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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Evaluation of Impact Energy Attenuators and Composite Material Designs of a UAM VTOL Concept Vehicle

The development of Vertical Take-off and Landing (VTOL) vehicles for the Urban Air Mobility (UAM) markets presents a need for light weight vehicle structures with effective occupant protection capabilities. The National Aeronautics and Space Administration (NASA) has been working to fill that need, recently developing a cadre of concept vehicles to help characterize UAM design feasibility. This paper describes a study, using these concept vehicles, to evaluate the use of advanced composite structure and energy attenuating designs in the UAM vehicle design space. A finite element model (FEM) of a single passenger quadrotor concept vehicle was developed in LS-Dyna® and simulated under nominal and off-nominal vertical impact conditions. A variety of energy attenuating design mechanisms were implemented within this model to quantify their effectiveness in improving occupant safety. The use of carbon composites in both the energy attenuation mechanisms and vehicle structure was evaluated. The results of this study found significant reduction in occupant injury risk with the implementation of energy absorbing composite crush tubes and landing gear within the vehicle design. Additionally the use of a carbon fiber as a structural material was found to provide significant weight reduction while maintaining similar occupant loads to that predicted with an aluminum structure. This work provides a preliminary evaluation of design mechanisms and materials that may be used to optimize occupant protection capabilities within the UAM market.

Putnam, Jacob↗
NASA NTRS1992

Flight-vehicle materials, structures, and dynamics - Assessment and future directions. Vol. 3 - Ceramics and ceramic-matrix composites

The present volume discusses ceramics and ceramic-matrix composites in prospective aerospace systems, monolithic ceramics, transformation-toughened and whisker-reinforced ceramic composites, glass-ceramic matrix composites, reaction-bonded Si3N4 and SiC composites, and chemical vapor-infiltrated composites. Also discussed are the sol-gel-processing of ceramic composites, the fabrication and properties of fiber-reinforced ceramic composites with directed metal oxidation, the fracture behavior of ceramic-matrix composites (CMCs), the fatigue of fiber-reinforced CMCs, creep and rupture of CMCs, structural design methodologies for ceramic-based materials systems, the joining of ceramics and CMCs, and carbon-carbon composites.

Levine, Stanley R.↗
NASA NTRS1991

Proceedings of the 7th Semiannual Meeting of the Nozzle Initiative Industry Advisory Committee on Standardization of Carbon-Phenolic Test Methods and Specifications

The application of carbon fibers and fabrics (CF) for producing rocket nozzles is discussed. These materials which are essential for fabricating the carbon composites used in aerospace systems gasify when exposed to high temperatures and the mechanical properties of the composites degrade. The oxidation kinetics under isothermal (IC) and non-isothermal (NIC) conditions are examined and a comparison is made between the characteristics of IC and NIC oxidation. Several CF, chars, and carbon blacks were examined, including a microporous char, a graphitized rayon fabric, and several carbonized rayon fabrics. A summary is given of the advantages and drawbacks of isothermal and non-isothermal oxidation of carbons. The proceedings are assembled in the form of a roundtable discussion.

Hall, William B.↗
NASA NTRS2006

Active Metal Brazing and Adhesive Bonding of Titanium to C/C Composites for Heat Rejection System

Robust assembly and integration technologies are critically needed for the manufacturing of heat rejection system (HRS) components for current and future space exploration missions. Active metal brazing and adhesive bonding technologies are being assessed for the bonding of titanium to high conductivity Carbon-Carbon composite sub components in various shapes and sizes. Currently a number of different silver and copper based active metal brazes and adhesive compositions are being evaluated. The joint microstructures were examined using optical microscopy, and scanning electron microscopy (SEM) coupled with energy dispersive spectrometry (EDS). Several mechanical tests have been employed to ascertain the effectiveness of different brazing and adhesive approaches in tension and in shear that are both simple and representative of the actual system and relatively straightforward in analysis. The results of these mechanical tests along with the fractographic analysis will be discussed. In addition, advantages, technical issues and concerns in using different bonding approaches will also be presented.

Singh, M.↗
NASA NTRS1991

The use of ultrasonic property measurements as the basis for finite element analysis of composite materials

In this work, the use of ultrasonic property measurements as the basis for finite element analysis of full scale composite components is presented. The approach utilizes multiple velocity measurements at oblique angles of incidence and quantitative analysis of radiographic images for the local determination of each of the nine orthotropic moduli in a woven carbon-carbon composite. These values were then used as input into a finite element code (NASTRAN) to analyze the response of the material to load: here, diametric compression. The predicted response was then compared with strain gage results at several locations to validate the approach.

