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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Effects of fiber, matrix, and interphase on carbon fiber composite compression strength

The major goal of this project was to obtain basic information on compression failure properties of carbon fiber composites. To do this, we investigated fiber effects, matrix effects, and fiber/matrix interface effects. Using each of nine fiber types, we prepared embedded single-fiber specimens, single-ply specimens, and full laminates. From the single-fiber specimens, in addition to the standard fragmentation test analysis, we were able to use the low crack density data to provide information about the distribution of fiber flaws. The single-ply specimens provided evidence of a correlation between the size of kink band zones and the quality of the interface. Results of the laminate compression experiments mostly agreed with the results from single-ply experiments, although the ultimate compression strengths of laminates were higher. Generally, these experiments showed a strong effect of interfacial properties. Matrix effects were examined using laminates subjected to precracking under mixed-mode loading conditions. A large effect of precracking conditions on the mode 1 toughness of the laminates was found. In order to control the properties of the fiber/matrix interface, we prepared composites of carbon fiber and polycarbonate and subjected these to annealing. The changes in interfacial properties directly correlated with changes in compression strength.

Nairn, John A.↗
DOE OSTI2020

Direct observation on supersonic microprojectile penetration of carbon fiber composites with ultrafast synchrotron X-ray phase contrast imaging

High-speed penetration into carbon fiber composites is of fundamental importance to materials science and impact engineering, but research along this line suffers considerably from the lack of direct experimental observations. Here we investigate such penetration dynamics of a unidirectional carbon fiber reinforced epoxy (UCFRE) composite, with a combination of in situ, ultrafast, synchrotron phase contrast imaging and finite element (FE) analysis. The experiments yield the first direct observation on projectile trajectories and fiber-scale deformation and damage in the UCFRE composites during supersonic microprojectile penetration, for different fiber orientations (0 degrees - 90 degrees from the impact direction) and projectile velocities (600 - 850 m.s -1 ), at unprecedented temporal (~ 100 ps) and spatial (5 μm) resolutions. The maximum penetration depth decreases with increasing fiber orientation angles, as a result of anisotropic damage evolution in the composite sample. Strain localizations are prone to develop along a direction perpendicular to the fiber orientation, while the damage or cavity region, along the fiber direction. FE modeling with a three-dimensional Hashin criterion yields consistent projectile trajectory and cavity morphology with the experimental results. Finally, with increasing fiber orientation angles, damage analyses show a transition in the damage mode from fiber compression to matrix compression damage, in line with the increasing maximum penetration depth.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Enhanced through-thickness electrical conductivity and lightning strike damage response of interleaved vertically aligned short carbon fiber composites

Through-thickness electrical conductivity of carbon fiber reinforced polymers (CFRPs) is a key characteristic that determines the severity of lighting strike-induced damage. Carbon Fibers (CFs) are inherently electrically conductive and therefore provide high conductivity in the direction of the fiber orientation. However, electrical conductivities through the thickness and orthogonal to the CF orientation in CFRPs are governed by the insulating polymer matrix present between CFs. Here, in this work, through the thickness alignment of short CFs in between layers of CFRP laminates is demonstrated to improve the through-thickness electrical conductivity. Composites with interleaved vertically aligned short CF fibers (<150 μm) will be referred as V-fiber composites hereafter. The effect of the V-fiber on the lightning strike damage is evaluated against an artificial lightning strike of 100 kA (modified waveform A of SAE ARP-5412B standard). The improved through-thickness electrical conductivity of CFRP laminates (1.15 S/cm) through vertical alignment of short CFs was compared to reference CFRP laminates (0.13 S/cm) and was found to dissipate the artificial lightning strike current more efficiently. The surface damage after the artificial lightning strike in the V-fiber composites was reduced to 12.69 cm 2 compared to the reference CFRP surface damage of 57.67 cm 2 , a 78% reduction. It was also demonstrated that Joule heat generated due to lightning strike on the composites was significantly less than the reference sample using infrared (IR) thermography. A high retention (up to 78%) of flexural properties (modulus and strength) was observed in V-fiber composites post lightning strike impact as compared to only 47% retention in the reference panel.

