improve the mechanical properties of PICA without significantly increasing the density.

Thornton, Jeremy↗

NASA NTRS1994

Actuator Feasibility Study for Active Control of Ducted Axial Fan Noise

A feasibility study was performed to investigate actuator technology which is relevant for a particular application of active noise control for gas turbine stator vanes. This study investigated many different classes of actuators and ranked them on the order of applicability. The most difficult requirements the actuators had to meet were high frequency response, large amplitude deflections, and a thin profile. Based on this assessment, piezoelectric type actuators were selected as the most appropriate actuator class. Specifically, Rainbows (a new class of high performance piezoelectric actuators), and unimorphs (a ceramic/metal composite) appeared best suited to the requirements. A benchtop experimental study was conducted. The performance of a variety of different actuators was examined, including high polymer films, flextensional actuators, miniature speakers, unimorphs, and Rainbows. The displacement/frequency response and phase characteristics of the actuators were measured. Physical limitations of actuator operation were also examined. This report includes the first known, high displacement, dynamic data obtained for Rainbow actuators. A new "hard" ceramic Rainbow actuator which does not appear to be limited in operation by self heating as "soft" ceramic Rainbows was designed, constructed and tested. The study concludes that a suitable actuator for active noise control in gas turbine engines can be achieved with state of the art materials and processing.

Simonich, John C.↗

NASA NTRS1991

A comparison of fiber effects on polymer matrix composite oxidation

A number of thermo-oxidative stability studies addressing the effects of fiber reinforcement on composite thermal stability and influence of geometry on the results of aging studies were performed at NASA-Lewis. The information presented herein, a compilation of some results from these studies, shows the influence of the reinforcement fibers on the oxidative degradation of various PMR-15 composites. Reinforcement of graphite and ceramics were studied and three composite oxidation mechanisms were observed. One was a dominant attack of the reinforcement fiber, the second was the aggressive oxidation of the matrix material, and the third was interfacial degradation.

Bowles, Kenneth J.↗

NASA NTRS2019

A thin-ply composite with embedded metallic mesh for a spaceborne antenna

This study presents a technique developed for embedding a conductive metallic mesh into the layup of thin-ply carbon fiber reinforced polymer (CFRP) composite material. Thermal cycling and subsequent mechanical testing on fabricated samples has been used to evaluate thin-ply composites as a crack mitigation technique. Furthermore, the construction of thin-ply CFRP composite tubes has been demonstrated for both straight segments and curved segments utilizing a novel sacrificial ceramic molding method. These prototypes represent the building blocks for a 1 m scale radiating element and are the first test articles for the evaluation of thin-ply CFRP composites with an embedded metallic mesh. The successful implementation of a CFRP composite with an embedded metallic mesh would enable ultra-lightweight conductive structures for future applications, such as antennas, requiring survival in cryogenic temperatures.

Sakovsky, Maria↗

NASA NTRS2012

Nanostructured Solar Irradiation Control Materials for Solar Energy Conversion

Tailoring the solar absorptivity (alpha(sub s)) and thermal emissivity (epsilon(sub T)) of materials constitutes an innovative approach to solar energy control and energy conversion. Numerous ceramic and metallic materials are currently available for solar absorbance/thermal emittance control. However, conventional metal oxides and dielectric/metal/dielectric multi-coatings have limited utility due to residual shear stresses resulting from the different coefficient of thermal expansion of the layered materials. This research presents an alternate approach based on nanoparticle-filled polymers to afford mechanically durable solar-absorptive and thermally-emissive polymer nanocomposites. The alpha(sub s) and epsilon(sub T) were measured with various nano inclusions, such as carbon nanophase particles (CNPs), at different concentrations. Research has shown that adding only 5 wt% CNPs increased the alpha(sub s) and epsilon(sub T) by a factor of about 47 and 2, respectively, compared to the pristine polymer. The effect of solar irradiation control of the nanocomposite on solar energy conversion was studied. The solar irradiation control coatings increased the power generation of solar thermoelectric cells by more than 380% compared to that of a control power cell without solar irradiation control coatings.

Kang, Jinho↗

NASA NTRS1986

Effect of loading rate on dynamic fracture of reaction bonded silicon nitride

Wedge-loaded, modified tapered double cantilever beam (WL-MTDCB) specimens under impact loading were used to determine the room temperature dynamic fracture response of reaction bonded silicon nitride (RBSN). The crack extension history, with the exception of the terminal phase, was similar to that obtained under static loading. Like its static counterpart, a distinct crack acceleration phase, which was not observed in dynamic fracture of steel and brittle polymers, was noted. Unlike its static counterpart, the crack continued to propagate at nearly its terminal velocity under a low dynamic stress intensity factor during the terminal phase of crack propagation. These and previously obtained results for glass and RBSN show that dynamic crack arrest under a positive dynamic stress intensity factor is unlikely in static and impact loaded structural ceramics.

