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Adhesives and the ATS satellite

Adhesives in the ATS satellite allow the designers to save weight, simplify design and fabrication and provide thermal and electrical conductivity or resistivity as required. The selections of adhesives are restricted to those few which can pass rigorous outgassing tests in order to avoid contaminating lenses and thermal control surfaces in space. An epoxy adhesive is used to construct the honeycomb panels which constitute most of the satellite's structure. General purpose epoxy adhesives hold doublers and standoffs in place and bond the truss to its fittings. Specialized adhesives include a high temperature resistant polyamide, a flexible polyurethane and filled epoxies which conduct heat or electricity.

Hancock, F. E.↗

An Ultrasonic Technique to Determine the Residual Strength of Adhesive Bonds

In this work, ultrasonic techniques to nondestructively evaluate adhesive bond degradation have been studied. The key to the present approach is the introduction of an external factor which pulls the adhesive bond in the nonlinear range, simultaneously with the application of an ultrasonic technique. With the aid of an external static tensile loading, a superimposed longitudinal wave has.been used to obtain the slopes of the stress-strain curve of an adhesive bond at a series of load levels. The critical load, at which a reduction of the slope is detected by the superimposed longitudinal wave, is an indication of the onset of nonlinear behavior of the adhesive bond, and therefore of bond degradation. This approach has been applied to the detection of adhesive bond degradation induced by cyclic fatigue loading. Analogously to the longitudinal wave case, a superimposed shear wave has been used to obtain the effective shear modulus of adhesive layers at different shear load levels. The onset of the nonlinear behavior of an adhesive bond under shear loading has been detected by the use of a superimposed shear wave. Experiments show that a longitudinal wave can also detect the nonlinear behavior when an adhesive bond is subjected to shear loading. An optimal combination of ultrasonic testing and mechanical loading methods for the detection of degradation related nonlinear behavior of adhesive bonds has been discussed. For the purpose of a practical application, an ultrasonic technique that uses a temperature increase as an alternative to static loading has also been investigated. A general strain-temperature correspondence principle that relates a mechanical strain to a temperature has been presented. Explicit strain-temperature correspondence relations for both the tension and shear cases have been derived. An important parameter which quantifies the relation between the wave velocity and temperature has been defined. This parameter, which is indicative of adhesive bond nonlinearity and which can be conveniently obtained by an ultrasonic measurement, has been used as an indication of adhesive bond degradation. Experimental results have shown that the temperature increase method is a convenient and productive alternative to static loading. A technique which uses the reflected waveform data to obtain the fundamental ultrasonic parameters (transit time, reflection coefficient and attenuation coefficient) of an adhesive bond has also been presented.

Achenbach, J. D.↗

Thin film molybdenum silicide as potential temperature sensors for turbine engines

Temperature measurements of Mo-Si-based thin-film resistance thermometers were studied. Annealing in an argon ambient at a temperature above 1000 C for at least 1 h is required to form the stable tetragonal MoSi2 phase. With a crack-free 2-micron-thick AlN barrier layer on top, a sensor was tested up to 1200 C. The resistivity vs temperature characteristic shows the room temperature resistivity and temperature coefficient of resistivity (TCR) of the sensor to be approximately 350 microohm and 0.01195 K, respectively. No film adhesion problems were observed for at least four testing cycles.

Ho, C. H.↗

Impact Ice Adhesion at NASA Glenn: Current Experimental Methods and Supporting Measurements

When examining the literature on the adhesion strength of impact ice, there have been a wide range of methodologies tried to measure the required stresses to induce interfacial delamination. Utilizing the Icing Research Tunnel at the NASA Glenn Research Center to generate the impact ice required for this work, several different mechanical tests have been and are being developed to determine the stresses along the interface between ice and coupon. This set of tests includes the technical mature modified lap joint test which has been used to conduct ice adhesion studies through a wide sweep of icing conditions. To conduct in situ ice adhesion measurements inside of the Icing Research Tunnel, several new experiments are currently being developed to make ice adhesion measurements during and immediately after ice accretion. In addition to these experimental methods, several supporting measurement techniques have been developed to allow for a better understanding on the influence of icing cloud conditions on the mechanical behavior of impact ice. Digital image correlation has been successfully implemented to augment the data generated by the modified lap joint test with full field surface displacement and strain measurements which allow for insight into the deformation processes present during a test. Both optical microscopy of impact ice samples along with ice replication techniques have been used to study the grain structure of the impact ice. This has led to a deeper understanding of the results from the modified lap joint method and how the structure of impact ice changes as it is accreted during an icing spray. The freezing process of impact ice generated by supercooled liquid water is not a volume conserving process, which leads to the presence of residual strains along the interface between ice and substrate. These strains have been observed using both a simplified flat geometry and a representative airfoil. The data gathered by these experimental adhesion methods and supporting measurements allows for a comprehensive understanding on the behavior of impact ice which will be critical to the development of future ice shedding models.