42 ENGINEERING↗
NASA NTRS1987

Improving the interlaminar shear strength of carbon fiber-epoxy composites through carbon fiber bromination

The use of bromine to improve the interlaminar shear strength of PAN-based carbon fibers was investigated. Composite test specimens fabicated from brominated T-300 fibers and a MY720 matrix exhibited on average a 30% improvement in ILSS over their pristine counterparts. Mass, electrical resistivity, density, contact angle, and scanning Auger microscopy results suggested a mechanism in which the bromine was covalently bonded to the surface of the fiber, and this resulted in an increased van der Waal's adhesion between fiber and matrix.

Jaworske, Donald A.↗
NASA NTRS1998

Fabrication and Resistivity of IBr Intercalated Vapor-Grown Carbon Fiber Composites

Composites using vapor-crown carbon fibers (VGCF), the most conductive of the carbon fiber types, are attractive for applications where low density, high strength, and at least moderate conductivity are required, such as electromagnetic interference shielding covers for spacecraft. The conductivity can be enhanced another order of magnitude by intercalation of the VGCF. If a high Z intercalate is used, the protection of components from ionizing radiation can be enhanced also. Thus, the intercalation of VGCF with IBr is reported. Since composite testing is required to verify properties, the intercalation reaction optimization, stability of the intercalation compound, scale-up of the intercalation reaction, composite fabrication, and resistivity of the resulting composites is also reported. The optimum conditions for low resistivity and uniformity for the scaled up reaction (20-30 g of product) were 114 C for at least 72 hr, yielding a fiber with a resistivity of 8.7+/-2 micro-Omega-cm. The thermal stability of these fibers was poor, with degradation occurring at temperatures as low as 40 C in air, though they were insensitive to water vapor. Composite resistivity was 20-30 micro-Omega-cm, as measured by contactless conductivity measurements, about a factor of five higher than would be expected from a simple rule of mixtures. The addition of 1.0 percent Br2, intercalated microfibers increased the resistivity of the composites by more than 20 percent.

Gaier, James R.↗
NASA NTRS1979

An Assessment of the Risks Presented by the Use of Carbon Fiber Composites in Commercial Aviation. Volume 1: Final Report. Volume 2: Supporting Appendices

Carbon fiber (CF) composites are being used to an increasing extent in commercial aircraft, due to their excellent structural properties. Since carbon fibers are highly conductive, a potential risk was identified in the event that an aircraft with CF composite structures is involved in an accidental fire. If carbon fibers are released from the fire, they could disperse in the atmosphere and eventually cause damaging short circuits in electronic equipment at remote locations. This phenomenon could conceivably result in economic losses. The purpose of this study was to assess the risks presented to the nation as a whole by the use of CF composites in commercial aircraft, in terms of the potential economic losses from air carrier accidents.

Kalelkar, A. S.↗
DOE OSTI2023

Optimized Carbon Fiber Composites in Wind Turbine Blade Design: Follow-On Studies