Liaw, B. M.↗

NASA NTRS2022

Fabrication and Testing of a Novel Ceramic-Based Additively Manufactured Humidity Sensor

A material capable of detecting minute changes in ambient humidity via a change in its electrical properties is critical to enabling the success of vapor-sensitive components on Earth and abroad. Manufacturing of these hydrophilic materials currently follows an extensive process of heat treating focused on removing the solvent and organic vehicle. This research aims to reduce the complexity of manufacturing these novel sensors by eliminating the high-temperature (>850 °C) processing stages. A method based on printing a polymer embedded with hydrophilic nanoparticles is accomplished through selected additively manufactured methods. This research branches into the elimination of physical spare parts with the ability to print highly sensitive in-situ sensors, reducing the environmental footprint in space-critical environments like the International Space Station (ISS).

sensor↗

NASA NTRS2012

Demonstration of Minimally Machined Honeycomb Silicon Carbide Mirrors

Honeycomb silicon carbide composite mirrors are made from a carbon fiber preform that is molded into a honeycomb shape using a rigid mold. The carbon fiber honeycomb is densified by using polymer infiltration pyrolysis, or through a reaction with liquid silicon. A chemical vapor deposit, or chemical vapor composite (CVC), process is used to deposit a polishable silicon or silicon carbide cladding on the honeycomb structure. Alternatively, the cladding may be replaced by a freestanding, replicated CVC SiC facesheet that is bonded to the honeycomb. The resulting carbon fiber-reinforced silicon carbide honeycomb structure is a ceramic matrix composite material with high stiffness and mechanical strength, high thermal conductivity, and low CTE (coefficient of thermal expansion). This innovation enables rapid, inexpensive manufacturing. The web thickness of the new material is less than 1 millimeter, and core geometries tailored. These parameters are based on precursor carbon-carbon honeycomb material made and patented by Ultracor. It is estimated at the time of this reporting that the HoneySiC(Trademark) will have a net production cost on the order of $38,000 per square meter. This includes an Ultracor raw material cost of about $97,000 per square meter, and a Trex silicon carbide deposition cost of $27,000 per square meter. Even at double this price, HoneySiC would beat NASA's goal of $100,000 per square meter. Cost savings are estimated to be 40 to 100 times that of current mirror technologies. The organic, rich prepreg material has a density of 56 kilograms per cubic meter. A charred carbon-carbon panel (volatile organics burnt off) has a density of 270 kilograms per cubic meter. Therefore, it is estimated that a HoneySiC panel would have a density of no more than 900 kilograms per cubic meter, which is about half that of beryllium and about onethird the density of bulk silicon carbide. It is also estimated that larger mirrors could be produced in a matter of weeks. Each cell is completely uniform, maintaining the shape of the inserted mandrel. Furthermore, the layup creates pressure that insures node bond strength. Each node is a composite laminate using only the inherent resin system to form the bond. This contrasts starkly with the other known method of producing composite honeycomb, in which individual corrugations are formed, cured, and then bonded together in a secondary process. By varying the size of the mandrels within the layup, varying degrees of density can be achieved. Typical sizes are 3/8 and 3/16 in. (approximately 10 and 5 millimeters). Cell sizes up to 1 in. (approximately 25 millimeters) have been manufactured. Similarly, the shape of the core can be altered for a flexible honeycomb structure.

Goodman, William↗

NASA NTRS1994

Copper-containing ceramic precursor synthesis: Solid-state transformations and materials technology

Three copper systems with relevance to materials technology are discussed. In the first, a CuS precursor, Cu4S1O (4-methylpyridine)(sub 4)- (4-MePy), was prepared by three routes: reaction of Cu2S, reaction of CuBr-SMe2, and oxidation of copper powder with excess sulfur in 4-methylpyridine by sulfur. In the second, copper powder was found to react with excess thiourea (H2NC(S)NH2) in 4-methylpyridine to produce thiocyanate (NCS(-)) complexes. Three isolated and characterized compounds are: Cu(NCS)(4-MePy)(sub 2), a polymer, (4-MePy-H)(Cu(NCS)(sub 3)(4-MePy)(sub 2)), a salt, and t-Cu(NCS)(sub 2)(4-MePy)(sub 4). Finally, an attempt to produce a mixed-metal sulfide precursor of Cu and Ga in N-methylimidazole (N-MeIm) resulted in the synthesis of a Cu-containing polymer, Cu(SO4)(N-MeIm). The structures are presented; the chemistry will be briefly discussed in the context of preparation and processing of copper-containing materials for aerospace applications.

