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DOE OSTI2023

Low Weight, High Strength Coal-Based Building Materials for Infrastructure Products (Rev.A)

Semplastics has developed, tested, and proven the viability of a new class of composite infrastructure components that use coal as the primary component. Phase I resulted in the production of brick and block components, called X-BRIX and X-BLOX, with dimensions comparable to commercially available bricks and concrete blocks, but with superior mechanical strength, lower weight, greater hardness, improved toughness, greater abrasion resistance, and greater chemical resistance than concrete. Multiple samples of full-size (16” × 8” × 8”) X-BLOX and full-size (8” × 4” × 2.5”) X-BRIX were made to demonstrate the technology, and to support the development of mortar or joining techniques. Phase I moved the coal-based composite materials technology from a current Technology Readiness Level (TRL) of 3 to TRL 5. Semplastics’ coal-based composite materials exhibit a number of high-performance characteristics, including high strength (five times the flexure strength of the best commercial brick, and more than twice the compressive strength of construction-grade concrete block), lower density (by 37 to 41%), improved mechanical durability and abrasion resistance, and resistance to chemicals, acids, salts, and chemical wastewater. These properties offer significant improvements over conventional bricks, concrete blocks, and pavers. The coal particles are completely encapsulated and bonded using a specially formulated polymer-derived ceramic (PDC) that is cured to form an “aggregate” of coal and PDC resin. This aggregate can be further processed and lightly pressed (at 10 to 50 psi) to produce a brick. After pyrolyzing (similar to the processing used to make standard clay bricks), the finished coal-based brick is significantly harder and more abrasion-resistant than regular bricks. We have produced prototype X-BRIX and X-BLOX that contain at least 55% coal by weight (71% carbon by weight, due to the controlled carbon content of the PDC) and showed their superior mechanical properties through in-house and contracted testing.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1969

Abrasion and resistant discharge valve developed

Discharge valve capable of withstanding intense radiation and high abrasion was developed for use in a fluidized bed reactor. The valve which employs a replaceable Teflon seal, has only one moving part and is designed for remote assembly and disassembly.

Gottwald, W. L.↗

NASA NTRS1984

Sunglass Lens

Foster Grant's Space Technology Lens, manufactured under license from NASA, combines NASA technology with Foster Grant's own technology. The NASA contribution was a highly abrasion-resistant coating developed at Ames Research Center as a means of protecting plastic surfaces of aerospace equipment from the sometimes harsh environments to which they are subjected. The Space Tech Lens, now manufactured by Fosta-Tek, surpasses glass in abrasion resistant properties and has five times better scratch resistance than the most popular corrective lenses.

Source record↗

NASA NTRS1995

Development of LaRC (TM): IA thermoplastic polyimide coated aerospace wiring

NASA Langley has invented LaRC(exp TM) IA and IAX which are thermoplastic polyimides with good melting, thermal and chemical resistance properties. It was the objective of this contract to prepare and extrude LaRC (exp TM) polyimide onto aircraft wire and evaluate the polymers performance in this critical application. Based on rheology and chemical resistance studies at Imitec, LaRC (exp TM) IAX melts readily in an extruder, facilitating the manufacture of thin wall coatings. The polyimide does not corode the extruder, develop gel particles nor advance in viscosity. The insulated wire was tested according to MiL-W-22759E test specifications. The resulting wire coated with LaRC (exp TM) IAX displayed exceptional properties: surface resistance, non blocking, non burning, hot fluid resistance, impulse dielectric, insulation resistance, low temperature flexibility, thermal aging, wire weight, dimensions, negligible high temperature shrinkage and stripability. The light weight and other properties merit its application in satellites, missiles and aircraft applications. The extruded IAX results in a polyimide aircraft insulation without seams, outstanding moisture resistance, continuous lengths and abrasion resistance.

Keating, Jack↗

NASA NTRS1994

Balloon Catheter Prevents Contamination

Balloon catheter similar to that used in such medical procedures as angioplasty and heart surgery protects small orifices against contamination and blockage by chips generated in machining operations. Includes small, inflatable balloon at end of thin, flexible tube. Contains additional features adapting it to anticontamination service: balloon larger to fit wider channel it must block; made of polyurethane (rather than latex), which does not fragment if bursts; material made thicker to resist abrasion better; and kink-resistant axial wire helps catheter negotiate tight bends.