This project has identified opportunities to bring further reductions in the mass and cost of modern wind turbine blades through the use of alternative material systems and manufacturing processes. The fiber reinforced polymer material systems currently used by the wind industry have stagnated as the technology continues to mature and as a means to reduce risk while introducing new products with continually increasing blade lengths. However, as blade lengths continue to increase, the challenge of controlling blade mass becomes even more critical to enabling the associated levelized cost of energy reductions. Stiffer and stronger reinforcement fibers can help to resolve the challenges of meeting the loading demands while limiting the increase in weight, but these materials are substantially more expensive than the traditional E-glass fiber systems. One goal of this project and associated work is to identify pathways that improve the cost-effectiveness of carbon fiber such that it is the reinforcement of choice in the primary structural elements of wind blades. The use of heavy-tow textile carbon fiber material systems has been shown to reduce the blade mass by 30-31% when used in the spar cap and by up to 7% when used in edgewise reinforcement. A pultrusion cost model was developed to enable a material cost comparison that includes an accurate estimate of the intermediate manufacturing step of pultrusion for the carbon fiber composite. Material cost reductions were revealed in most cases for the heavy-tow textile carbon fiber compared to infused fiberglass. The use of carbon fiber in the edgewise reinforcement produced the most notable material cost reduction of 33% for the heavy-tow textile carbon fiber. The mass and cost savings observed when using carbon fiber in edgewise reinforcement demonstrate a clear opportunity of this design approach. A carbon fiber conversion cost model was expanded to include a characterization of manufacturing costs when using advanced conversion processes with atmospheric plasma oxidation. This manufacturing approach was estimated to reduce the cost of carbon fiber material systems by greater than 10% and can be used with textile carbon systems or traditional carbon fiber precursors. The pultrusion cost model was also used to assess the opportunity for using pultruded fiberglass in wind blades, studying conventional E-glass fiber reinforcement. When using pultruded fiberglass as the spar cap material for two design classifications, the blade weight was reduced by 6% and 9% compared to infused fiberglass. However, due to the relatively large share of the pultrusion manufacturing cost compared to fiber cost, the spar cap material cost increased by 12% and 7%. When considering the system benefits of reduced blade mass and potentially lower blade manufacturing costs for pultruded composites, there may be opportunity for pultruded E-glass in wind blade spar caps, but further studies are needed. There is a clearer outcome for using pultruded fiberglass in the edgewise reinforcement where it resulted in a blade mass reduction of 2% and associated reinforcement material cost reduction of 1% compared to infused E-glass. The use of higher performing glass fibers, such as S-glass and H-glass systems, will produce greater mass savings but a study is needed to assess the cost implications for these more expensive systems. The most likely opportunity for these high-performance glass fibers is in the edgewise reinforcement, where the increased strength will reduce the damage accumulation of this fatigue-driven component. The blade design assessments in this project characterize the controlling material properties for the primary structural components in the flapwise and edgewise directions for modern wind blades. The observed trends with low and high wind speed turbine classifications for carbon and glass fiber reinforced polymer systems help to identify where cost reductions are needed, and where improvements in mechanical properties would help to reduce the material demands.

17 WIND ENERGY↗
NASA NTRS1980

Assessment of risk due to the use of carbon fiber composites in commercial and general aviation

The development of a national risk profile for the total annual aircraft losses due to carbon fiber composite (CFC) usage through 1993 is discussed. The profile was developed using separate simulation methods for commercial and general aviation aircraft. A Monte Carlo method which was used to assess the risk in commercial aircraft is described. The method projects the potential usage of CFC through 1993, investigates the incidence of commercial aircraft fires, models the potential release and dispersion of carbon fibers from a fire, and estimates potential economic losses due to CFC damaging electronic equipment. The simulation model for the general aviation aircraft is described. The model emphasizes variations in facility locations and release conditions, estimates distribution of CFC released in general aviation aircraft accidents, and tabulates the failure probabilities and aggregate economic losses in the accidents.

Fiksel, J.↗
DOE OSTI2023

Performance of hybrid Innegra-carbon fiber composites

Abstract In this work material synergy with high stiffness carbon fiber with ductile high strength polypropylene fiber (Innegra S), (referred to as Innegra, herein) have been evaluated in a range of laminate designs. Both woven and discontinuous carbon fiber have been considered. The discontinuous fibers are based on three-dimensional deposition (3DEP) (referred to as 3DEP, herein) carbon fiber preform process. Eleven (11) variants of Innegra-carbon fiber hybrid laminates were investigated for tensile, flexure, compression, in-plane shear and low velocity impact response. The effect of position of Innegra within the laminate was studied and found to influence strength and stiffness properties. In terms of overall trends, Innegra provides upward of 18% improvement in strain (ductility) to the composite and eliminates brittle fracture of carbon fiber. The moduli trends follow the proportionality of Innegra fiber to carbon fiber plies. However, the strength is controlled by the interface between Innegra and carbon fiber. The primary failure mode in tension and compression is via onset of debonding between Innegra and carbon fiber. The 3DEP carbon fiber constituents provided highest values of in-plane shear indicating that three-dimensional (3D) network of carbon fiber provides higher shear resistance. The Innegra intensive variants exhibited superior energy absorption under low velocity impact, at energy levels 15–60 J. This work provides insight for designers to incorporate Innegra and carbon fiber hybrids in composite structures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Interfacial Strength in Hierarchical Carbon Fiber Composites: Interplay of Interphase Modulus and Roughness