Madaras, E. I.↗
NASA NTRS2007

Condition Assessment of Kevlar Composite Materials Using Raman Spectroscopy

This viewgraph presentation includes the following main concepts. Goal: To evaluate Raman spectroscopy as a potential NDE tool for the detection of stress rupture in Kevlar. Objective: Test a series of strand samples that have been aged under various conditions and evaluate differences and trends in the Raman response. Hypothesis: Reduction in strength associated with stress rupture may manifest from changes in the polymer at a molecular level. If so, than these changes may effect the vibrational characteristics of the material, and consequently the Raman spectra produced from the material. Problem Statement: Kevlar composite over-wrapped pressure vessels (COPVs) on the space shuttles are greater than 25 years old. Stress rupture phenomena is not well understood for COPVs. Other COPVs are planned for hydrogen-fueled vehicles using Carbon composite material. Raman spectroscopy is being explored as an non-destructive evaluation (NDE) technique to predict the onset of stress rupture in Kevlar composite materials. Test aged Kevlar strands to discover trends in the Raman response. Strength reduction in Kevlar polymer will manifest itself on the Raman spectra. Conclusions: Raman spectroscopy has shown relative changes in the intensity and FWHM of the ~1613 cm(exp -1) peak. Reduction in relative intensity for creep, fleet leader, and SIM specimens compared to the virgin strands. Increase in FWHM has been observed for the creep and fleet leader specimens compared to the virgin strands. Changes in the Raman spectra may result from redistributing loads within the material due to the disruption of hydrogen bonding between crystallites or defects in the crystallites from aging the Kevlar strands. Peak shifting has not been observed to date. Analysis is ongoing. Stress measurements may provide a tool in the short term.

Washer, Glenn↗
NASA NTRS1990

Lightweight piston architecture

The invention is an improvement in a lightweight carbon-carbon composite piston, the improvement uses near-net shape knitted or warp-interlock preforms to improve the structural qualities of the piston. In its preferred embodiment, a one piece, tubular, closed-ended, knitted preform (a sock) of carbon fibers embedded within the matrix of the piston structure forms the crown, side wall, skirt and inner surface of the piston, and wrap-interlock preforms strengthen the piston crown and wrist pin bosses.

Taylor, Allan H.↗
NASA NTRS2004

On-Orbit Repair of RCC Structures

On-orbit repair technologies for reinforced carbon-carbon composite (RCC) structures are critically needed for space shuttle return to flight (RTF) efforts. These technologies are also critically needed for the repair and refurbishment of thermal protection system of future Crew Entry Vehicles (CEV) of space exploration programs. GRABER (Glenn Adhesive Refractory for Bonding and Exterior Repair) has shown multiuse capability for in-space repair of both large repairs and small cracks in space shuttle Reinforced Carbon Carbon (RCC) leading edge material. The concept consists of preparing an adhesive paste and then applying the paste tot he damaged/cracked area of the RCC composites with caulking gun. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during vehicle re-entry conditions. Further development and testing are underway to optimize the materials properties and extend the application temperature.

Singh, M.↗
NASA NTRS2023

A Summary of Structural Test and Simulation Results for Hawker 4000 Composite Fuselage Hardware

NASA Langley Research Center (LaRC) was able to obtain a partially fabricated Hawker Beechcraft Model 4000 (Hawker 4000) aft aircraft section to use for study. The Hawker 4000 is a medium sized business jet (14 Code of Federal Regulations Part 25 – Transport Category Aircraft) with seating for 8 to 14 people and fabricated out of carbon composite. The Hawker 4000 was designed in the early 2000s to compete with Gulfstream and Bombardier business jet units. The Hawker Beechcraft business unit declared bankruptcy in 2012, and abruptly halted production of the 4000 series aircraft. As a result, only 73 full production aircraft were built. This all-composite aft fuselage section was an ideal candidate to utilize for investigations of composite structures undergoing dynamic loading in order to satisfy NASA Revolutionary Vertical Lift Technology (RVLT) project objectives. Thus, a team at NASA LaRC embarked on a test and simulation program in late 2021 in order to generate test data of composite structures undergoing dynamic loading conditions. As a part of these investigations, methods including reverse engineering the geometry, conducting as-fabricated materials testing and using non-destructive evaluation (NDE) techniques such as ultrasonic through transmission were utilized in order to develop digital twin finite element models for use in computational simulations.

dynamic composite testing↗
NASA NTRS1999

Nondestructive Superresolution Imaging of Defects and Nonuniformities in Metals, Semiconductors, Dielectrics, Composites, and Plants Using Evanescent Microwaves

We have imaged and mapped material nonuniformities and defects using microwaves generated at the end of a microstripline resonator with 0.4 micrometer lateral spatial resolution at 1 GHz. Here we experimentally examine the effect of microstripline substrate permittivity, the feedline-to-resonator coupling strength, and probe tip geometry on the spatial resolution of the probe. Carbon composites, dielectrics, semiconductors, metals, and botanical samples were scanned for defects, residual stresses, subsurface features, areas of different film thickness, and moisture content. The resulting evanescent microwave probe (EMP) images are discussed. The main objective of this work is to demonstrate the overall capabilities of the EMP imaging technique as well as to discuss various probe parameters that can be used to design EMPs for different applications.

