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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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NASA NTRS1992

High performance polymers and polymer matrix composites for spacecraft structural applications

A program implemented by NASA Langley Research Center to develop and evaluate new polymers and polymer matrix composites for spacecraft structural applications is examined. Various polymeric films, moldings, and adhesives are evaluated for resistance to atomic oxygen and high energy electron and UV radiation. Thin films from the poly(arylene ether)s containing phenylphosphine oxide groups and the siloxane-epoxies exhibited minor weight loss compared to Kapton polyimide after exposure. Large doses (greater than 10 exp 9 rads) of electron radiation, simulating 30 yr of exposure in GEO, are found to alter the chemical structure of epoxies by both chain scission and cross-linking. The thermal cycling representative of both LEO and GEO environments can cause microcracking in composites which can in turn affect the dimensional stability and produce mechanical property reductions. The processing and fabrication issues associated with precision composite spacecraft components are also addressed.

Bowles, D. E.↗
NASA NTRS1993

Freeze-Drying Makes Improved IPN And Semi-IPN Polymers

Novel process developed for production of interpenetrating polymer networks (IPN's) or semi-IPN's with greater fracture toughness and resistance to microcracks. Process controls degree of phase separation in IPN's. In experiment, IPN's and semi-IPN's formed by dissolving constituents in another common solvent in traditional method. Resins and composite materials produced were tested for both traditional and freeze-drying processes. Glass-transition temperatures and data from dynamic mechanical tests of freeze-dried IPN's and semi-IPN's demonstrated freeze-drying process provided much improved IPN's and semi-IPN's.

Pater, Ruth H.↗
NASA NTRS1992

Space environmental effects on LDEF low Earth orbit exposed graphite reinforced polymer matrix composites

The Long Duration Exposure Facility (LDEF) was deployed on April 7, 1984 in low earth orbit (LEO) at an altitude of 482 kilometers. On board experiments experienced the harsh LEO environment including atomic oxygen (AO), ultraviolet radiation (UV), and thermal cycling. During the 5.8 year mission, the LDEF orbit decayed to 340 kilometers where significantly higher AO concentrations exist. LDEF was retrieved on January 12, 1990 from this orbit. One experiment on board LDEF was M0003, Space Effects on Spacecraft Materials. As a subset of M0003 nearly 500 samples of polymer, metal, and glass matrix composites were flown as the Advanced Composites Experiment M0003-10. The Advanced Composites Experiment is a joint effort between government and industry with the Aerospace Corporation serving as the experiment integrator. A portion of the graphite reinforced polymer matrix composites were furnished by the Boeing Defense and Space Group, Seattle, Washington. Test results and discussions for the Boeing portion of M0003-10 are presented. Experiment and specimen location on the LDEF are presented along with a quantitative summary of the pertinent exposure conditions. Matrix materials selected for the test were epoxy, polysulfone, and polyimide. These composite materials were selected due to their suitability for high performance structural capability in spacecraft applications. Graphite reinforced polymer matrix composites offer higher strength to weight ratios along with excellent dimensional stability. The Boeing space exposed and corresponding ground control composite specimens were subjected to post flight mechanical, chemical, and physical testing in order to determine any changes in critical properties and performance characteristics. Among the more significant findings are the erosive effect of atomic oxygen on leading edge exposed specimens and microcracking in non-unidirectionally reinforced flight specimens.

George, Pete↗
NASA NTRS1992

Method and apparatus for evaluating multilayer objects for imperfections

A multilayer object where the layers are arranged in a stacking direction is evaluated for imperfections such as voids, delaminations, and microcracks. First, an acoustic wave is transmitted into the object in the stacking direction via an appropriate transducer/waveguide combination. The wave propagates through the multilayer object and is received by another transducer/waveguide combination preferably located on the same surface as the transmitting combination. The received acoustic wave is correlated with the presence or absence of imperfections by generating pulse echo signals indicative of the received acoustic wave, wherein the successive signals form distinct groups over time. The respective peak amplitudes of each group are sampled and fitted to an exponential curve, wherein a substantial fit of approximately 80-90 percent indicates the absence of imperfections. Alternatively, the time interval between distinct groups can be measured, wherein equal intervals indicate the absence of imperfections and unequal intervals indicate the presence of imperfections.

Heyman, Joseph S.↗
NASA NTRS1992

A tough high performance composite matrix

This invention is a semi-interpenetrating polymer network which includes a high performance thermosetting polyimide having a nadic end group acting as a crosslinking site and a high performance linear thermoplastic polyimide. An improved high temperature matrix resin is provided which is capable of performing in the 200 to 300 C range. This resin has significantly improved toughness and microcracking resistance, excellent processability, mechanical performance and moisture and solvent resistances.