A facile, direct deposition approach that exploits van der Waals interactions between carbonaceous materials is utilized to create unidirectional hybrid carbon fiber composites. Two small molecule crosslinkers, a trifunctional aromatic (TL) and a difunctional aliphatic (DL) acyl chloride, are first utilized to create a crosslinked interphase with a softer and stiffer modulus respectively. TL crosslinked interphase with a higher modulus improved the tensile strength by 50%, despite non-covalent linking between fiber and matrix, elucidating the critical role of the interphase in alleviating modulus mismatch between the high modulus carbon fiber and the rubbery matrix. Fractional quantities of carbon nanotubes are additionally dispersed in the small molecule crosslinkers which behaved as a dispersant, helping introduce nanoasperities on the carbon fiber surface. Strong “pi-pi” interactions between CNTs and CF contributed to tensile properties, which are increased by 66% compared to the control. A cohesive zone model suggests that a stiffer interphase is better able to exploit surface heterogeneities and roughness on the fiber, synergistically enhancing interfacial strength.

36 MATERIALS SCIENCE↗
NASA NTRS1980

An investigation of possible electrical hazards of carbon fiber composites

Results of an assessment of the public risk associated with the release of carbon fibers from crash-fire accidents of civil aircraft having carbon composite structures are presented. The overall national impact is shown to be extremely low in 1993. Personal injury is found to be extremely unlikely. Based on these findings, the risk of electrical failure from carbon fibers should not prevent the exploitation of composites in aircraft, and additional protection of aircraft avionics to guard aginst carbon fibers is unnecessary.

Huston, R. J.↗
DOE OSTI2023

Crashworthiness of recycled carbon fiber composite sinusoidal structures at dynamic rates

Fiber reinforced polymer composites are finding applications in the automotive space for structurally critical applications including crash management. The use of recycled carbon fiber reinforcement can greatly reduce carbon emissions. In this study, recycled carbon fiber composites were manufactured into a self-supporting geometry using three matrices: polyphenylene sulfide (PPS), acrylonitrile butadiene styrene (ABS), and a structural epoxy, and subsequently crushed between flat platens at dynamic rates ranging from 4.6 to 9.1 ms -1 at temperatures in a range of -40°C to 80°C. Load-displacement data was used to evaluate their specific energy absorption, crush efficiency, and steady-state crush stress. Further, the energy absorption of the ABS composites was strongly sensitive to temperature, while the PPS composites exhibited strong crush efficiency dependence with both rate and temperature. The epoxy composites exhibited stable crush behavior at dynamic crush rates but exhibited a dramatic reduction in crush efficiency relative to quasi-static tests. The results of this study indicate that recycled fiber composites can achieve very high energy absorption levels (50–80kJkg -1 at room temperature) that make them an excellent alternative to more expensive and less environmentally friendly continuous virgin fiber laminates.

42 ENGINEERING↗
NASA NTRS1987

Fabrication and characterization of amine terminated poly(arylene ether sulfone) modified epoxy-carbon fiber composites

Multifunctional epoxy resin networks were chemically modified with thermoplastic amine terminated poly(arylene ether sulfones) of controlled molecular weights. This system was then examined as both neat resin and as a matrix resin for carbon fiber composites. The neat resin displayed a significant increase in both fracture toughness and energy release rate values. This was attributed to the altered morphology, which could be varied from particles of polysulfone in an epoxy matrix to that of a quasi-continuous polysulfone phase.

Cecere, James A.↗
DOE OSTI2023

The Influence of Carbon Fiber Composite Specimen Design Parameters on Artificial Lightning Strike Current Dissipation and Material Thermal Damage

Previous artificial lightning strike direct effect research has examined a broad range of specimen design parameters. No works have studied how such specimen design parameters and electrical boundary conditions impact the dissipation of electric current flow through individual plies. This article assesses the influence of carbon fiber composite specimen design parameters (design parameters = specimen size, shape, and stacking sequence) and electrical boundary conditions on the dissipation of current and the spread of damage resulting from Joule heating. Thermal-electric finite element (FE) modelling is used and laboratory scale (<1 m long) and aircraft scale (>1 m long) models are generated in which laminated ply current dissipation is predicted, considering a fixed artificial lightning current waveform. The simulation results establish a positive correlation between the current exiting the specimen from a given ply and the amount of thermal damage in that ply. The results also establish that the distance to ground, from the strike location to the zero potential boundary conditions (ground), is the controlling factor which dictates the electric current dissipation in each ply. Significantly, this distance to ground is dependent on each of the specimen shape, dimensions, stacking sequence, and location of ground boundary conditions. Therefore, it is not possible to decouple current dissipation and damage from specimen design and boundary condition setup. However, it is possible to define a specimen size for a given specimen shape, stacking sequence, and waveform which limit the influence of specimen dimensions on the resulting current distribution and damage. For a rectangular specimen design which appears in literature multiple times, as 100 × 150 mm and with a stacking sequence of [45/0/-45/90] 4s , a specimen design of greater than 300 × 200 mm is required to limit the influence of specimen dimensions on current distribution and damage.

