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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Potential for on-orbit manufacture of large space structures using the pultrusion process

On-orbit manufacture of lightweight, high-strength, advanced-composite structures using the pultrusion process is proposed. This process is adaptable to a zero-gravity environment by using preimpregnated graphite-fiber reinforcement systems. The reinforcement material is preimpregnated with a high-performance thermoplastic resin at a ground station, is coiled on spools for compact storage, and is transported into Earth orbit. A pultrusion machine is installed in the Shuttle cargo bay from which very long lengths of the desired structure is fabricated on-orbit. Potential structural profiles include rods, angles, channels, hat sections, tubes, honeycomb-cored panels, and T, H, and I beams. A potential pultrudable thermoplastic/graphite composite material is presented as a model for determining the effect on Earth-to-orbit package density of an on-orbit manufacture, the package density is increased by 132 percent, and payload volume requirement is decreased by 56.3 percent. The fabrication method has the potential for on-orbit manufacture of structural members for space platforms, large space antennas, and long tethers.

Wilson, Maywood L.↗
NASA NTRS1988

Status of Gr/glass composites technology at UTOS

The TSC (Thermally Stable Composite) refers to a family of graphite reinforced glass matrix composite materials developed by UTOS. This fiber matrix combination exhibits low coefficients of thermal expansion (CTE), exceptional dimensional stability, high specific strength and stiffness, adequate fracture toughness, and space environment compatibility. The dimensional stability of a TSC mirror structure was experimentally characterized at the Steward Observatory. Preliminary results indicate that TSC is significantly more thermally stable than most current structural composite materials. In addition, the use of lower CTE glass matrix materials, such as 96 percent silica glass, have the potential for producing graphite/glass panels with expansion rates and stability comparable to that of fused silica.

Mayor, Ramon A.↗
NASA NTRS1990

Graphite fluoride fibers and their applications in the space industry

Characterization and potential space applications of graphite fluoride fibers from commercially available graphitized carbon fibers are presented. Graphite fluoride fibers with fluorine to carbon ratios of 0.65 and 0.68 were found to have electrical resistivity values of 10(exp 4) and 10(exp 11) Ohms-cm, respectively, and thermal conductivity values of 24 and 5 W/m-K, respectively. At this fluorine content range, the fibers have tensile strength of 0.25 + or - 0.10 GPa (36 + or - 14 ksi), Young's modulus of 170 + or - 30 GPa (25 + or - 5 Msi). The coefficient of thermal expansion value of a sample with fluorine to carbon ratio of 0.61 was found to be 7 ppm/C. These properties change and approach the graphite value as the fluorine content approach 0. Electrically insulative graphite fluoride fiber is at least five times more thermally conductive than fiberglass. Therefore, it can be used as a heat sinking printed circuit board material for low temperature, long life power electronics in spacecraft. Also, partially fluorinated fiber with tailor-made physical properties to meet the requirements of certain engineering design can be produced. For example, a partially fluorinated fiber could have a predetermined CTE value in -1.5 to 7 ppm/C range and would be suitable for use in solar concentrators in solar dynamic power systems. It could also have a predetermined electrical resistivity value suitable for use as a low observable material. Experimental data indicate that slightly fluorinated graphite fibers are more durable in the atomic oxygen environment than pristine graphite. Therefore, fluorination of graphite used in the construction of spacecraft that would be exposed to the low Earth orbit atomic oxygen may protect defect sites in atomic oxygen protective coatings and therefore decrease the rate of degradation of graphite.