Ice Adhesion↗

Impact Ice Adhesion at NASA Glenn: Current Experimental Methods and Supporting Measurements

When examining the literature on the adhesion strength of impact ice, there have been a wide range of methodologies tried to measure the required stresses to induce interfacial delamination. Utilizing the Icing Research Tunnel at the NASA Glenn Research Center to generate the impact ice required for this work, several different mechanical tests have been and are being developed to determine the stresses along the interface between ice and coupon. This set of tests includes the technical mature modified lap joint test which has been used to conduct ice adhesion studies through a wide sweep of icing conditions. To conduct in situ ice adhesion measurements inside of the Icing Research Tunnel, several new experiments are currently being developed to make ice adhesion measurements during and immediately after ice accretion. In addition to these experimental methods, several supporting measurement techniques have been developed to allow for a better understanding on the influence of icing cloud conditions on the mechanical behavior of impact ice. Digital image correlation has been successfully implemented to augment the data generated by the modified lap joint test with full field surface displacement and strain measurements which allow for insight into the deformation processes present during a test. Both optical microscopy of impact ice samples along with ice replication techniques have been used to study the grain structure of the impact ice. This has led to a deeper understanding of the results from the modified lap join method and how the structure of impact ice changes as it is accreted during an icing spray. The freezing process of impact ice generated by supercooled liquid water is not a volume conserving process, which leads to the presence of residual strains along the interface between ice and substrate. These strains have been observed using both a simplified flat geometry and a representative airfoil. The data gathered by these experimental adhesion methods and supporting measurements allows for a compressive understanding on the behavior of impact ice which will be critical to the development of future ice shedding models.

Ice Adhesion↗

Mixed mode stress field effect in adhesive fracture

Numerical or analytical analyses were performed on seven different test specimens including blister test, 90-degree peel test, torsion test, and various cone tests. These specimens are in general subjected to complex stress fields having various amounts of Mode I, Mode II, and Mode III loads. The specimens were then constructed using polymethyl methacrylate for the adherends and a transparent polyurethane elastomer (Solithane 113) for the adhesive. This combination permitted direct observation of the bondline as load was applied. Although initial debonds as well as bond end termination singularities were present in all specimens, in some cases the debond did not initiate at the singularity points as would normally have been expected. An explanation for this behavior is presented, as well as a comparison of loading mode effect on those specimens for which the debond did propagate from a bond terminus singular point.

Anderson, G. P.↗

An Overview of Advanced Elastomeric Seal Development and Testing Capabilities at NASA Glenn Research Center

NASA is developing advanced space-rated elastomeric seals to support future space exploration missions to low Earth orbit, the Moon, near Earth asteroids, and other destinations. This includes seals for a new docking system and vehicle hatches. These seals must exhibit extremely low leak rates to ensure that astronauts have sufficient breathable air for extended missions. Seal compression loads must be below prescribed limits so as not to overload the mechanisms that compress them, and seal adhesion forces must be low to allow the sealed interface to be separated when required (e.g., during undocking or hatch opening). NASA Glenn Research Center has developed a number of unique test fixtures to measure the leak rates and compression and adhesion loads of candidate seal designs under simulated thermal, vacuum, and engagement conditions. Tests can be performed on fullscale seals with diameters on the order of 50 in., subscale seals that are about 12 in. in diameter, and smaller specimens such as O-rings. Test conditions include temperatures ranging from -238 to 662degF (-150 to 350degC), operational pressure gradients, and seal-on-seal or seal-on-flange mating configurations. Nominal and off-nominal conditions (e.g., incomplete seal compression) can also be simulated. This paper describes the main design features and capabilities of each type of test apparatus and provides an overview of advanced seal development activities at NASA Glenn.

