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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 NTRS1989

Bonding Gauges To Carbon/Carbon Composites

Thermal-expansion properties modified to prevent bonds from failing. Proposed transition layer deposited between substrate and strain or temperature gauge to be bonded to substrate. Intended particularly for gauges that must operate at temperatures above 600 degrees F (320 degrees C) and substrates like fiber-reinforced carbon/carbon composites. Reduces stress caused by difference between thermal expansions of gauge and substrate materials. Without transition layer, stress often weakens or breaks bond.

Lemcoe, M. M.↗
NASA NTRS1991

Filament Winding Of Carbon/Carbon Structures

Improved method of winding carbon filaments for carbon/carbon composite structures less costly and labor-intensive, also produces more consistent results. Involves use of roller squeegee to ensure filaments continuously wet with resin during winding. Also involves control of spacing and resin contents of plies to obtain strong bonds between carbon filaments and carbon matrices. Lends itself to full automation and involves use of filaments and matrix-precursor resins in their simplest forms, thereby reducing costs.

Jacoy, Paul J.↗
NASA NTRS1992

Carbon/Carbon Fasteners For Use At High Temperatures

Fasteners made of advanced carbon/carbon material perform well at ambient and high temperatures. Exhibit shear strengths of more than 10 kpsi at room temperature and 13 kpsi at temperature of 2,700 degrees F. However, fasteners exhibited poor tensile strength at room temperature. Best suited to applications in which exposed to shear loads with minimal tension loads. Parts reused after thermal cycling.

Bohlmann, Frank J.↗
NASA NTRS1993

A combined experimental and finite element study to predict the failure mechanisms in SiC coated carbon/carbon composites at room and elevated temperatures under flexural loading

Response of quasi-isotropic laminates of SiC coated Carbon/Carbon (C/C) composites have been investigated under flexural loading at various temperatures. Variation of load-deflection behavior with temperatures are studied. Increase in flexural strength and stiffness are observed with the rise in temperature. Extensive analyses through Optical Microscope (OM) and Non-Destructive Evaluation (NDE) have been performed to understand the failure mechanisms. Damage zone is found only within the neighborhood of the loading plane. Isoparametric layered shell elements developed on the basis of the first order shear deformation theory have been used to model the thin laminates of C/C under flexural loading. Large deformation behavior has been considered in the finite element analysis to account for the non-linearities encountered during the actual test. Data generated using finite element analysis are presented to corroborate the experimental findings, and a comparison in respect of displacement and stress-strain behavior are given to check the accuracy of the finite element analysis. Reasonable correlation between the experimental and finite element results have been established.

Mahfuz, Hassan↗
NASA NTRS1992

Acoustic fatigue characterization of carbon/carbon panels

Data from a sonic fatigue test of a blade-stiffened carbon/carbon panel is analyzed to determine the progression of damage to failure. The reduction in stiffness, as observed from acceleration measurements taken during the test, is correlated with the physical damage. Damage was measured through visual inspection, thermographic measurements, and through the novel use of vibration data collected using a scanning laser vibrometer.

Rizzi, S. A.↗
NASA NTRS1995

Thermochemical Degradation Mechanisms for the Reinforced Carbon/Carbon Panels on the Space Shuttle

The wing leading edge and nose cone of the Space Shuttle are fabricated from a reinforced carbon/carbon material (RCC). The material attains its oxidation resistance from a diffusion coating of SiC and a glass sealant. During re-entry, the RCC material is subjected to an oxidizing high temperature environment, which leads to degradation via several mechanisms. These mechanisms include oxidation to form a silica scale, reaction of the SiO2 with the SiC to evolve gaseous products, viscous flow of the glass, and vaporization of the glass. Each of these is discussed in detail. Following extended service and many missions, the leading-edge wing surfaces have exhibited small pinholes. A chloridation/oxidation mechanism is proposed to arise from the NaCl deposited on the wings from the sea-salt laden air in Florida. This involves a local chloridation reaction of the SiC and subsequent re-oxidation at the external surface. Thermodynamic calculations indicate the feasibility of these reactions at active pits. Kinetic calculations predict pore depths close to those observed.