Hung, Ching-Chen↗
NASA NTRS1991

Near-Earth asteroids: Metals occurrence, extraction, and fabrication

Near-earth asteroids occur in three principle types of orbits: Amor, Apollo, and Aten. Amor asteroids make relatively close (within 0.3 AU) approaches to the earth's orbit, but do not actually overlap it. Apollo asteroids spend most of their time outside the earth's orbital path, but at some point of close approach to the sun, they cross the orbit of the earth. Aten asteroids are those whose orbits remain inside the earth's path for the majority of their time, with semi-major axes less than 0.1 AU. Near-earth orbit asteroids include: stones, stony-irons, irons, carbonaceous, and super-carbonaceous. Metals within these asteroids include: iron, nickel, cobalt, the platinum group, aluminum, titanium, and others. Focus is on the extraction of ferrous and platinum group metals from the stony-iron asteroids, and the iron asteroids. Extraction of the metal fraction can be accomplished through the use of tunnel-boring-machines (TBM) in the case of the stony-irons. The metals within the story-iron asteroids occur as dispersed granules, which can be separated from the stony fraction through magnetic and gaseous digestion separation techniques. The metal asteroids are processes by drilling and gaseous digestion or by gaseous digestion alone. Manufacturing of structures, housings, framing networks, pressure vessels, mirrors, and other products is accomplished through the chemical vapor deposition (CVD) of metal coating on advanced composites and on the inside of contour-defining inflatables (CDI). Metal coatings on advanced composites provide: resistance to degradation in the hostile environments of space; superior optical properties; superior heat dissipation; service as wear coatings; and service as evidential coatings. Metal coatings on the inside of CDI produce metal load-bearing products. Fibers such as graphite, kevlar, glass, ceramic, metal, etc., can be incorporated in the metal coatings on the inside of CDI producing metal matrix products which exhibit high strength and resist crack propagation.

Westfall, Richard↗
NASA NTRS1991

Characterization of the dimensional stability of advanced metallic materials using an optical test bench structure

The dimensional stability of low-density high specific-strength metal-matrix composites (including 30 vol pct SiC(p)/SXA 24-T6 Al, 25 vol pct SiC(p)/6061-T6 Al, 40 vol pct graphite P100 fiber/6061 Al, 50 vol pct graphite P100 fiber/6061 Al, and 40 vol pct P100 graphite fiber/AZ91D Mg composites) and an Al-Li-Mg metal alloy was evaluated using a specially designed five-strut optical test bench structure. The structure had 30 thermocouple locations, one retroreflector, one linear interferometer multilayer insulation, and various strip heaters. It was placed in a 10 exp -7 torr capability vacuum chamber with a laser head positioned at a window port, and a laser interferometer system for collecting dimensional change data. It was found that composite materials have greater 40-C temporal dimensional stability than the AL-Li-Mg alloy. Aluminum-based composites demonstrated better 40-C temporal stability than Mg-based composites.

Hsieh, Cheng↗
NASA NTRS1980

Silicone modified resins for graphite fiber laminates

Six silicone modified resins were selected for evaluation in unidirectional filament wound graphite laminates. Neat samples of these resins had 1,000 C char residues of 6-63%. The highest flexural values measured for the laminates were a strength of 1,220 MPa and a modulus of 105 GPa. The highest interlaminar shear strength was 72 MPa.

Frost, L. W.↗
NASA NTRS1982

Effects of fiber/matrix interactions on the properties of graphite/epoxy composites

A state-of-the-art literature review of the interactions between fibers and resin within graphite epoxy composite materials was performed. Emphasis centered on: adhesion theory; wetting characteristics of carbon fiber; load transfer mechanisms; methods to evaluate and measure interfacial bond strengths; environmental influence at the interface; and the effect of the interface/interphase on composite performance, with particular attention to impact toughness. In conjunction with the literature review, efforts were made to design experiments to study the wetting behavior of carbon fibers with various finish variants and their effect on adhesion joint strength. The properties of composites with various fiber finishes were measured and compared to the base-line properties of a control. It was shown that by tailoring the interphase properties, a 30% increase in impact toughness was achieved without loss of mechanical properties at both room and elevated temperatures.

