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A low-density article comprising a flexible substrate and a pyrolizable material impregnated therein, methods of preparing, and devices using the article are disclosed. The pyrolizable material pyrolizes above 350 C and does not flow at temperatures below the pyrolysis temperature. The low-density article remains flexible after impregnation and continues to remain flexible when the pyrolizable material is fully pyrolized.
The effect of microcracking in the phenolic matrix of a three-dimensional woven thermal protection system (TPS) and the resulting material stiffness reduction was studied via a comparison of finite element analysis results from a linear analysis and an iterative linear analysis. A TPS is necessary to protect space vehicles from the aerodynamic heating of planetary entry. The Heatshield for Extreme Entry Environment Technology (HEEET) project has developed a TPS for use in high heat-flux and pressure missions. The material is a dual-layer continuous dry weave, which is then infiltrated with a low-density phenolic resin matrix to form a rigid ablator. The phenolic resin matrix does not have structural load transfer requirements, and testing has shown that the phenolic resin can fully satisfy thermal requirements when the matrix contains microcracks. Due to high stresses in the through-the-thickness direction of the material, phenolic microcracks may form in the matrix material, which would result in a reduction of stiffness. An exploratory study was conducted to determine if reduction in material stiffness would change the load paths and/or decrease the structural margins. A comparison was performed between a linear finite element analysis that did not take into account phenolic microcracking and an iterative linear finite element analysis that accounted for propagation of phenolic microcracking. Four subcases using varying assumptions were analyzed and the results indicate that the assumed strength at which the phenolic microcracking propagates was the critical parameter for determining the extent of microcracking in the phenolic matrix. Phenolic microcracking does not have an adverse effect on the structural response of the test article and is not a critical failure.
The promise of filamentary composite materials, whose development may be considered as entering its second generation, continues to generate intense interest and applications activity. Fiber reinforced composite materials offer substantially improved performance and potentially lower costs for aerospace hardware. Much progress has been achieved since the initial developments in the mid 1960's. Rather limited applications to primary aircraft structure have been made, however, mainly in a material-substitution mode on military aircraft, except for a few experiments currently underway on large passenger airplanes in commercial operation. To fulfill the promise of composite materials completely requires a strong technology base. NASA and AFOSR recognize the present state of the art to be such that to fully exploit composites in sophisticated aerospace structures, the technology base must be improved. This, in turn, calls for expanding fundamental knowledge and the means by which it can be successfully applied in design and manufacture.
Accelerated weathering and material compatibility testing for polymeric and asphaltic materials. NLR will be testing the durability of the polymeric materials proposed for use in the supporting structures designed by TESCI solar. This will include the bare materials and coupons attached to asphalt shingles. The exposure will be in damp heat and separately heat, humidity and UV light, all followed by mechanical evaluation. Modification 1 is an extension of the first round of testing with both a continuation of some of the same testing and addition of new testing methods and materials. The testing of materials in the condition of A3 looking at mechanical durability will be continued looking at the materials used in the mounting brackets. We will be adding in testing of the silicone adhesive to the module and of the module itself. For the mounting brackets, testing will also be conducted at multiple temperatures and humidity levels to allow for extrapolation to the field.
Multimaterial heterostructures have led to characteristics surpassing the individual components. Nature controls the architecture and placement of multiple materials through biomineralization of nanoparticles (NPs); however, synthetic heterostructure formation remains limited and generally departs from the elegance of self-assembly. Here, in this study, a class of block polymer structure-directing agents (SDAs) are developed containing repeat units capable of persistent (covalent) NP interactions that enable the direct fabrication of nanoscale porous heterostructures, where a single material is localized at the pore surface as a continuous layer. This SDA binding motif (design rule 1) enables sequence-controlled heterostructures, where the composition profile and interfaces correspond to the synthetic addition order. This approach is generalized with 5 material sequences using an SDA with only persistent SDA-NP interactions (“P-NP 1 –NP 2 ”; NP i = TiO 2 , Nb 2 O 5 , ZrO 2 ). Expanding these polymer SDA design guidelines, it is shown that the combination of both persistent and dynamic (noncovalent) SDA-NP interactions (“PD-NP 1 –NP 2 ”) improves the production of uniform interconnected porosity (design rule 2). The resulting competitive binding between two segments of the SDA (P- vs D-) requires additional time for the first NP type (NP 1 ) to reach and covalently attach to the SDA (design rule 3). The combination of these three design rules enables the direct self-assembly of heterostructures that localize a single material at the pore surface while preserving continuous porosity.
We report on the design of a six-channel tunable laser absorption spectroscopy instrument for measuring ambient gas-phase concentrations of CO, HCl, HCN, HF, CO2, and O2 in spacecraft environments. Monitoring of these compounds can provide early warning detection of fire events while also indicating what materials have been exposed to heating. Continued post-fire monitoring of these hazardous gases can also facilitate safe and effective cleanup. The sensor is a miniaturized version of a five-channel prototype that was previously validated in ground-based oxidative pyrolysis tests. Here, we describe absorption line selection and theoretical detection limits for a sensor with reduced absorption pathlengths for each detection channel, which allows for a substantial reduction in overall instrument footprint. Ultimately, the new instrument is designed to be used in fire safety tests conducted by NASA, where various materials will undergo oxidative pyrolysis in an unmanned spacecraft returning from low Earth orbit.