Jacobson, Nathan S.↗
NASA NTRS1998

Fabrication and Testing of Mo-Re Heat Pipes Embedded in Carbon/Carbon

Refractory-composite/heat-pipe-cooled wing an tail leading edges are being considered for use on hypersonic vehicles to limit maximum temperatures to values below material reuse limits and to eliminate the need to actively cool the leading edges. The development of a refractory-composite/heat-pipe-cooled leading edge has evolved from the design stage to the fabrication and testing of heat pipes embedded in carbon/carbon (C/C). A three-foot-long, molybdenum-rhenium heat pipe with a lithium working fluid was fabricated and tested at an operating temperature of 2460 F to verify the individual heat-pipe design. Following the fabrication of this heat pipe, three additional heat pipes were fabricated and embedded in C/C. The C/C heat-pipe test article was successfully tested using quartz lamps in a vacuum chamber in both a horizontal and vertical orientation. Start up and steady state data are presented for the C/C heat-pipe test article. Radiography and eddy current evaluations were performed on the test article.

Glass, David E.↗
NASA NTRS2003

An Innovative Manufacturing of CCC Ion Thruster Grids by North Carolina A&T's RTM Carbon/Carbon Process

Electric ion thrusters are the preferred engines for deep space missions, because of very high specific impulse. The ion engine consists of screen and accelerator grids containing thousands of concentric very small holes. The xenon gas accelerates between the two grids, thus developing the impulse force. The dominant life-limiting mechanism in the state-of-the-art molybdenum thrusters is the xenon ion sputter erosion of the accelerator grid. Carbon/carbon composites (CCC) have shown to be have less than 1/7 the erosion rates than the molybdenum, thus for interplanetary missions CCC engines are inevitable. Early effort to develop CCC composite thrusters had a limited success because of limitations of the drilling technology and the damage caused by drilling. The proposed is an in-situ manufacturing of holes while the CCC is made. Special low CTE molds will be used along with the NC A&T s patented resin transfer molding (RTM) technology to manufacture the CCC grids. First, a manufacture process for 10-cm diameter thruster grids will be developed and verified. Quality of holes, density, CTE, tension, flexure, transverse fatigue and sputter yield properties will be measured. After establishing the acceptable quality and properties, the process will be scaled to manufacture 30-cm diameter grids. The properties of the two grid sizes are compared with each other.

Haag, Thomas W.↗
NASA NTRS2004

As-Fabricated Reinforced Carbon/Carbon Characterized

Reinforced carbon/carbon (RCC) is a critical material for the space shuttle orbiter. It is used on the wing leading edge and the nose cap, where maximum temperatures are reached on reentry. The existing leading-edge system is a single-plate RCC composite construction with a wall thickness of approximately 1/4 in., making it a prime reliant protection scheme for vehicle operation.

Jacobson, Nathan S.↗
NASA NTRS2005

Followup to Columbia Investigation: Reinforced Carbon/Carbon From the Breach Location in the Wing Leading Edge Studied

Initial estimates on the temperature and conditions of the breach in the Space Shuttle Columbia's wing focused on analyses of the slag deposits. These deposits are complex mixtures of the reinforced carbon/carbon (RCC) constituents, insulation material, and wing structural materials. Identification of melted/solidified Cerachrome insulation (Thermal Ceramics, Inc., Augusta, GA) indicated that the temperatures at the breach had exceeded 1760 C.

Jacobson, Nathan S.↗
NASA NTRS2005

Analysis of Carbon/Carbon Fragments From the Columbia Tragedy

The extensive investigation following the Space Shuttle Orbiter Columbia accident of February 1, 2003 determined that hot gases entered the wing through a breach in the protective reinforced carbon/carbon (RCC) leading edge. In the current study, the exposed edges of the recovered RCC from the vicinity of the breach are examined with scanning electron microscopy and Raman spectroscopy. Electron microscopy of the exposed edges revealed regions of pointed carbon fibers, characteristic of exposure to high temperature oxidizing gases. The Raman technique relates the observed 1350 and 1580 to 1600 cm(-1) bands to graphitic dom ains and their corresponding temperatures of formation. Some of the regions showed evidence of exposure temperatures beyond 2700 ?C during the accident.

Tallant, David R.↗
NASA NTRS2006

Oxidation Microstructure Studies of Reinforced Carbon/Carbon

Laboratory oxidation studies of reinforced carbon/carbon (RCC) are discussed with particular emphasis on the resulting microstructures. This study involves laboratory furnace (500-1500 C deg) and arc-jet exposures (1538 C deg) on various forms of RCC. RCC without oxidation protection oxidized at 800 and 1100 C deg exhibits pointed and reduced diameter fibers, due to preferential attack along the fiber edges. RCC with a SiC conversion coating exhibits limited attack of the carbon substrate at 500, 700 and 1500 C deg. However samples oxidized at 900, 1100, and 1300 C deg show small oxidation cavities at the SiC/carbon interface below through-thickness cracks in the SiC coating. These cavities have rough edges with denuded fibers and can be easily distinguished from cavities created in processing. Arc-jet tests at 1538 C deg show limited oxidation attack when the SiC coating and glass sealants are intact. When the SiC/sealant protection system is damaged, attack is extensive and proceeds through matrix cracks, creating denuded fibers on the edges of the cracks. Even at 1538 C deg, where diffusion control dominates, attack is non-uniform with fiber edges oxidizing in preference to the bulk fiber and matrix.