Hepp, Aloysius F.↗

NASA NTRS1992

Effect of fiber reinforcement on thermo-oxidative stability and mechanical properties of polymer matrix composites

A number of studies have investigated the thermooxidative behavior of polymer matrix composites. Two significant observations have been made from these research efforts: (1) fiber reinforcement has a significant effect on composite thermal stability; and (2) geometric effects must be considered when evaluating thermal aging data. The polyimide PMR-15 was the matrix material used in these studies. The control composite material was reinforced with Celion 6000 graphite fiber. T-4OR graphite fibers, along with some very stable ceramic fibers were selected as reinforcing fibers because of their high thermal stability. The ceramic fibers were Nicalon (silicon carbide) and Nextel 312 (alumina-silica-boron oxide). The mechanical properties of the two graphite fiber composites were significantly different, probably owing to variations in interfacial bonding between the fibers and the polyimide matrix. Three oxidation mechanisms were observed: (1) the preferential oxidation of the Celion 6000 fiber ends at cut surfaces, leaving a surface of matrix material with holes where the fiber ends were originally situated; (2) preferential oxidation of the composite matrix; and (3) interfacial degradation by oxidation. The latter two mechanisms were also observed on fiber end cut surfaces. The fiber and interface attacks appeared to initiate interfiber cracking along these surfaces.

Bowles, K. J.↗

NASA NTRS2000

NDE for Material Characterization in Aeronautic and Space Applications

This paper describes selected nondestructive evaluation (NDE) approaches that were developed or tailored at the NASA Glenn Research Center for characterizing advanced material systems. The emphasis is on high-temperature aerospace propulsion applications. The material systems include monolithic ceramics, superalloys, and high temperature composites. In the aeronautic area, the highlights are cooled ceramic plate structures for turbine applications, F-TiAl blade materials for low-pressure turbines, thermoelastic stress analysis (TSA) for residual stress measurements in titanium based and nickel based engine materials, and acousto ultrasonics (AU) for creep damage assessment in nickel-based alloys. In the space area, examples consist of cooled carbon-carbon composites for gas generator combustors and flywheel rotors composed of carbon fiber reinforced polymer matrix composites for energy storage on the international space station (ISS). The role of NDE in solving manufacturing problems, the effect of defects on structural behavior, and the use of NDE-based finite element modeling are discussed. NDE technology needs for improved microelectronic and mechanical systems as well as health monitoring of micro-materials and components are briefly discussed.

Baaklini, George Y.↗

NASA NTRS2004

Issues for Ultra-High Temperature Composites

Ultra-high temperature ceramics (UHTC) have performed unreliably due to material flaws and attachment design. These deficiencies are brought to the fore by the low fracture toughness and thermal shock resistance of UHTC. In addition, poor oxidation resistance is a limitation on UHTC applicability to reu'sable launch vehicles. We have been addressing these deficiencies by investigating methods for improving the oxidation resistance of UHTC and by evaluating the performance of an early polymer precursor derived UHTC composite. Processing, mechanical property, and furnace oxidation and oxyacetylene torch exposure results are reported. From these results guidelines for UHTC composite architecture, constituents, and processing are developed.

Levine, Stanley R.↗

NASA NTRS2001

Nondestructive Evaluation Approaches Developed for Material Characterization in Aeronautics and Space Applications

At the NASA Glenn Research Center, nondestructive evaluation (NDE) approaches were developed or tailored for characterizing advanced material systems. The emphasis was on high-temperature aerospace propulsion applications. The material systems included monolithic ceramics, superalloys, and high-temperature composites. In the aeronautics area, the major applications were cooled ceramic plate structures for turbine applications, gamma-TiAl blade materials for low-pressure turbines, thermoelastic stress analysis for residual stress measurements in titanium-based and nickel-based engine materials, and acousto-ultrasonics for creep damage assessment in nickel-based alloys. In the space area, applications consisted of cooled carbon-carbon composites for gas generator combustors and flywheel rotors composed of carbon-fiber-reinforced polymer matrix composites for energy storage on the International Space Station.

Baaklini, George Y.↗