Mcmahon, P. E.↗
NASA NTRS1984

Durability and damage tolerance of Large Composite Primary Aircraft Structure (LCPAS)

Analysis and testing addressing the key technology areas of durability and damage tolerance were completed for wing surface panels. The wing of a fuel-efficient, 200-passenger commercial transport airplane for 1990 delivery was sized using graphite-epoxy materials. Coupons of various layups used in the wing sizing were tested in tension, compression, and spectrum fatigue with typical fastener penetrations. The compression strength after barely visible impact damage was determined from coupon and structural element tests. One current material system and one toughened system were evaluated by coupon testing. The results of the coupon and element tests were used to design three distinctly different compression panels meeting the strength, stiffness, and damage-tolerance requirements of the upper wing panels. These three concepts were tested with various amounts of damage ranging from barely visible impact to through-penetration. The results of this program provide the key technology data required to assess the durability and damage-tolerance capability or advanced composites for use in commercial aircraft wing panel structure.

Mccarty, John E.↗
NASA NTRS2001

Overview of SBIR Phase II Work on Hollow Graphite Fibers

Ultra-Lightweight materials are enabling for producing space based optical components and support structures. Heretofore, innovative designs using existing materials has been the approach to produce lighter-weight optical systems. Graphite fiber reinforced composites, because of their light weight, have been a material of frequent choice to produce space based optical components. Hollow graphite fibers would be lighter than standard solid graphite fibers and, thus, would save weight in optical components. The Phase I SBIR program demonstrated it is possible to produce hollow carbon fibers that have strengths up to 4.2 GPa which are equivalent to commercial fibers, and composites made from the hollow fibers had substantially equivalent composite strengths as commercial fiber composites at a 46% weight savings. The Phase II SBIR program will optimize processing and properties of the hollow carbon fiber and scale-up processing to produce sufficient fiber for fabricating a large ultra-lightweight mirror for delivery to NASA. Information presented here includes an overview of the strength of some preliminary hollow fibers, photographs of those fibers, and a short discussion of future plans.

Stallcup, Michael↗
DOE OSTI2022

DEVELOPMENT OF AN APPROACH FOR DOWNBLENDING AND DISPOSITION OF IRRADIATED GRAPHITE FUEL

The IGR reactor, a pulse-type test experimental reactor, reached full power in 1961. The reactor contains a center axial experimental ampoule that is subjected to a large pulse of neutrons (neutron flux maximum density of 7×1016 n/cm2·s, peak power 10GW) when the reactor is operated. The fuel form for the IGR reactor is graphite cubes and rods impregnated with highly enriched (90%) uranyl-dinitrate (UO2(NO3)2·6H2O). This fuel is eligible for return to Russia for reprocessing under the Russian Research Reactor Fuel Return program. However due to some technical and licensing issues it was decided to immobilize this fuel in Kazakhstan. The disposition approach thus selected for the spent HEU fuel involves down-blending of the fuel followed by cementation. Development of the process for down-blending and subsequent cementation requires a process that satisfies many criteria, including fissile content, compressive strength, permeability, and containment of radioactivity, among others. One key goal of the final product is to meet the criteria for termination of safeguards. This paper will describe the overall challenge associated with disposition of irradiated HEU graphite spent fuel, the identification of the objectives of the disposition process, and the constraints associated with development of the process and the waste form.

Gaines, Kris↗
NASA NTRS1981

An assessment of buffer strips for improving damage tolerance

Graphite/epoxy panels with buffer strips were tested in tension to measure their residual strength with crack-like damage. Panels were made with 45/0/-45/90(2S) and 45/0/450(2S) layups. The buffer strips were parallel to the loading directions. They were made by replacing narrow strips of the 0 deg graphite plies with strips of either 0 deg S-Glass/epoxy or Kevlar-49/epoxy on either a one for one or a two for one basis. In a third case, O deg graphite/epoxy was used as the buffer material and thin, perforated Mylar strips were placed between the 0 deg piles and the cross-plies to weaken the interfaces and thus to isolate the 0 deg plies. Some panels were made with buffer strips of different widths and spacings. The buffer strips arrested the cracks and increased the residual strengths significantly over those plain laminates without buffer strips. A shear-lag type stress analysis correctly predicted the effects of layups, buffer material, buffer strip width and spacing, and the number of plies of buffer material.