The development of a space continuous flow electrophoresis system (CFES) is discussed. The objectives of the experiment were: (1) to use a model sample material at a high concentration to evaluate the continuous flow electrophoresis process in the McDonnell Douglass CFES instrument and compare its separation resolution and sample throughput with related devices on Earth, and (2) to expand the basic knowledge of the limitations imposed by fluid flows and particle concentration effects on the electrophoresis process by careful design and evaluation of the space experiment. Hemoglobin and polysaccharide were selected as samples of concentration effects. The results from space show a large band spread of the high concentration of the single species of hemoglobin that was principally due to the mismatch of electrical conductivity between the sample and buffer.
This report covers the second 6 month period for the year March 1, 1994 to February 28, 1995. The material outlined in this semi-annual report continues from the previous semi-annual report. The Fein Focus Inc. x-ray source was delivered in September and coincides with the beginning of the second 6 month effort. As a result, and as outlined in the statement of work, this period was dedicated to the evaluation, testing and calibration of the x-ray source. In addition, in this period the modeling effort was continued and extended by the Tiger series of Monte-Carlo simulation programs for photon and electron interactions with materials obtained from the Oak Ridge RISC Library. Some further calculations were also made with the absorption model.
Materials tested for degradation by heat and light. Report presents early results of continuing series of photothermal aging tests of some candidate encapsulating materials for solar photovoltaic modules. Objectives of testing program: contribute to development of durable, low-cost encapsulants and predict lifetimes of encapsulated photovoltaic modules placed outdoors. Toward these ends, tests designed to reveal physical and chemical degradation mechanisms that affect encapsulants.
This work introduces recently implemented capabilities in the SCALE code system’s TRITON reactor physics sequence that improve molten salt reactor (MSR) modeling: (1) a volume balancing option, which automatically balances the volumes of the fed material with a corresponding material removal to maintain fixed mixture volumes in the neutron transport model and accurate densities, and (2) continuous feed from mixtures, which enables users to define material feed streams directly from salt mixture definitions rather than individual nuclides. The new capabilities were demonstrated via SCALE/TRITON simulations of two representative MSR concepts. Simulations of the 180 MWth molten chloride fast reactor—a system with a fixed fuel salt volume in the reactor core—applied continuous refueling with fresh fuel salt. The results confirm approximately constant reactivity when the new volume balancing capability is used. Additionally, excellent agreement with a manual feed-and-drain method for volume balancing further verified the new implementation. Simulations of the 400 MWth EIRENE reactor, an integral MSR in which the salt volume may grow over time within the reactor core, demonstrated the capability to represent growing salt volume within the TRITON depletion calculation. Compared with reference solutions, the results show consistent trends in reactivity and isotopic evolution, confirming that these new user-friendly capabilities provide accurate, physically consistent approaches for modeling MSRs in SCALE.
The optimization of functional materials is important to enhance their properties, but their complex geometries pose great challenges to optimization. Data-driven algorithms efficiently navigate such complex design spaces by learning relationships between material structures and performance metrics to discover high-performance functional materials. Surrogate-based active learning, continually improving its surrogate model by iteratively including high-quality data points, has emerged as a cost-effective data-driven approach. Furthermore, it can be coupled with quantum computing to enhance optimization processes, especially when paired with a special form of surrogate model (i.e., quadratic unconstrained binary optimization), formulated by factorization machine (FM). However, current practices often overlook the variability in design space sizes when determining the initial data size for optimization. In this work, we investigate the optimal initial data sizes required for efficient convergence across various design space sizes. By employing averaged piecewise linear regression, we identify initiation points where convergence begins, highlighting the crucial role of employing adequate initial data in achieving efficient optimization. These results contribute to the efficient optimization of functional materials by ensuring faster convergence and reducing computational costs in FM-based active learning.
Neutron-induced gamma ray production is an important source of background in Compton scatter gamma ray telescopes where organic scintillator material is used. Most important is deuteron formation when atmospheric albedo and locally produced neutrons are thermalized and subsequently absorbed in the hydrogenous material. The resulting 2.2 MeV gamma ray line radiation essentially represents a continuous isotropic source within the scintillator itself. Interestingly, using a scintillator material with a high hydrogen-to-carbon ratio to minimize the scintillator material with a high hydrogen-to-carbon ratio to minimize the neutron-induced 4.4 MeV carbon line favors the np reaction. The full problem of neutron-induced background in Compton scatter telescopes has been previously discussed. Results are presented of observations with the University of California balloon-borne Compton scatter telescope where the 2.2 MeV induced line emission is prominently seen.