Leakage↗

The Effect of Thin Film Adhesives on Mode I Interlaminar Fracture Toughness in Carbon Fiber Composites with Shape Memory Alloy Inserts

Shape Memory Alloy (SMA) was placed within Polymer Matrix Composite (PMC) panels alongside film adhesives to examine bonding. Double cantilever beam (DCB) testing was performed using ASTM D5528. C-scanning was performed before testing, modal acoustic emissions (MAE) were monitored during testing, and microscopy performed post-test. Data was analyzed using modified beam theory (MBT), compliance calibration (CC) and modified compliance calibration (MCC) methods. Fracture toughness for control specimens was higher than previously reported due to fiber-bridging. Specimens with SMAs and adhesives stabilized crack propagation. Results revealed SMA-bridging; a phenomenon mimicking fiber-bridging which increased the load and fracture toughness of SMA specimens.

Derek J Quade↗

Deployment, Foam Rigidization, and Structural Characterization of Inflatable Thin-Film Booms

Detailed investigation of the construction, packaging/deployment, foam rigidization, and structural characterization of polyimide film inflatable booms is described. These structures have considerable potential for use in space with solar concentrators, solar sails, space power systems including solar arrays, and other future missions. Numerous thin-film booms or struts were successfully constructed, inflated, injected with foam, and rigidized. Both solid-section and annular test articles were fabricated, using Kapton polyimide film, various adhesives, Styrofoam end plugs, and polyurethane pressurized foam. Numerous inflation/deployment experiments were conducted and compared to computer simulations using the MSC/DYTRAN code. Finite element models were developed for several foam-rigidized struts and compared to model test results. Several problems encountered in the construction, deployment, and foam injection/rigidization process are described. Areas of difficulty included inadequate adhesive strength, cracking of the film arid leakage, excessive bending of the structure during deployment, problems with foam distribution and curing properties, and control of foam leakage following injection into the structure. Many of these problems were overcome in the course of the research.

Schnell, Andrew R.↗

Debond propagation in composite-reinforced metals

Strain energy release rates were used to correlate cyclic debonding between metal sheets and composite reinforcement. An expression for the strain energy release rate was derived and applied to fatigue test results for three material systems: graphite bonded to aluminum with both a room temperature and an elevated temperature curing adhesive; and, S-glass bonded to aluminum with an elevated temperature curing adhesive. For each material system, specimens of several thicknesses were tested with a range of fatigue loads. Cyclic debonding was monitored using a photoelastic technique. A close correlation was found between the observed debond rates and the calculated strain energy release rates for each material system.

Roderick, G. L.↗

Method and apparatus for gripping uniaxial fibrous composite materials

A strip specimen is cut from a unidirectional strong, brittle fiber composite material, and the surfaces of both ends of the specimen are grit blasted. The specimen is then placed between metal load transfer members having grit blasted surfaces. Sufficient compressive stress is applied to the load transfer members to prevent slippage during testing at both elevated temperatures and room temperatures. The need for adhesives, load pads, and other secondary composite processing is eliminated. This gripping system was successful in tensile testing, creep rupture testing, and fatigue testing uniaxial composite materials at 316 C.

Whittenberger, J. D.↗

Electron Emission Properties of Insulator Materials Pertinent to the International Space Station

We present the results of our measurements of the electron emission properties of selected insulating and conducting materials used on the International Space Station (ISS). Utah State University (USU) has performed measurements of the electron-, ion-, and photon-induced electron emission properties of conductors for a few years, and has recently extended our capabilities to measure electron yields of insulators, allowing us to significantly expand current spacecraft material charging databases. These ISS materials data are used here to illustrate our various insulator measurement techniques that include: i) Studies of electron-induced secondary and backscattered electron yield curves using pulsed, low current electron beams to minimize deleterious affects of insulator charging. ii) Comparison of several methods used to determine the insulator 1st and 2nd crossover energies. These incident electron energies induce unity total yield at the transition between yields greater than and less than one with either negative or positive charging, respectively. The crossover energies are very important in determining both the polarity and magnitude of spacecraft surface potentials. iii) Evolution of electron emission energy spectra as a function of insulator charging used to determine the surface potential of insulators. iv) Surface potential evolution as a function of pulsed-electron fluence to determine how quickly insulators charge, and how this can affect subsequent electron yields. v) Critical incident electron energies resulting in electrical breakdown of insulator materials and the effect of breakdown on subsequent emission, charging and conduction. vi) Charge-neutralization techniques such as low-energy electron flooding and UV light irradiation to dissipate both positive and negative surface potentials during yield measurements. Specific ISS materials being tested at USU include chromic and sulfuric anodized aluminum, RTV-silicone solar array adhesives, solar cell cover glasses, Kapton, and gold. Further details of the USU testing facilities, the instrumentation used for insulator measurements, and the NASA/SEE Charge Collector materials database are provided in other Spacecraft Charging Conference presentations (Dennison, 2003b). The work presented was supported in part by the NASA Space Environments and Effects (SEE) Program, the Boeing Corporation, and a NASA Graduate Fellowship. Samples were supplied by Boeing, the Environmental Effects Group at Marshall Space Flight Center, and Sheldahl, Inc.

