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NASA NTRS2005

Flammability of Epoxy Resins Containing Phosphorus

As part of a program to develop fire-resistant exterior composite structures for future subsonic commercial and general aviation aircraft, flame-retardant epoxy resins are under investigation. Epoxies and their curing agents (aromatic diamines) containing phosphorus were synthesized and used to prepare epoxy formulations. Phosphorus was incorporated within the backbone of the epoxy resin and not used as an additive. The resulting cured neat epoxy formulations were characterized by thermogravimetric analysis, propane torch test, elemental analysis, microscale combustion calorimetry, and fire calorimetry. Several formulations showed excellent flame retardation with phosphorous contents as low as 1.5% by weight. The fracture toughness and compressive strength of several cured formulations showed no detrimental effect due to phosphorus content. The chemistry and properties of these new epoxy formulations are discussed.

Flammability studies↗

NASA NTRS1992

Poly-phenylated diamines and their use as polycondensation monomers in the synthesis of polyamide, poly(amide-imide), and polyimide polymers

New polyphenylated polynuclear aromatic diamines, such as 1,3-bis[4-aminophenyl]-2,3,5-triphenylbenzene, a process for their manufacture and their use as polycondensation components for the manufacture of polyamide, polyamide-imide and polyimide polymers are described. The polymers obtained with the aromatic diamines according to the invention are readily soluble, rigid-rod polymers and are distinguished by outstanding modulus, tensile compression strength, energy absorption, coefficient of expansion and electrical properties.

Harris, Frank W.↗

NASA NTRS2008

Mechanical Properties and Durability of "Waterless Concrete"

Waterless concrete consists of molten elementary sulfur and aggregate. The aggregates in lunar environment will be lunar rocks and soil. Sulfur is present on the Moon in Troilite soil (FeS) and by oxidation soil iron and sulfur can be produced. Iron can be used to reinforce the sulfur concrete. Sulfur concrete specimens were cycled between liquid nitrogen (approximately 191 C) and room temperature (approximately 21 C) to simulate exposure to a lunar environment. Cycled and control specimens were subsequently tested in compression at room temperatures (approximately 21 C) and approximately 101 C. Test results showed that due to temperature cycling, compressive strength of cycled specimens was 20% of those non-cycled. Microscopic examination of the fracture surfaces from the cycled samples showed clear de-bonding of the sulfur from the aggregate material whereas it was seen well bonded in those non-cycled. This reduction in strength can be attributed to the large differences in thermal coefficients of expansion of the materials constituting the concrete which promoted cracking. Similar sulfur concrete mixtures were strengthened with short and long glass fibers. The glass fibers from lunar regolith simulant was melted in a 25 cc Pt-Rh crucible in a Sybron Thermoline high temperature MoSi2 furnace at melting temperatures of 1450 to 1600 C for times of 30 min to 1 hour. Glass fibers were cast from the melt into graphite crucibles and were annealed for a couple of hours at 600 C. Glass fibers and small rods were pulled from the melt. The glass melt wets the ceramic rod and long continuous glass fibers were easily hand drawn. The glass fibers were immediately coated with a protective polymer to maintain the mechanical strength. The glass fibers were used to reinforce sulfur concrete plated to improve the flexural strength of the sulfur concrete. Prisms beams strengthened with glass fibers were tested in 4-point bending test. Beams strengthened with glass fiber showed to exhibit an increase in the flexura strength by as much as 45%.

Toutanji, Houssam↗

NASA NTRS2006

Evaluation of Alternative Refractory Materials for the Main Flame Deflectors at KSC Launch Complexes

The deterioration of the refractory materials used to protect the KSC launch complex steel base structures from the high temperatures during launches results in frequent and costly repairs and safety hazards. KSC-SPEC-P-0012, Specification for Refractory Concrete, is ineffective in qualifying refractory materials. This study of the specification and of alternative refractory materials recommends a complete revision of the specification and further investigation of materials that were found to withstand the environment of the Solid Rocket Booster main flame deflector better than the refractory materials in current use in terms of compressive strength, tensile strength, modulus of rupture, shrinkage, and abrasion.

Calle, Luz Marina↗

NASA NTRS2009

Performance of "Waterless Concrete"

Waterless concrete consists of molten elementary sulfur and aggregate. The aggregates in a lunar environment will be lunar rocks and soil. Sulfur is present on the Moon in Troilite soil (FeS) and, by oxidation of the soil, iron and sulfur can be produced. Sulfur concrete specimens were cycled between liquid nitrogen (approx.]91 C) and room temperature (^21 C) to simulate exposure to a lunar environment. Cycled and control specimens were subsequently tested in compression at room temperatures (^21 C) and ^-101 C. Test results showed that due to temperature cycling, the compressive strength of cycled specimens was 20% of those non-cycled. This reduction in strength can be attributed to the large differences in thermal coefficients of expansion of the materials constituting the concrete which promoted cracking. Similar sulfur concrete mixtures were strengthened with short and long glass fibres. The lunar regolith simulant was melted in a 25 cc Pt- Rh crucible in a Sybron Thermoline high temperature MoSi2 furnace at melting temperatures of 1450 to 1600 C for times of 30 min to i hour. Glass fibres and small rods were pulled from the melt. The glass fibres were used to reinforce sulfur concrete plated to improve the flexural strength of the sulfur concrete. Beams strengthened with glass fibres showed to exhibit an increase in the flexural strength by as much as 45%.