Poe, C. C., Jr.↗
DOE OSTI2020

Low-temperature carbonization of polyacrylonitrile/graphene carbon fibers: A combined ReaxFF molecular dynamics and experimental study

Graphene inclusion in a polymer matrix is a promising route to significantly enhance the mechanical properties of low-grade carbon fibers (CFs). Using ReaxFF molecular dynamics simulation, the atomistic mechanism leading to this enhancement is investigated. We demonstrate that the graphene edges along with the nitrogen and oxygen functional groups play a catalytic role and act as seeds to expedite alignment of the all-carbon rings, which are starting sites for the growth of graphitic structures. To examine the role of this proposed mechanism that enhances the graphitic structure of PAN/graphene CFs, we discuss the experimental results wherein the PAN/graphene CFs carbonized at 1250 C demonstrate 91% (from 632 to 1207 MPa) increase in strength and 101% (from 88 to 177 GPa) enhancement in Young’s modulus compared to PAN-based CFs carbonized at 1500 C. In conclusion, these enhanced mechanical properties of low-grade carbon fibers achieved via graphene inclusion at decreased carbonization temperature provide a means to realize both energy savings and cost reduction.

42 ENGINEERING↗
NASA NTRS1975

Design, Fabrication and Test of Multi-Fiber Laminates

Unidirectional and angleply multifiber laminates were tested for improved impact strength and other mechanical properties. The effects of several variables on the mechanical properties of epoxy matrix materials were described. These include fiber type (HMS and AS graphites, glass, and Kevlar 49), ratio of primary to hybridizing fiber and hybrid configuration. It is demonstrated that AS graphite/S glass in an intraply configuration results in the best combination of static and Charpy impact properties as well as superior ballistic impact resistance. Pendulum impact tests which were conducted on thin specimens are shown to produce different ranking of materials than tests conducted on standard thickness Charpy specimens. It is shown that the thin specimen results are in better agreement with the ballistic impact data. Additional static test data are reported as a function of temperature for the seven best hybrid configurations having epoxy, polyimide (PMR-15) and polyphenylquinoxaline resins as the matrix.

Pike, R. A.↗
NASA NTRS1975

Development of lightweight reinforced plastic laminates for spacecraft interior applications

Lightweight, Kevlar - reinforced laminating systems that are non-burning, generate little smoke in the space shuttle environment, and are physically equivalent to the fiberglass/polyimide system used in the Apollo program for non-structural cabin panels, racks, etc. Resin systems representing five generic classes were screened as matrices for Kevlar 49 reinforced laminates. Of the systems evaluated, the polyimides were the most promising with the phenolics a close second. Skybond 703 was selected as the most promising resin candidate. With the exception of compression strength, all program goals of physical and mechanical properties were exceeded. Several prototype space shuttle mobility and translation handrail segments were manufactured using Kevlar/epoxy and Kevlar-graphite/epoxy. This application shows significant weight savings over the baseline aluminum configuration used previous. The hybrid Kevlar-graphite/epoxy is more suitable from a processing standpoint.

Hertz, J.↗
NASA NTRS1979

Silicone modified resins for graphite fiber laminates

The development of silicon modified resins for graphite fiber laminates which will prevent the dispersal of graphite fibers when the composites are burned is discussed. Eighty-five silicone modified resins were synthesized and evaluated including unsaturated polyesters, thermosetting methacrylates, epoxies, polyimides, and phenolics. Neat resins were judged in terms of Si content, homogeneity, hardness, Char formation, and thermal stability. Char formation was estimated by thermogravimetry to 1,000 C in air and in N2. Thermal stability was evaluated by isothermal weight loss measurements for 200 hrs in air at three temperatures. Four silicone modified epoxies were selected for evaluation in unidirectional filament wound graphite laminates. Neat samples of these resins had 1,000 C char residues of 25 to 50%. The highest flexural values measured for the laminates were a strength of 140 kpsi and a modulus of 10 Mpsi. The highest interlaminar shear strength was 5.3 kpsi.