36 MATERIALS SCIENCE↗
NASA NTRS1979

The scatter of mechanical values of carbon fiber composites and its causes

The scatter of experimental data obtained in an investigation of the parameters of structural components was investigated. Strength parameters which are determined by the resin or the adhesion between fiber and resin were included. The statistical characteristics of the mechanical parameters of carbon fiber composites, and the possibilities which exist to reduce this scatter were emphasized. It is found that quality control tests of fiber and resin are important for such a reduction.

Roth, S.↗
NASA NTRS1972

Carbon fiber composites for cryogenic filament-wound vessels

Advanced unidirectional and bidirectional carbon fiber/epoxy resin composites were evaluated for physical and mechanical properties over a cryogenic to room temperature range for potential application to cryogenic vessels. The results showed that Courtaulds HTS carbon fiber was the superior fiber in terms of cryogenic strength properties in epoxy composites. Of the resin systems tested in ring composites, CTBN/ERLB 4617 exhibited the highest composite strengths at cryogenic temperatures, but very low interlaminar shear strengths at room temperature. Tests of unidirectional and bidirectional composite bars showed that the Epon 828/Empol 1040 resin was better at all test temperatures. Neither fatigue cycling nor thermal shock had a significant effect on composite strengths or moduli. Thermal expansion measurements gave negative values in the fiber direction and positive values in the transverse direction of the composites.

Larsen, J. V.↗
NASA NTRS1980

Risk Assessment of Carbon Fiber Composite in Surface Transportation

The vulnerability of surface transportation to airborne carbon fibers and the national risk associated with the potential use of carbon fibers in the surface transportation system were evaluated. Results show airborne carbon fibers may cause failure rates in surface transportation of less than one per year by 1995. The national risk resulting from the use of carbon fibers in the surface transportation system is discussed.

Hathaway, W. T.↗
NASA NTRS2010

Modeling of Failure for Analysis of Triaxial Braided Carbon Fiber Composites

In the development of advanced aircraft-engine fan cases and containment systems, composite materials are beginning to be used due to their low weight and high strength. The design of these structures must include the capability of withstanding impact loads from a released fan blade. Relatively complex triaxially braided fiber architectures have been found to yield the best performance for the fan cases. To properly work with and design these structures, robust analytical tools are required that can be used in the design process. A new analytical approach models triaxially braided carbon fiber composite materials within the environment of a transient dynamic finite-element code, specifically the commercially available transient dynamic finite-element code LS-DYNA. The geometry of the braided composites is approximated by a series of parallel laminated composites. The composite is modeled by using shell finite elements. The material property data are computed by examining test data from static tests on braided composites, where optical strain measurement techniques are used to examine the local strain variations within the material. These local strain data from the braided composite tests are used along with a judicious application of composite micromechanics- based methods to compute the stiffness properties of an equivalent unidirectional laminated composite required for the shell elements. The local strain data from the braided composite tests are also applied to back out strength and failure properties of the equivalent unidirectional composite. The properties utilized are geared towards the application of a continuum damage mechanics-based composite constitutive model available within LS-DYNA. The developed model can be applied to conduct impact simulations of structures composed of triaxially braided composites. The advantage of this technology is that it facilitates the analysis of the deformation and damage response of a triaxially braided polymer matrix composite within the environment of a transient dynamic finite-element code such as LS-DYNA in a manner which accounts for the local physical mechanisms but is still computationally efficient. This methodology is tightly coupled to experimental tests on the braided composite, which ensures that the material properties have physical significance. Aerospace or automotive companies interested in using triaxially braided composites in their structures, particularly for impact or crash applications, would find the technology useful. By the development of improved design tools, the amount of very expensive impact testing that will need to be performed can be significantly reduced.

Goldberg, Robert K.↗