Tabib-Azar, M.↗
NASA NTRS1972

Carbon isotopic studies of organic matter in Precambrian rocks.

A survey has been undertaken of the carbon composition of the total organic fraction of a suite of Precambrian sediments to detect isotopic trends possibly correlative with early evolutionary events. Early Precambrian cherts of the Fig Tree and upper and middle Onverwacht groups of South Africa were examined for this purpose. Reduced carbon in these cherts was found to be isotopically similar to photosynthetically produced organic matter of younger geological age. Reduced carbon in lower Onverwacht cherts was found to be anomalously heavy; it is suggested that this discontinuity may reflect a major event in biological evolution.

Oehler, D. Z.↗
NASA NTRS2008

Special Polymer/Carbon Composite Films for Detecting SO2

A family of polymer/carbon films has been developed for use as sensory films in electronic noses for detecting SO2 gas at concentrations as low as 1 part per million (ppm). Most previously reported SO2 sensors cannot detect SO2 at concentrations below tens of ppm; only a few can detect SO2 at 1 ppm. Most of the sensory materials used in those sensors (especially inorganic ones that include solid oxide electrolytes, metal oxides, and cadmium sulfide) must be used under relatively harsh conditions that include operation and regeneration at temperatures greater than 100 C. In contrast, the present films can be used to detect 1 ppm of SO2 at typical opening temperatures between 28 and 32 C and can be regenerated at temperatures between 36 and 40 C. The basic concept of making sensing films from polymer/carbon composites is not new. The novelty of the present family of polymer/carbon composites lies in formulating the polymer components of these composites specifically to optimize their properties for detecting SO2. First-principles quantum-mechanical calculations of the energies of binding of SO2 molecules to various polymer functionalities are used as a guide for selecting polymers and understanding the role of polymer functionalities in sensing. The polymer used in the polymer-carbon composite is a copolymer of styrene derivative units with vinyl pyridine or substituted vinyl pyridine derivative units. To make a substituted vinyl pyridine for use in synthesizing such a polymer, poly(2-vinyl pyridine) that has been dissolved in methanol is reacted with 3-chloropropylamine that has been dissolved in a solution of methanol. The methanol is then removed to obtain the copolymer. Later, the copolymer can be dissolved in an appropriate solvent with a suspension of carbon black to obtain a mixture that can be cast and then dried to obtain a sensory film.

Homer, Margie↗
NASA NTRS1998

An Evanescent Microwave Probe for Super-Resolution Nondestructive Imaging of Metals, Semiconductors, Dielectrics, Composites and Biological Specimens

Using evanescent microwaves with decay lengths determined by a combination of microwave wavelength (lambda) and waveguide termination geometry, we have imaged and mapped material non-uniformities and defects with a resolving capability of lambda/3800=79 microns at 1 GHz. In our method a microstrip quarter wavelength resonator was used to generate evanescent microwaves. We imaged materials with a wide range of conductivities. Carbon composites, dielectrics (Duroid, polymers), semiconductors (3C-SiC, polysilicon, natural diamond), metals (tungsten alloys, copper, zinc, steel), high-temperature superconductors, and botanical samples were scanned for defects, residual stresses, integrity of brazed junctions, subsurface features, areas of different film thickness and moisture content. The evanescent microwave probe is a versatile tool and it can be used to perform very fast, large scale mapping of a wide range of materials. This method of characterization compares favorably with ultrasound testing, which has a resolution of about 0.1 mm and suffers from high absorption in composite materials and poor transmission across boundaries. Eddy current methods which can have a resolution on the order of 50 microns are restricted to evaluating conducting materials. Evanescent microwave imaging, with careful choice of operating frequency and probe geometry, can have a resolution of up to 1 micron. In this method we can scan hot and moving objects, sample preparation is not required, testing is non-destructive, non-invasive and non-contact, and can be done in air, in liquid or in vacuum.