Higginson, Gregory A.↗

NASA NTRS1987

Protective coatings for composite tubes in space applications

Protective coatings for graphite/epoxy (Gr/Ep) tubular structures for a manned Space Station truss structure were evaluated. The success of the composite tube truss structure depends on its stability to long-term exposure to the low earth orbit (LEO) environment, with particular emphasis placed on atomic oxygen. Concepts for protectively coating Gr/Ep tubes include use of inorganic coated metal foils and electroplating. These coatings were applied to Gr/Ep tubes and then subjected to simulated LEO environment to evaluate survivability of coatings and coated tubes. Evaluation included: atomic oxygen resistance, changes in optical properties and adhesion, abrasion resistance, surface preparation required, coating uniformity, and formation of microcracks in the Gr/Ep tubes caused by thermal cycling. Program results demonstrated that both phosphoric and chromic acid anodized Al foil provided excellent adhesion to Gr/Ep tubes and exhibited stable optical properties when subjected to simulated LEO environment. The SiO2/Al coatings sputtered onto Al foils also resulted in an excellent protective coating. Electroplated Ni exhibited unacceptable adhesion loss to Gr/Ep tubes during atomic oxygen exposure.

Dursch, Harry W.↗

NASA NTRS2003

NASA Glenn/AADC-Rolls Royce Collaborated to Measure Erosion Resistance on Coated Polymer Matrix Composites

Polymer matrix composites (PMCs) are increasingly used in aerospace and automotive applications because of their light weight and high strength-to-weight ratio relative to metals. However, a major drawback of PMCs is poor abrasion resistance, which restricts their use, especially at high temperatures. Simply applying a hard coating on PMCs to improve abrasion and erosion resistance is not effective since coating durability is short lived (ref. 1). Generally, PMCs have higher coefficients of thermal expansion than metallic or ceramic coatings have, and coating adhesion suffers because of poor interfacial adhesion strength. One technique commonly used to improve coating adhesion or durability is the use of bond coats that are interleaved between a coating and a substrate with vastly different coefficients of thermal expansion. An example of this remedy is the use of bondcoats for ceramic thermal barrier coatings on metallic turbine components (ref. 2). Prior collaborative research between the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) demonstrated that bond coats sandwiched between PMCs and high-quality plasma-sprayed, erosion-resistant coatings substantially improved the erosion resistance of PMCs (ref. 3). One unresolved problem in this earlier collaboration was that there was no easy, accurate way to measure the coating erosion wear scar. Coating wear was determined by both profilometry and optical microscopy. Both techniques are time consuming. Wear measurement by optical microscopy requires sample destruction and does not provide a comprehensive measure of the entire wear volume. An even more subtle, yet critical, problem is that these erosion coatings contain two or more materials with different densities. Therefore, simply measuring specimen mass loss before and after erosion will not provide an accurate gauge for coating and/or substrate volume loss. By using a noncontact technique called scanning optical interferometry, which was recently developed at Glenn, researchers can accurately determine the wear performance of erosion-coated PMCs while preserving the sample. An example of this interferometry technique is shown in the preceding figure for an erosion-coated inlet guide vane from a Rolls Royce AE3007 regional gas turbine jet engine. Erosion was conducted with coated and uncoated PMC vanes, with the abrasive material moving at a velocity of 229 m/s at impingement angles of 20 and 90 degrees. The coatings for PMCs remarkably reduced the erosion volume loss by a factor of approximately 10. Currently, several erosion coatings for PMCs are being compared and downselected for engine testing at Rolls Royce.

Miyoshi, Kazuhisa↗

NASA NTRS1992

Electron Microscopy Abrasion Analysis of Candidate Fabrics for Planetary Space Suit Protective Overgarment Application

The Electron Microscopy Abrasion Analysis of Candidate Fabrics for Planetary Space Suit Protective Overgarment Application is in support of the Abrasion Resistance Materials Screening Test. The fundamental assumption made for the SEM abrasion analysis was that woven fabrics to be used as the outermost layer of the protective overgarment in the design of the future, planetary space suits perform best when new. It is the goal of this study to determine which of the candidate fabrics was abraded the least in the tumble test. The sample that was abraded the least will be identified at the end of the report as the primary candidate fabric for further investigation. In addition, this analysis will determine if the abrasion seen by the laboratory tumbled samples is representative of actual EVA Apollo abrasion.