Thomson, C. D.↗

Mode 1 and Mode 2 Analysis of Graphite/Epoxy Composites Using Double Cantilever Beam and End-Notched Flexure Tests

The critical strain energy release rates associated with debonding of the adhesive bondlines in graphite/epoxy IM6/3501-6 interlaminar fracture specimens were investigated. Two panels were manufactured for this investigation; however, panel two was layed-up incorrectly. As a result, data collected from Panel Two serves no real purpose in this investigation. Double Cantilever Beam (DCB) specimens were used to determine the opening Mode I interlaminar fracture toughness, G1(sub c), of uni-directional fiber re-inforced composites. The five specimens tested from Panel One had an average value of 946.42J/sq m for G1(sub c) with an acceptable coefficient of variation. The critical strain energy release rate, G2(sub c), for initiation of delamination under inplane shear loading was investigated using the End-Notched Flexure (ENF) Test. Four specimens were tested from Panel One and an average value of 584.98J/sq m for G2(sub c) was calculated. Calculations from the DCB and ENF test results for Panel One represent typical values of G1(sub c) and G2(sub c) for the adhesive debonding in the material studied in this investigation.

Hufnagel, Kathleen P.↗

Materials research for High Speed Civil Transport and generic hypersonics: Adhesive durability

This report covers a portion of an ongoing investigation of the durability of adhesives for the High Speed Civil Transport (HSCT) program. Candidate HSCT adhesives need to possess the high-temperature capability required for supersonic flight. This program was designed to initiate an understanding of the behavior of candidate HSCT materials when subjected to combined mechanical and thermal loads. Two adhesives (K3A and FM57) and two adherends (IM7/K3B polymeric composite and the titanium alloy Ti-6Al-4V) were used to fabricate thick adherend lap shear specimens. Due to processing problems, only the FM57/titanium bonds could be fabricated successfully. These are currently undergoing thermomechanical fatigue (TMF) testing. There is an acute need for an adhesive to secondarily bond polymeric composite adherends or, alternately, polymeric composites that remain stable at the processing temperatures of today's adhesives.

Allen, Mark R.↗

Flexibilized copolyimide adhesives

Two copolyimides, LARC-STPI and STPI-LARC-2, with flexible backbones were processed and characterized as adhesives. The processability and adhesive properties were compared to those of a commercially available form of LARC-TPI. Lap shear specimens were fabricated using adhesive tape prepared from each of the three polymers. Lap shear tests were performed at room temperature, 177 C, and 204 C before and after exposure to water-boil and to thermal aging at 204 C for up to 1000 hours. The three adhesive systems possess exceptional lap shear strengths at room temperature and elevated temperatures both before and after thermal exposure. LARC-STPI, because of its high glass transition temperature provided high lap shear strengths up to 260 C. After water-boil, LARC-TPI exhibited the highest lap shear strengths at room temperature and 177 C, whereas the LARC-STPI retained a higher percentage of its original strength when tested at 204 C. These flexible thermoplastic copolyimides show considerable potential as adhesives based on this study and because of the ease of preparation with low cost, commercially available materials.

Progar, Donald J.↗

Microgravity Experiments to Evaluate Electrostatic Forces in Controlling Cohesion and Adhesion of Granular Materials