Toutanji, H. A.↗

NASA NTRS2009

Polyimide Composites Based on Asymmetric Dianhydrides (a-ODPA vs a-BPDA)

Two series of low-melt viscosity imide resins (2-15 poise at 260-280 C) were formulated from either asymmetric oxydiphthalic anhydride (a-ODPA) or asymmetric biphenyl dianhydride (a- BPDA) with 4-phenylethynyl endcap (PEPA), along with 3,4'-oxydianiline, 3,4 - methylenedianiline, 3,3 -methylenedianiline or 3,3 -diaminobenzophenone, using a solvent-free melt process. These low-melt viscosity imide resins were fabricated into polyimide/T650-35 carbon fabric composites by resin transfer molding (RTM). Composites from a-ODPA based resins display better open-hole compression strength and short beam shear strength from room temperature to 288 C than that of the corresponding a-BPDA based resins. However, due to the lower Tg s of a-ODPA based resins (265-330 C), their corresponding composites do not possess 315 C use capability while the a-BPDA based composites do. In essence, RTM 370 (T g = 370 C), derived from a-BPDA and 3,4 -ODA and PEPA, exhibits the best overall property performance at 315 C (600 F).

Chuang, Kathy C.↗

NASA NTRS2010

Drilling on the Moon and Mars: Developing the Science Approach for Subsurface Exploration with Human Crews

DOMEX (Drilling on the Moon and Mars in Human Exploration) is using analog missions to develop the approach for using human crews to perform science activities on the Moon and Mars involving exploration and sampling of the subsurface. Subsurface science is an important activity that may be uniquely enabled by human crews. DOMEX provides an opportunity to plan and execute planetary mission science activities without the expense and overhead of a planetary mission. Objectives: The objective of this first in a series of DOMEX missions were to 1) explore the regional area to understand the geologic context and determine stratigraphy and geologic history of various geologic units in the area. 2) Explore for and characterize sites for deploying a deep (10 m depth) drilling system in a subsequent field season. 3) Perform GPR on candidate drill sites. 4) Select sites that represent different geological units deposited in different epochs and collect soil cores using sterile procedures for mineralogical, organic and biological analysis. 5) Operate the MUM in 3 different sites representing different geological units and soil characteristics. 6) Collect rock and soil samples of sites visited and analyze them at the habitat. Results: At mission start the crew performed a regional survey to identify major geologic units that were correlated to recognized stratigraphy and regional geologic maps. Several candidate drill sites were identified. During the rest of the mission, successful GPR surveys were conducted in four locations. Soil cores were collected in 5 locations representing soils from 4 different geologic units, to depths up to 1m. Soil cores from two locations were analyzed with PCR in the laboratory. The remainder were reserved for subsequent analysis. XRD analysis was performed in the habitat and in the field on 39 samples, to assist with sample characterization, conservation, and archiving. MUM was deployed at 3 field locations and 1 test location (outside the habitat) where it operated autonomously for 2-4 hours at each site. Depths achieved ranged from 15 to 70 cm depending on the soil compressive strength and the presence and depth of subsurface indurated layers. Subsurface samples weighing 0.5 to 1 g were collected at the deepest depth encountered at each of the sites using the MUM automated sample collection system, and subsequently analyzed with XRD. Downhole inspection of holes produced by MUM with the Raman spectrometer was acquired on two of the holes and spectral features associated with selenite were identified in specific soil layers. Previously unreported fossilized remains of vertebrate fauna from the Jurassic era were discovered during our mission. Analysis of mineral biomarkers associated with this discovery are underway.