Hennessy, Mary J.↗

NASA NTRS1971

Improved fire-resistant coatings

Water-base coatings containing potassium silicate show improvement in areas of quick air-drying, crack, craze, and abrasion resistance, adherence, and leach resistance. Coatings are useful as thermal-barrier layers in furnaces, and as general purpose fire resistant surfaces where vapor impermeability is not a requirement.

Hutt, J. B.↗

DOE OSTI2021

Additive Manufacturing of Corrosion Resistant UHTC Materials for Chloride Salt-to-sCO2 Brayton Cycle Heat Exchangers

The objectives of the project include: (1) screen high-purity, high density ultra-high-temperature ceramics (UHTCs) for chloride salt corrosion resistance, (2) develop binder-jet additive manufacturing and sintering for ZrB 2 -MoSi 2 blends using literature and experiments to demonstrate feasibility, and (3) evaluate chloride salt corrosion resistance of additively manufactured ZrB 2 -MoSi 2 . These initial objectives support the development of a durable and reliable ultra-compact high-efficiency salt-to-sCO 2 heat exchanger for closed-loop Brayton power cycles based on corrosion resistant, high-strength, thermally conductive UHTC materials and novel designs enabled by additive manufacturing. The UHTC materials are also abrasion resistant so that they could be applicable to all three thermal carrier media pathways identified in the CSP Gen3 Roadmap.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Validation Testing and Statistical Analysis of the Rotary Tumbler Fabric Abrasion Method

The Artemis space suit glove environmental protection garment (EPG) will be the first line of protection used to shield the crewmember’s hands from the environments encountered during extravehicular activity (EVA). As the Artemis missions will include more extreme environments than those experienced on the International Space Station, development, verification, and validation of gloves requires the development of new test methods. A previous paper focused on the development of a test procedure to characterize lunar EVA glove fabrics using ASTM standardized test methods and the design and validation of a new standardized test procedure for comparing abrasion resistance between fabrics using a dust and rock filled rotary tumbler. Preliminary results of testing were presented in that paper. This paper reports on the validation testing and statistical analysis of the newly developed tumbler abrasion test method.

Robert J Jones↗

NASA NTRS1978

Development of aircraft lavatory compartments with improved fire resistance characteristics

The Boeing's participation in a NASA-funded program (FIREMEN) included developing materials for use as lavatory wall panels, sidewall panels, and ceiling panels possessing flammability, smoke, and toxicity (FS&T) characteristics superior to current materials of construction is described. A sandwich panel system is developed for improving FS&T characteristics and acceptable cost, processing requirements, aesthetic qualities, abrasion resistance, strain resistance, scuff resistance, and washability.

Anderson, R. A.↗

NASA NTRS1986

Detecting Foreign Particles in Wind Tunnels

Simple scratch test tells whether particles, which distort results, present in test. Detector developed for tests of abrasion resistance of flexible insulation blankets. Now, when detector indicates particles present in test, results interpreted accordingly. Small pits and scratches on metal foil indicate particles struck surface during wind-tunnel test. Detector used in tests of paints and coatings to determine whether abrasive particles present.

Sharp, H. L.↗

NASA NTRS1995

Thin-film sulfuric acid anodizing as a replacement for chromic acid anodizing

Chromic acid has long been used to produce a thin, corrosion resistant (Type I) coating on aluminum. Following anodizing, the hardware was sealed using a sodium dichromate solution. Sealing closes up pores inherent in the anodized coating, thus improving corrosion resistance. The thinness of the brittle coating is desirable from a fatigue standpoint, and chromium was absorbed by the coating during the sealing process, further improving corrosion resistance. Unfortunately, both chromic acid and sodium dichromate contain carcinogenic hexavalent chromium. Sulfuric acid is being considered as a replacement for chromic acid. Sulfuric acid of 10-20 percent concentration has traditionally been used to produce relatively thick (Types II and III) or abrasion resistant (Type III) coatings. A more dilute, that is five weight percent, sulfuric acid anodizing process, which produces a thinner coating than Type II or III, with nickel acetate as the sealant has been developed. The process was evaluated in regard to corrosion resistance, throwing power, fatigue life, and processing variable sensitivity, and shows promise as a replacement for the chromic acid process.