Jacobson, Nathan S.↗
NASA NTRS2000

Thermal Engineering of Mars Entry Carbon/Carbon Non-Ablative Aeroshell - Part 2

Candidate Aeroshell Test models composed of a quasi-isotropic Carbon/Carbon (C/C) front face sheet (F/S), eggcrate core, C/C back F/S, Carbon Aerogel insulation, C/C radiation shield and the C/C close-out were constructed based on the analytical temperature predictions presented in Part One of this work.

Mars entry vehicle↗
NASA NTRS2011

Lightweight, Ultra-High-Temperature, CMC-Lined Carbon/Carbon Structures

Carbon/carbon (C/C) is an established engineering material used extensively in aerospace. The beneficial properties of C/C include high strength, low density, and toughness. Its shortcoming is its limited usability at temperatures higher than the oxidation temperature of carbon . approximately 400 C. Ceramic matrix composites (CMCs) are used instead, but carry a weight penalty. Combining a thin laminate of CMC to a bulk structure of C/C retains all of the benefits of C/C with the high temperature oxidizing environment usability of CMCs. Ultramet demonstrated the feasibility of combining the light weight of C/C composites with the oxidation resistance of zirconium carbide (ZrC) and zirconium- silicon carbide (Zr-Si-C) CMCs in a unique system composed of a C/C primary structure with an integral CMC liner with temperature capability up to 4,200 F (.2,315 C). The system effectively bridged the gap in weight and performance between coated C/C and bulk CMCs. Fabrication was demonstrated through an innovative variant of Ultramet fs rapid, pressureless melt infiltration processing technology. The fully developed material system has strength that is comparable with that of C/C, lower density than Cf/SiC, and ultra-high-temperature oxidation stability. Application of the reinforced ceramic casing to a predominantly C/C structure creates a highly innovative material with the potential to achieve the long-sought goal of long-term, cyclic high-temperature use of C/C in an oxidizing environment. The C/C substructure provided most of the mechanical integrity, and the CMC strengths achieved appeared to be sufficient to allow the CMC to perform its primary function of protecting the C/C. Nozzle extension components were fabricated and successfully hot-fire tested. Test results showed good thermochemical and thermomechanical stability of the CMC, as well as excellent interfacial bonding between the CMC liner and the underlying C/C structure. In particular, hafnium-containing CMCs on C/C were shown to perform well at temperatures exceeding 3,500 F (.1,925 C). The melt-infiltrated CMC-lined C/C composites offered a lower density than Cf/SiC. The melt-infiltrated composites offer greater use temperature than Cf/SiC because of the more refractory ceramic matrices and the C/C substructure provides greater high-temperature strength. The progress made in this work will allow multiple high-temperature components used in oxidizing environments to take advantage of the low density and high strength of C/C combined with the high-temperature oxidation resistance of melt-infiltrated CMCs.

Wright, Matthew J.↗
NASA NTRSDate not supplied

Assessing Degradation of Advanced Coatings for Carbon/Carbon Composites

Carbon/carbon (C/C) composites are a well-utilized material system for hot structures to enable hypersonic flight. However, C/C materials are susceptible to attack by environmental degradation mechanisms, notably oxidation, which can limit the durability of components resulting in premature failure. Environmental barrier coatings (EBCs) have been developed to mitigate deleterious oxidation. Coating compositions based on silicon carbide (SiC) offer promise as a protective coating material for C/C composites. Under particular hypersonic flight conditions, a passivating silica scale can form at the surface of the EBC, acting as a barrier that can protect the underlying coating and substrate. However, the transition from passive to active oxidation, which varies with temperature and pressure, causes the formation of gaseous SiO that volatilizes leading to detrimental consumption of the SiC coating. In this work, arc-jet testing of SiC-based coatings developed to protect Advanced C/C-6 (ACC-6) was performed under a range of conditions to replicate varying oxidation conditions. In-situ optical emission spectroscopic measurements of the gas-surface interactions were collected and evaluated to render compositional degradation of the coating and underlying composite during arc-jet testing. Specimens were evaluated before, during and after arc-jet testing using destructive and non-destructive materials characterization methods, including optical and scanning electron microscopy and energy dispersive spectroscopy.

Coatings, Hypersonics, Composites↗