Stoker, C. R.↗

NASA NTRS2007

Two-Band, Low-Loss Microwave Window

A window for a high-sensitivity microwave receiving system allows microwave radiation to pass through to a cryogenically cooled microwave feed system in a vacuum chamber, while keeping ambient air out of the chamber and helping to keep the interior of the chamber cold. The microwave feed system comprises a feed horn and a low-noise amplifier, both of which are required to be cooled to a temperature of 15 K during operation. The window is designed to exhibit very little microwave attenuation in two frequency bands: 8 to 9 GHz and 30 to 40 GHz. The window is 15 cm in diameter. It includes three layers (see figure): 1) The outer layer is made of a poly(tetrafluoroethylene) film 0.025 mm thick. This layer serves primarily to reflect and absorb solar ultraviolet radiation to prolong the life of the underlying main window layer, which is made of a polyimide that becomes weakened when exposed to ultraviolet. The poly(tetrafluoroethylene) layer also protects the main window layer against abrasion. Moreover, the inherent hydrophobicity of poly(tetrafluoroethylene) helps to prevent the highly undesirable accumulation of water on the outer surface. 2) The polyimide main window layer is 0.08 mm thick. This layer provides the vacuum seal for the window. 3) A 20-mm-thick layer of ethylene/ propylene copolymer foam underlies the main polyimide window layer. This foam layer acts partly as a thermal insulator: it limits radiational heating of the microwave feed horn and, concomitantly, limits radiational cooling of the window. This layer has high compressive strength and provides some mechanical support for the main window layer, reducing the strength required of the main window layer. The ethylene/propylene copolymer foam layer is attached to an aluminum window ring by means of epoxy. The outer poly(tetrafluoroethylene) film and the main polyimide window layer are sandwiched together and pressed against the window ring by use of a bolted clamp ring. The window has been found to introduce a microwave loss of only about 0.4 percent. The contribution of the window to the noise temperature of the microwave feed system has been found to be less than 1 K at 32 GHz and 0.2 K at 8.4 GHz.

Britcliffe, Michael↗

NASA NTRS2010

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

A methodology to compute probabilistically-combined thermo-mechanical fatigue life of polymer matrix laminated composites has been developed and is demonstrated. Matrix degradation effects caused by long-term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress-dependent multifactor-interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability-integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/-45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical-cyclic loads and low thermal-cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical-cyclic loads and high thermal-cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗

NASA NTRS2010

Probabilistic Simulation for Combined Cycle Fatigue in Composites

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multifactor interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗

NASA NTRS2010

Design of Structurally Efficient Tapered Struts (SETS)

A study was conducted to develop mass efficient composite struts. A closed-form design methodology for composite struts was developed using well established analyses to predict Euler buckling, local wall buckling; compression strength, damage tolerance, and interlaminar shear at geometric gradients. The methodology was coded in a spreadsheet suitable for convenient and rapid sizing of tapered composite struts. This spreadsheet analysis was used to determine the influence of several variables such as material stiffness, strut diameter, and material allowables on strut weight for given loading conditions. The comparison showed that, while the Park Aerospace design method was well suited to preliminary sizing for a conservative design, the closed-form-analyses-based spreadsheet accounts for all possible failure modes and is a good optimum strut design tool. The report concludes with a set of recommendations for future work in analytical design and analysis methodology enhancements.

Ravi Deo↗

NASA NTRS2010

Refractory Materials for Flame Deflector Protection

Fondu Fyre (FF) is currently the only refractory material qualified for use in the flame trench at KSC's Shuttle Launch Pads 39A and 3913. However, the material is not used as it was qualified and has undergone increasingly frequent and severe degradation due to the launch blasts. This degradation is costly as well as dangerous for launch infrastructure, crew and vehicle. The launch environment at KSC is unique. The refractory material is subject to the normal seacoast environment, is completely saturated with water before launch, and is subjected to vibrations and aggressive heat/blast conditions during launch. This report presents results comparing two alternate materials, Ultra-Tek FS gun mix and Kruzite GR Plus, with Fondu Fyre. The materials were subjected to bulk density, porosity, compression strength, modulus of rupture and thermal shock tests. In addition, test specimens were exposed to conditions meant to simulate the launch environment at KSC to help better understand how the materials will perform once installed.