Pater, Ruth H.↗
NASA NTRS1992

Stress analysis and damage evaluation of flawed composite laminates by hybrid-numerical methods

Structural components in flight vehicles is often inherited flaws, such as microcracks, voids, holes, and delamination. These defects will degrade structures the same as that due to damages in service, such as impact, corrosion, and erosion. It is very important to know how a structural component can be useful and survive after these flaws and damages. To understand the behavior and limitation of these structural components researchers usually do experimental tests or theoretical analyses on structures with simulated flaws. However, neither approach has been completely successful. As Durelli states that 'Seldom does one method give a complete solution, with the most efficiency'. Examples of this principle is seen in photomechanics which additional strain-gage testing can only average stresses at locations of high concentration. On the other hand, theoretical analyses including numerical analyses are implemented with simplified assumptions which may not reflect actual boundary conditions. Hybrid-Numerical methods which combine photomechanics and numerical analysis have been used to correct this inefficiency since 1950's. But its application is limited until 1970's when modern computer codes became available. In recent years, researchers have enhanced the data obtained from photoelasticity, laser speckle, holography and moire' interferometry for input of finite element analysis on metals. Nevertheless, there is only few of literature being done on composite laminates. Therefore, this research is dedicated to this highly anisotropic material.

Yang, Yii-Ching↗
NASA NTRS1993

Characterization and durability testing of plasma-sprayed zirconia-yttria and hafnia-yttria thermal barrier coatings. Part 1: Effect of spray parameters on the performance of several lots of partially stabilized zirconia-yttria powder

Initial experiments conducted on thermal barrier coatings prepared in the newly upgraded research plasma spray facility and the burner rig test facilities are discussed. Part 1 discusses experiments which establish the spray parameters for three baseline zirconia-yttria coatings. The quality of five similar coating lots was judged primarily by their response to burner rig exposure supplemented by data from other sources such as specimen characterizations and thermal diffusivity measurements. After allowing for burner rig variability, although there appears to be an optimum density (i.e., optimum microstructure) for maximum burner rig life, the distribution tends to be rather broad about the maximum. In Part 2, new hafnia-yttria-based coatings were evaluated against both baseline and alternate zirconia-yttria coatings. The hafnia-yttria coatings and the zirconia-yttria coatings that were prepared by an alternate powder vendor were very sensitive to plasma spray parameters, in that high-quality coatings were only obtained when certain parameters were employed. The reasons for this important observation are not understood. Also not understood is that the first of two replicate specimens sprayed for Part 1 consistently performed better than the second specimen. Subsequent experiments did not display this spray order affect, possibly because a chiller was installed in the torch cooling water circuit. Also, large changes in coating density were observed after switching to a new lot of electrodes. Analyses of these findings were made possible, in part, because of the development of a sensitive density measurement technique described herein in detail. The measured thermal diffusivities did not display the expected strong relationship with porosity. This surprising result was believed to have been caused by increased microcracking of the denser coatings on the stainless steel substrates.

Miller, Robert A.↗
NASA NTRS1993

The growth of small corrosion fatigue cracks in alloy 2024

The corrosion fatigue crack growth characteristics of small surface and corner cracks in aluminum alloy 2024 is established. The damaging effect of salt water on the early stages of small crack growth is characterized by crack initiation at constituent particle pits, intergranular microcracking for a less than 100 micrometers, and transgranular small crack growth for a micrometer. In aqueous 1 percent NaCl and at a constant anodic potential of -700 mV(sub SCE), small cracks exhibit a factor of three increase in fatigue crack growth rates compared to laboratory air. Small cracks exhibit accelerated corrosion fatigue crack growth rates at low levels of delta-K (less than 1 MPa square root of m) below long crack delta-K (sub th). When exposed to Paris regime levels of crack tip stress intensity, small corrosion fatigue cracks exhibit growth rates similar to that observed for long cracks. Results suggest that crack closure effects influence the corrosion fatigue crack growth rates of small cracks (a less than or equal to 100 micrometers). This is evidenced by similar small and long crack growth behavior at various levels of R. Contrary to the corrosion fatigue characteristics of small cracks in high strength steels, no pronounced chemical crack length effect is observed for Al by 2024 exposed to salt water.

Piascik, Robert S.↗
NASA NTRS1991

Probabilistic fracture finite elements

The Probabilistic Fracture Mechanics (PFM) is a promising method for estimating the fatigue life and inspection cycles for mechanical and structural components. The Probability Finite Element Method (PFEM), which is based on second moment analysis, has proved to be a promising, practical approach to handle problems with uncertainties. As the PFEM provides a powerful computational tool to determine first and second moment of random parameters, the second moment reliability method can be easily combined with PFEM to obtain measures of the reliability of the structural system. The method is also being applied to fatigue crack growth. Uncertainties in the material properties of advanced materials such as polycrystalline alloys, ceramics, and composites are commonly observed from experimental tests. This is mainly attributed to intrinsic microcracks, which are randomly distributed as a result of the applied load and the residual stress.