Frost, L. W.↗
NASA NTRS2013

Nickel-Graphite Composite Compliant Interface and/or Hot Shoe Material

Next-generation high-temperature thermoelectric-power-generating devices will employ segmented architectures and will have to reliably withstand thermally induced mechanical stresses produced during component fabrication, device assembly, and operation. Thermoelectric materials have typically poor mechanical strength, exhibit brittle behavior, and possess a wide range of coefficient of thermal expansion (CTE) values. As a result, the direct bonding at elevated temperatures of these materials to each other to produce segmented leg components is difficult, and often results in localized microcracking at interfaces and mec hanical failure due to the stresses that arise from the CTE mismatch between the various materials. Even in the absence of full mechanical failure, degraded interfaces can lead to increased electrical and thermal resistances, which adversely impact conversion efficiency and power output. The proposed solution is the insertion of a mechanically compliant layer, with high electrical and thermal conductivity, between the low- and high-temperature segments to relieve thermomechanical stresses during device fabrication and operation. This composite material can be used as a stress-relieving layer between the thermoelectric segments and/or between a thermoelectric segment and a hot- or cold-side interconnect material. The material also can be used as a compliant hot shoe. Nickel-coated graphite powders were hot-pressed to form a nickel-graphite composite material. A freestanding thermoelectric segmented leg was fabricated by brazing the compliant pad layer between the high-temperature p- Zintl and low-temperature p-SKD TE segments using Cu-Ag braze foils. The segmented leg stack was heated in vacuum under a compressive load to achieve bonding. The novelty of the innovation is the use of composite material that re duces the thermomechanical stresses en - countered in the construction of high-efficiency, high-temperature therm - o-electric devices. The compliant pad enables the bonding of dissimilar thermoelectric materials while maintaining the desired electrical and thermal properties essential for efficient device operation. The modulus, CTE, electrical, and thermal conductances of the composite can be controlled by varying the ratio of nickel to graphite.

Firdosy, Samad A.↗
DOE OSTI2020

Magnetic states of atomic vacancies in graphite probed by scanning tunneling microscopy

Intrinsic defects in graphitic materials, like vacancies and edges, have been expected to possess magnetic states from the many-body interaction of localized electrons. However, charge screening from graphite bulk carriers significantly reduces the localization effect and hinders the observation of those magnetic states. Here, we use an ultra-low-temperature scanning tunneling microscope with a high magnetic field to observe the magnetic states of atomic vacancies in graphite generated by ion sputtering. Scanning tunneling spectroscopy reveals localized states at the vacancies, which exhibit splitting at a certain magnetic field whose separation increases with the field strength. The transition is well described by the “Anderson model,” which describes the emergence of localized magnetic states inside the metallic reservoir through electron–electron interaction. The interaction strength is estimated to be between 1 meV and 3 meV, which is supported by the density functional theory calculation. The observation provides an important foundation for application of intrinsic defects to carbon-based spintronic devices.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Fracture modes in off-axis fiber composites

Criteria were developed for identifying, characterizing, and quantifying fracture modes in high-modulus graphite-fiber/resin unidirectional composites subjected to off-axis tensile loading. Procedures are described which use sensitivity analyses and off-axis data to determine the uniaxial strength of fiber composites. It was found that off-axis composites fail by three fracture modes which produce unique fracture surface characteristics. The stress that dominates each fracture mode and the load angle range of its dominance can be identified. Linear composite mechanics is adequate to describe quantitatively the mechanical behavior of off-axis composites. The uniaxial strengths predicted from off-axis data are comparable to these measured in uniaxial tests.

Sinclair, J. H.↗