Calle, Luz M.↗

NASA NTRS2011

Approaches for Tensile Testing of Braided Composites

For angleply composites, lamina tension and compression strengths are commonly determined by applying classical lamination theory to test data obtained from testing of angleply composite specimens. For textile composites such as 2D triaxial braids, analysis is more complex and standard test methods do not always yield reliable strength measurements. This paper describes recent research focused on development of more reliable tensile test methods for braided composites and presents preliminary data for various approaches. The materials investigated in this work have 0deg+/-60 2D triaxial braid architecture with nearly equal fiber volume fraction in each of the three fiber directions. Flat composite panels are fabricated by resin transfer molding (RTM) using six layers of the braided preform aligned along the 0deg fiber direction. Various epoxy resins are used as matrix materials. Single layer panels are also fabricated in order to examine local variations in deformation related to the braid architecture. Specimens are cut from these panels in the shape of standard straight-sided coupons, an alternative bowtie geometry, and an alternative notched geometry. Axial tensile properties are measured using specimens loaded along the 0deg fiber direction. Transverse tensile properties are measured using specimens loaded perpendicular to the 0deg fibers. Composite tubes are also fabricated by RTM. These tubes are tested by internal pressurization using a soft rubbery material sealed between the inside diameter of the tube and the load fixtures. The ends of the tube are unconstrained, so the primary load is in the hoop direction. Tubes are fabricated with the 0deg fibers aligned along the tube axis by overbraiding the preform on a mandrel. Since the loading is in the hoop direction, testing of the overbraided tube provides a measure of transverse tensile strength. Previous work has indicated that straight-sided coupons yield a transverse tensile strength that is much lower than the expected material strength because of premature edge-initiated failure. Full-field strain measured during transverse tensile tests clearly showed accumulation of edge damage prior to failure. In the current work, high speed video and testing of single layer specimens are used to investigate potential failure mechanisms in more detail. High speed video clearly shows the edge initiation in six layer transverse tensile test coupons. Specimens with the bowtie geometry and the notched geometry minimize this edge effect and yield significantly higher transverse tensile strength values compared to the straight-sided coupons. However, bowtie and notched specimens geometries are not ideal because of the non-uniform stress and strain fields in the region of failure. Testing of tubes using internal pressurization eliminates edge-initiated failure and provides a more uniform state of stress and strain. Preliminary results indicate that bowtie, notched, and tube specimens yield comparable values for transverse tensile strength and that these values are much higher than the strength measured using a straight-sided coupon.

Roberts, Gary D.↗

NASA NTRS2011

Investigation of Hygro-Thermal Aging on Carbon/Epoxy Materials for Jet Engine Fan Sections

This poster summarizes 2 years of aging on E862 epoxy and E862 epoxy with triaxial braided T700s carbon fiber composite. Several test methods were used to characterize chemical, physical, and mechanical properties of both the resin and composite materials. The aging cycle that was used included varying temperature and humidity exposure. The goal was to evaluate the environmental effects on a potential jet engine fan section material. Some changes were noted in the resin which resulted in increased brittleness, though this did not significantly affect the tensile and impact test results. A potential decrease in compression strength requires additional investigation.

Kohlman, Lee W.↗

NASA NTRS2011

Low Velocity Impact Damage to Carbon/Epoxy Laminates

Impact damage tends to be more detrimental to a laminate's compression strength as compared to tensile strength. Proper use of Non Destructive Evaluation (NDE) Techniques can remove conservatism (weight) from many structures. Test largest components economically feasible as coupons. If damage tolerance is a driver, then consider different resin systems. Do not use a single knockdown factor to account for damage.

Nettles, Alan T.↗

NASA NTRS2011

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

Chamis, Christos C.↗

NASA NTRS2011

Resilient and Corrosion-Proof Rolling Element Bearings Made from Superelastic Ni-Ti Alloys for Aerospace Mechanism Applications

Mechanical components (bearings, gears, mechanisms) typically utilize hard materials to minimize wear and attain long life. In such components, heavily loaded contact points (e.g., meshing gear teeth, bearing ball-raceway contacts) experience high contact stresses. The combination of high hardness, heavy loads and high elastic modulus often leads to damaging contact stress. In addition, mechanical component materials, such as tool steel or silicon nitride exhibit limited recoverable strain (typically less than 1 percent). These material attributes can lead to Brinell damage (e.g., denting) particularly during transient overload events such as shock impacts that occur during the launching of space vehicles or the landing of aircraft. In this paper, a superelastic alloy, 60NiTi, is considered for rolling element bearing applications. A series of Rockwell and Brinell hardness, compressive strength, fatigue and tribology tests are conducted and reported. The combination of high hardness, moderate elastic modulus, large recoverable strain, low density, and intrinsic corrosion immunity provide a path to bearings largely impervious to shock load damage. It is anticipated that bearings and components made from alloys with such attributes can alleviate many problems encountered in advanced aerospace applications.

DellaCorte, Christopher↗

NASA NTRS2003

Dry Process for Making Polyimide/ Carbon-and-Boron-Fiber Tape

A dry process has been invented as an improved means of manufacturing composite prepreg tapes that consist of high-temperature thermoplastic polyimide resin matrices reinforced with carbon and boron fibers. Such tapes are used (especially in the aircraft industry) to fabricate strong, lightweight composite-material structural components. The inclusion of boron fibers results in compression strengths greater than can be achieved by use of carbon fibers alone. The present dry process is intended to enable the manufacture of prepreg tapes (1) that contain little or no solvent; (2) that have the desired dimensions, fiber areal weight, and resin content; and (3) in which all of the fibers are adequately wetted by resin and the boron fibers are fully encapsulated and evenly dispersed. Prepreg tapes must have these properties to be useable in the manufacture of high-quality composites by automated tape placement. The elimination of solvent and the use of automated tape placement would reduce the overall costs of manufacturing.

Belvin, Harry L.↗