Liu, W. K.↗
NASA NTRS1992

A review of crack propagation under unsteady loading

The theories and research current available on crack propagation under unsteady loadings, especially those of acoustic origin, are reviewed. Since the original theories on fatigue failure did not account for random loading conditions, modified theories which provide statistical methods for evaluating the random loading have emerged. The impact of acoustic fatigue in the aerospace industry, basic principles such as fatigue crack initiation and propagation and load interactions, and testing procedures are discussed. Attention is also given to metal and metal alloy structures, fiber-reinforced composites and nonmetallic structures, short crack growth, and the effects of temperature, moisture, and corrosion on structures. Suggestions for future research in this field are presented, namely, studies on the effect of 'snap-through' response and associated crack growth patterns, studies in microcrack and 'small crack'; propagation under unsteady loading conditions, and the development of an accurate analytical model to predict acceleration and retardation effects in fatigue crack growth under random loading conditions.

Bryan, H. H.↗
NASA NTRS1991

A model for the progressive failure of laminated composite structural components

Laminated continuous fiber polymeric composites are capable of sustaining substantial load induced microstructural damage prior to component failure. Because this damage eventually leads to catastrophic failure, it is essential to capture the mechanics of progressive damage in any cogent life prediction model. For the past several years the authors have been developing one solution approach to this problem. In this approach the mechanics of matrix cracking and delamination are accounted for via locally averaged internal variables which account for the kinematics of microcracking. Damage progression is predicted by using phenomenologically based damage evolution laws which depend on the load history. The result is a nonlinear and path dependent constitutive model which has previously been implemented to a finite element computer code for analysis of structural components. Using an appropriate failure model, this algorithm can be used to predict component life. In this paper the model will be utilized to demonstrate the ability to predict the load path dependence of the damage and stresses in plates subjected to fatigue loading.

Allen, D. H.↗
NASA NTRS1992

A generic model for creep rupture lifetime estimation on fibrous ceramic composites

Because of their high strength and toughness at elevated temperatures, fiber reinforced ceramic composites such as SiC(f)/SiC and SiC(f)/Si3N4 have become candidates for next-generation turbine engine materials. A generic model is proposed for assessing the lifetime of this class of materials when subjected to long-term creep rupture conditions. This 2D model consists of interfacial cracks growing between square grains and rectangular fibers in the direction normal to the principal tensile stress axis. Neglecting transient effects, the total lifetime is derived based on the criterion that rupture is due to coalescence of adjacent cracks. Lifetime is inversely proportional to crack growth rate, volume fraction, and aspect ratio of the fibers; but extremely sensitive to the applied stress, due to the high power of the V-K(I) law. This lifetime estimation seems to be in fair agreement with the creep rupture data of SiC(w)/Si3N4 composite with 0 and 30 vol percent reinforcement tested at 1250 C in air. TEM performed on the postcrept specimens revealed that creep damage is predominantly in the form of microcracks at matrix/matrix as well as fiber/matrix interfaces, approximately in accord with the model simulation.

Chuang, Tze-Jer↗
NASA NTRS1992

Properties of intermingled carbon/PEEK 3-D woven composites

The presence of voids is one of the major problems associated with resin infiltration techniques when using 3-D woven preforms. Efforts to reduce the voids invariably result in the creation of microcracks. In this paper, the use of PEEK fibers intermingled with carbon fibers into a multi-layer preform is discussed. Influence of processing parameters, such as temperature, pressure, and consolidation time, on the composite properties is presented. One of the issues emphasized is the effect of pressure on buckling of the Z-reinforcement fibers and the bending behavior.

Mohamed, M. H.↗
NASA NTRS1992

The effect of multiple compliant layers at the fiber-matrix interface on residual thermal stresses in metal matrix composites

The large mismatch in thermoelastic properties of the fiber and matrix phases in advanced metal matrix composites, coupled with high consolidation temperatures, produces severe residual stresses that can be large enough to initiate microcracks in the matrix phase adjacent to the fiber/matrix interface. Previous investigations have demonstrated that the use of a compliant interfacial layer between fiber and matrix phases has the potential for reducing these residual stresses. In this paper, the influence of multiple compliant layers in reducing residual thermal stresses is investigated.

Pindera, Marek-Jerzy↗
NASA NTRS1993

Variation of the energy release rate as a crack approaches and passes through an elastic inclusion

The variation of the energy release rate (ERP) at the tip of a crack penetrating an elastic inclusion is analyzed using an approach involving modeling the random array of microcracks or other defects by an elastic inclusion with effective elastic properties. Computations are carried out using a finite element procedure. The eight-noded isoparametric serendipity element with the shift of the midpoint to the quarter-point is used to simulate the singularity at the crack tip, and the crack growth is accommodated by implementing a mesh regeneration technique. The ERP values were calculated for various crack tip positions which simulate the process of the crack approaching and penetrating the inclusion.