Kallenborn, K. J.↗

NASA NTRS1983

Shuttle Net, Tuna Net

Rockwell International, NASA's prime contractor for the Space Shuttle, asked West Coast Netting (WCN) to develop a safety net for personnel working on the Shuttle Orbiter. This could not be an ordinary net, it had to be relatively small, yet have extraordinary tensile strength. It also had to be fire resistant and resistant to ultraviolet (UV) light. After six months, WCN found the requisite fiber, a polyester-like material called NOMEX. The company was forced to invent a more sophisticated twisting process since conventional methods did not approach specified breaking strength. The resulting product, the Hyperester net, sinks faster and fishes deeper, making it attractive to fishing fleets. A patented treatment for UV protection and greater abrasion resistance make Hyperester nets last longer, and the no-shrink feature is an economic bonus.

Source record↗

NASA NTRSDate not supplied

Strategies Toward Lunar Dust Adhesion Mitigation

Recently, the NASA Space Technology Mission Directorate solicited feedback to prioritize shortfalls, which were defined as technology areas needed to enable future exploration missions. Lunar dust mitigation emerged as a critical area and is cross-cutting with many of the highest ranked shortfalls with passive dust mitigation technologies being directly ranked in the top 50. Hazards associated with lunar dust are ubiquitous across all aspects of long duration lunar surface missions, whether crewed or robotic, due to the abrasive, electrostatically charged, and chemically reactive properties of lunar dust. Compounding the issue, lunar dust moves across the lunar surface due to levitation, twilight craters, and plume-surface interactions, which can result in particle velocities exceeding 1 km/h. To address lunar dust challenges, NASA is developing active and passive adhesion mitigation technologies to address specific mission needs, including electrodynamic dust screens, piezoelectric materials, biomimetic engineered surfaces, among many others. Additionally, abrasion-resistant materials are being evaluated for applications for use near landing sites and in surface manipulation and excavation equipment. These approaches, as well as test methodologies both in the laboratory and on the lunar surface to evaluate technology efficacy, will be described.

Dust Mitigation↗

NASA NTRS1981

Development of silane-hydrolysate binder for UV-resistant thermal control coatings

Detailed characterizaton and formulation studies were performed on a methyltriakoxysilane hydrolysate as a binder for thermal control coatings. The binder was optimized by varying hydrolysis temperature, time, catalyst type, and water concentration. The candidate coating formulations, based on this binder with TiO2 pigment, were optimized via a detailed series of sprayed test panels that included the parameters of binder/pigment ratio, ethanol content, pigment particle size, coating thickness and cure conditions. A typical optimized coating was prepared by acetic acid catalyzed hydrolysis of methyltriethoxysilane with 3.25 mol-equivalents of water over a 24 hour period at room temperature. The resulting hydrolysate was directly mixed with pre-milled TiO2 (12 grams pigment/26 grams binder) to yield a sprayable consistency. Panels were sprayed to result in a nominal cure coating thickness of 2 mils. Cure was affected by air drying for 24 hr at room temperature plus 72 hr at 150 F. These coatings are typically extremely tough and abrasion-resistant, with an absorptance (alpha) of 0.20 and emittance (e) of 0.89. No significant coating damage was observed in the mandrel bend test, even after exposure to thermal cycling from -160 to 160 F. Vacuum exposure of the coatings for 930 hours at 1 equivalent UV sun resulted in no visible degradation and no significant increase in absorptance.

Patterson, W. J.↗

DOE OSTI2020

Graphene nanoplatelet for enhancement the mechanical properties and durability characteristics of alkali activated binder

The effects of the addition of graphene nanoplatelets (GNPs) on the microstructure, heat of hydration, mechanical properties and durability characteristics of alkali activated binders were investigated. A simple mixing process led to reasonably uniform dispersion of GNPs in the matrix, with minor agglomeration of GNPs detected via scanning electron microscopy. Tests on engineering properties indicated that the compressive strength of the alkali activated binder increased with the addition of GNPs at relatively low concentrations. Gains were also realized in the abrasion resistance and moisture sorptivity of the binder with GNPs addition. The heat of hydration investigations indicated that the addition of GNPs accelerates the hydration process and increases the amount of hydration products, especially at early ages. Scanning electron microscope investigations further indicated that GNPs could impede the development of microcracks and mitigate their propagation within matrix; indications of good bonding between the GNPs and the alkali activated matrix were also noted.

36 MATERIALS SCIENCE↗