Pathak, P. S.↗
NASA NTRS1993

A photovoltaic catenary-tent array for the Martian surface

To provide electrical power during an exploration mission to Mars, a deployable tent-shaped structure with a flexible photovoltaic (PV) blanket is proposed. The array is designed with a self-deploying mechanism utilizing pressurized gas expansion. The structural design for the array uses a combination of cables, beams, and columns to support and deploy the PV blanket. Under the force of gravity, a cable carrying a uniform load will take the shape of a catenary curve. A catenary-tent collector is self shading which must be taken into account in the solar radiation calculation. The shape and the area of the shadow on the array was calculated and used in the determination of the global irradiance on the array. The PV blanket shape and structure dimensions were optimized to achieve a configuration which maximizes the specific power (W/kg). The optimization was performed for three types of PV blankets (silicon, gallium arsenide over germanium, and amorphous silicon) and two types of structural materials (carbon composite and arimid fiber composite). The results show that the catenary shape of the PV blanket corresponding to zero end angle at the base with respect to the horizontal results in the highest specific power. The tent angle is determined by optimizing the specific mass and the output power for maximum specific power. The combination of carbon fiber structural material and amorphous silicon blanket produces the highest specific power.

Colozza, Anthony J.↗
NASA NTRS2012

Large Scale Composite Manufacturing for Heavy Lift Launch Vehicles

Risk reduction for the large scale composite manufacturing is an important goal to produce light weight components for heavy lift launch vehicles. NASA and an industry team successfully employed a building block approach using low-cost Automated Tape Layup (ATL) of autoclave and Out-of-Autoclave (OoA) prepregs. Several large, curved sandwich panels were fabricated at HITCO Carbon Composites. The aluminum honeycomb core sandwich panels are segments of a 1/16th arc from a 10 meter cylindrical barrel. Lessons learned highlight the manufacturing challenges required to produce light weight composite structures such as fairings for heavy lift launch vehicles.

Stavana, Jacob↗
NASA NTRS2012

In-Situ Nondestructive Evaluation of Kevlar(Registered Trademark)and Carbon Fiber Reinforced Composite Micromechanics for Improved Composite Overwrapped Pressure Vessel Health Monitoring

NASA has been faced with recertification and life extension issues for epoxy-impregnated Kevlar 49 (K/Ep) and carbon (C/Ep) composite overwrapped pressure vessels (COPVs) used in various systems on the Space Shuttle and International Space Station, respectively. Each COPV has varying criticality, damage and repair histories, time at pressure, and pressure cycles. COPVs are of particular concern due to the insidious and catastrophic burst-before-leak failure mode caused by stress rupture (SR) of the composite overwrap. SR life has been defined [1] as the minimum time during which the composite maintains structural integrity considering the combined effects of stress level(s), time at stress level(s), and associated environment. SR has none of the features of predictability associated with metal pressure vessels, such as crack geometry, growth rate and size, or other features that lend themselves to nondestructive evaluation (NDE). In essence, the variability or surprise factor associated with SR cannot be eliminated. C/Ep COPVs are also susceptible to impact damage that can lead to reduced burst pressure even when the amount of damage to the COPV is below the visual detection threshold [2], thus necessitating implementation of a mechanical damage control plan [1]. Last, COPVs can also fail prematurely due to material or design noncompliance. In each case (SR, impact or noncompliance), out-of-family behavior is expected leading to a higher probability of failure at a given stress, hence, greater uncertainty in performance. For these reasons, NASA has been actively engaged in research to develop NDE methods that can be used during post-manufacture qualification, in-service inspection, and in-situ structural health monitoring. Acoustic emission (AE) is one of the more promising NDE techniques for detecting and monitoring, in real-time, the strain energy release and corresponding stress-wave propagation produced by actively growing flaws and defects in composite materials [3,4,5,6,7,8]. To gain further insight into the mechanisms responsible for composite rupture, broadband modal acoustic emission analysis was used. Also, since AE data reduction proved to be very time consuming, specialized data reduction software was written to automate the process.

Waller, Jess↗
NASA NTRS1986

Evaluation of carbon-carbon for space engine nozzle

An investigation is underway to determine the suitability of carbon-carbon composite materials for lightweight nozzle extensions on the Orbit Transfer Vehicle (OTV). The best combinations of fiber precursor, matrix material, and oxidation protection coatings are being evaluated in a series of hot-fire tests in an O sub 2/H sub 2 rocket nozzle environment. Evaluation criteria include life expectancy (recession), strength to weight, producibility, maturity, and cost. A data base of carbon-carbon performance in the OTV nozzle environment will be established which may be used in designing a full-scale OTV nozzle extension.

Suhoza, J. P.↗