The workshop comprised a series of technical sessions on materials themes, followed by theme panel meetings. Themes included materials, environmental parameters, and data bases; contamination; thermal control and protective coatings and surface treatments; polymers and films; polymer matrix composites; metals, ceramics, and optical materials; lubricants adhesives, seals, fasteners, solar cells, and batteries. This report contains most of the papers presented at the technical sessions. It also contains theme panel reports and visual aids. This document continues the LDEF Space Environmental Effects on Materials Special Investigation Group (MSIG) pursuit of its charter to investigate the effects of LEO exposure on materials which where not originally planned to be test specimens and to integrate this information with data generated by principal investigators into an LDEF materials data base.
Results of tests designed to compare the charging properties of spacecraft material under a monoenergetic beam and under a continuously distributed beam are summarized. In the test setup the electron source was mounted in the top of a cylindrical vacuum chamber. A sheet of 5-mil-thick Kapton was placed on an insulated metal substrate at the bottom of the vacuum chamber. The dc current arriving on the substrate was measured and a field meter measured the potential of the test sample. A retarding potential analyzer measured the energy spectrum of the incident electron beam. With the monoenergetic beam, the sample charged to 12 kV and electrical discharges occurred. With the multi-energy spectra the samples charged to only 6 kV and 4 kV, and no discharger were observed. In these experiments, no effort was made to duplicate the spectra occurring in space. The tests were intended to simply to compare spacecraft material charging properties using monoenergetic and continuous multi-energy beams.
For ceramics to be used as structural components in high temperature applications, their fracture toughness is improved by embedding continuous ceramic fibers. Ceramic matrix composite (CMC) materials allow increasing the overall operating temperature, raising the temperature safety margins, avoiding the need for cooling, and improving the damping capacity, while reducing the weight at the same time. They also need to be reliable and available in large quantities as well. In this paper, an innovative rapid prototyping technique to fabricate continuous fiber reinforced ceramic matrix composites is described. The process is simple, robust and will be widely applicable to a number of high temperature material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The results of mechanical properties and microstructural characterization are presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts at an order of magnitude lower cost than current CVI and PIP processes.
For ceramics to be used as structural components in high temperature applications, their fracture toughness is improved by embedding continuous ceramic fibers. Ceramic matrix composite (CMC) materials allow increasing the overall operating temperature, raising the temperature safety margins, avoiding the need for cooling, and improving the damping capacity, while reducing the weight at the same time. They also need to be reliable and available in large quantities as well. In this paper, an innovative rapid prototyping technique to fabricate continuous fiber reinforced ceramic matrix composites is described. The process is simple, robust and will be widely applicable to a number of high temperature material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The results of mechanical properties and microstructural characterization are presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts at an order of magnitude lower cost than current chemical vapor infiltration (CVI) and polymer impregnation and pyrolysis (PIP) processes.
Facilities for measuring material reactive characteristics have been under development for several years and span the atom energy range from thermal to 5 eV, the orbital collision energy. One of the high-atom energy facilities (The High Intensity/Energy Atomic Oxygen Source) capable of simulating the reactive part of LEO is described, along with results of beam characterization and preliminary material studies. The oxygen atom beam source was a continuous wave plasma produced by focusing a high-power CO2 laser through a lens system into a rare gas/molecular oxygen mixture chamber at elevated temperature. Material samples were exposed to the high velocity beam through an external feedthrough. The facility showed good stability in continued operation for more than 100 hours, producing fluences of 10 to the 21st to 10 to the 22nd atoms/sq cm. Reaction efficiencies and surface morphology have been measured for several materials at energies of 1.5 and 2.8 eV, matching with data generated from previous space flights. Activation energies for carbon and Kapton as measured in this facility were 800 cal/mole.
The abundance and diversity of hydrogen applications necessitates continued and accelerated research into advanced storage technologies. Traditionally, hydrogen has been stored as either a high-pressure, warm gas; or a low-pressure, cryogenic liquid. Methods such as cryo-supercritical and cryo-adsorbed have been explored, but are not yet mainstream. Cryo-adsorbed is attractive because higher storage densities at higher temperatures than liquid may be achieved. Recently NASA, in partnership with Eta Space, Southwest Research Institute, the University of Central Florida, and Air Liquide, have been exploring the use of inexpensive, commercially available silica aerogel blanket materials for cryo-adsorbed hydrogen storage. Unlike most adsorbents, aerogel blanket is not a powder, but a robust, composite material that can be formed into complex shapes to aid in more efficient storage system designs, and has already been proven to uptake large quantities of fluids such as nitrogen and oxygen. Recent experimental efforts into the uptake of low-pressure hydrogen gas at 77 K, and liquid hydrogen at normal boiling point (NBP) will be discussed. Although preliminary in nature, the test results are promising, showing up to a 49% increase in storage density at 77 K over the gas alone, and greater than a one-to-one volume equivalency with NBP LH 2 .