Li, Rongshun↗
NASA NTRS1993

Prediction of thermal cycling induced cracking in polymer matrix composites

This report summarizes the work done in the period February 1993 through July 1993 on the 'Prediction of Thermal Cycling Induced Cracking In Polymer Matrix Composites' program. An oral presentation of this work was given to Langley personnel in September of 1993. This document was prepared for archival purposes. Progress studies have been performed on the effects of spatial variations in material strength. Qualitative agreement was found with observed patterns of crack distribution. These results were presented to NASA Langley personnel in November 1992. The analytical methodology developed by Prof. McManus in the summer of 1992 (under an ASEE fellowship) has been generalized. A method for predicting matrix cracking due to decreasing temperatures and/or thermal cycling in all plies of an arbitrary laminate has been implemented as a computer code. The code also predicts changes in properties due to the cracking. Experimental progressive cracking studies on a variety of laminates were carried out at Langley Research Center. Results were correlated to predictions using the new methods. Results were initially mixed. This motivated an exploration of the configuration of cracks within laminates. A crack configuration study was carried out by cutting and/or sanding specimens in order to examine the distribution of cracks within the specimens. These investigations were supplemented by dye-penetrant enhanced X-ray photographs. The behavior of thin plies was found to be different from the behavior of thicker plies (or ply groups) on which existing theories are based. Significant edge effects were also noted, which caused the traditional metric of microcracking (count of cracks on a polished edge) to be very inaccurate in some cases. With edge and configuration taken into account, rough agreement with predictions was achieved. All results to date were reviewed with NASA Langley personnel in September 1993.

Mcmanus, Hugh L.↗
NASA NTRS1993

The impact of LDEF results on the space application of metal matrix composites

Over 200 graphite/aluminum and graphite/magnesium composites were flown on the leading and trailing edges of LDEF on the Advanced Composites Experiment. The performance of these composites was evaluated by performing scanning electron microscopy and x-ray photoelectron spectroscopy of exposed surfaces, optical microscopy of cross sections, and on-orbit and postflight thermal expansion measurements. Graphite/aluminum and graphite/magnesium were found to be superior to graphite/polymer matrix composites in that they are inherently resistant to atomic oxygen and are less susceptible to thermal cycling induced microcracking. The surface foils on graphite/aluminum and graphite/magnesium protect the graphite fibers from atomic oxygen and from impact damage from small micrometeoroid or space debris particles. However, the surface foils were found to be susceptible to thermal fatigue cracking arising from contamination embrittlement, surface oxidation, or stress risers. Thus, the experiment reinforced requirements for carefully protecting these composites from prelaunch oxidation or corrosion, avoiding spacecraft contamination, and designing composite structures to minimize stress concentrations. On-orbit strain measurements demonstrated the importance of through-thickness thermal conductivity in composites to minimize thermal distortions arising from thermal gradients. Because of the high thermal conductivity of aluminum, thermal distortions were greatly reduced in the LDEF thermal environment for graphite/aluminum as compared to graphite/magnesium and graphite/polymer composites. The thermal expansion behavior of graphite/aluminum and graphite/magnesium was stabilized by on-orbit thermal cycling in the same manner as observed in laboratory tests.

Steckel, Gary L.↗
NASA NTRS1993

Low-Earth orbit effects on organic composite materials flown on LDEF

Over 35 different types of organic matrix composites were flown as part of 11 different experiments onboard the NASA Long Duration Exposure Facility (LDEF) satellite. This materials and systems experiment satellite flew in low-earth orbit (LEO) for 69 months. For that period, the experiments were subjected to the LEO environment including atomic oxygen (AO), ultraviolet (UV) radiation, thermal cycling, microvacuum, meteoroid and space debris (M&D), and particle radiation. Since retrieval of the satellite in January of 1990, the principal experiment investigators have been deintegrating, examining, and testing the materials specimens flown. The most detrimental environmental effect on all organic matrix composites was material loss due to AO erosion. AO erosion of uncoated organic matrix composites (OMC) facing the satellite ram direction was responsible for significant mechanical property degradations. Also, thermal cycling-induced microcracking was observed in some nonunidirectional reinforced OMC's. Thermal cycling and outgassing caused significant but predictable dimensional changes as measured in situ on one experiment. Some metal and metal oxide-based coatings were found to be very effective at preventing AO erosion of OMC's. However, M&D impacts and coating fractures which compromised these coatings allowed AO erosion of the underlying OMC substrates. The findings for organic matrix composites flown on the LDEF are summarized and the LEO environmental factors, their effects, and the influence on space hardware design factors for LEO applications are identified.

George, Pete E.↗