The bulk behavior of dispersed, fluidized, or undispersed stationary granular systems cannot be fully understood in terms of adhesive/cohesive properties without understanding the role of electrostatic forces acting at the level of the grains themselves. When grains adhere to a surface, or come in contact with one another in a stationary bulk mass, it is difficult to measure the forces acting on the grains, and the forces themselves that induced the cohesion and adhesion are changed. Even if a single gain were to be scrutinized in the laboratory, it might be difficult, perhaps impossible, to define the distribution and character of surface charging and the three- dimensional relationship that charges (electrons, holes) have to one another. The hypothesis that we propose to test in microgravity (for dielectric materials) is that adhesion and cohesion of granular matter are mediated primarily by dipole forces that do not require the presence of a net charge; in fact, nominally electrically neutral materials should express adhesive and cohesive behavior when the neutrality results from a balance of positive and negative charge carriers. Moreover, the use of net charge alone as a measure of the electrical nature of grain-to-grain relationships within a granular mass may be misleading. We believe that the dipole forces arise from the presence of randomly-distributed positive and negative fixed charge carriers on grains that give rise to a resultant dipole moment. These dipole forces have long-range attraction. Random charges are created whenever there is triboelectrical activity of a granular mass, that is, whenever the grains experience contact/separation sequences or friction. Electrostatic forces are generally under-estimated for their role in causing agglomeration of dispersed grains in particulate clouds, or their role in affecting the internal frictional relationships in packed granular masses. We believe that electrostatic, in particular dipole-mediated processes, are pervasive and probably affect, at some level, everything from astrophysical-scale granular systems such as interstellar nebulae, protoplanetary dust and debris disks, planetary-scale systems such as debris palls from meteorite impact, volcanic eruptions, and aeolian dust storms, all the way to industrial-scale systems in mining, powder and grain processing, pharmaceuticals, and smoke-stack technologies. NASA must concern itself with the electrostatic behavior of dust and sand on Mars because of its potentially critical importance to human exploration. The motion and adhesion of martian surface materials will affect the design and performance of spacesuits, habitats, processing plants, solar panels, and any externally exposed equipment such as surface rovers or communication and weather stations. Additionally, the adhesion of dust and sand could greatly enhance contact with the potentially toxic components of the martian soil.

Marshall, J.↗

Microgravity Experiments to Evaluate Electrostatic Forces in Controlling Cohesion and Adhesion of Granular Materials

The bulk behavior of dispersed, fluidized, or undispersed stationary granular systems cannot be fully understood in terms of adhesive/cohesive properties without understanding the role of electrostatic forces acting at the level of the grains themselves. When grains adhere to a surface, or come in contact with one another in a stationary bulk mass, it is difficult to measure the forces acting on the grains, and the forces themselves that induced the cohesion and adhesion are changed. Even if a single grain were to be scrutinized in the laboratory, it might be difficult, perhaps impossible, to define the distribution and character of surface charging and the three-dimensional relationship that charges (electrons, holes) have to one another. The hypothesis that we propose to test in microgravity (for dielectric materials) is that adhesion and cohesion of granular matter are mediated primarily by dipole forces that do not require the presence of a net charge; in fact, nominally electrically neutral materials should express adhesive and cohesive behavior when the neutrality results from a balance of positive and negative charge carriers. Moreover, the use of net charge alone as a measure of the electrical nature of grain-to-grain relationships within a granular mass may be misleading. We believe that the dipole forces arise from the presence of randomly-distributed positive and negative fixed charge carriers on grains that give rise to a resultant dipole moment. These dipole forces have long-range attraction. Random charges are created whenever there is triboelectrical activity of a granular mass, that is, whenever the grains experience contact/separation sequences or friction.

Marshall, J.↗

Evaluation of Brushing as a Lunar Dust Mitigation Strategy for Thermal Control Surfaces

Evaluation of brushing to remove lunar simulant dust from thermal control surfaces is described. First, strip brushes made with nylon, PTFE, or Thunderon bristles were used to remove JSC-1AF dust from AZ93 thermal control paint or aluminized FEP (AlFEP) thermal control surface under ambient laboratory conditions. Nylon and PTFE bristles removed a promising amount of dust from AZ93, and nylon and Thunderon bristles from AlFEP. But when these were tested under simulated lunar conditions in the lunar dust adhesion bell jar (LDAB), they were not effective. In a third effort, seven brushes made up of three different materials, two different geometries, and different bristle lengths and thicknesses were tested under laboratory conditions against AZ93 and AlFEP. Two of these brushes, the Zephyr fiberglass fingerprint brush and the Escoda nylon fan brush, removed over 90 percent of the dust, and so were tested in the fourth effort in the LDAB. They also performed well under these conditions recovering 80 percent or more of the original thermal performance (solar absorptance/thermal emittance) of both AZ93 and AgFEP after 20 strokes, and 90 or more percent after 200 strokes.

Gaier, James R.↗