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DOE OSTI2024

Evaluating Iodine Immobilization Technologies: Cermets, Polycermets, and Polyhalmets

The work in this report documents the efforts conducted to assess the feasibility of some of the ideas documented in Pacific Northwest National Laboratory invention disclosure reports (IDRs) including: 1) Iodine capture in polyacrylonitrile (PAN)-containing composite sorbents (32451-E). In this work, the composites evaluated included Ag0, Bi0, Cu0, Bi2S3, and Cu2S embedded in PAN. 2) Metal iodide removal from these sorbents through dissolution in dimethyl sulfoxide (DMSO) (32729-E). In this work, PAN dissolution was evaluated for multiple types of sorbents including Ag-Pan, Bi-PAN, Cu-PAN, Bi2S3-PAN, and Cu2S-PAN. 3) Using metal-sulfide sorbents for iodine capture (32647-E). In this work, the composites evaluated under this IDR included Ag2S, Bi2S3, and Cu2S embedded in PAN. 4) Using low-melting metals to immobilize (encapsulate) iodine-loaded and polymer-containing sorbents into polymer-ceramic-metal (called polycermet) or polymer-halide-metal (called polyhalmet) composite waste forms (32625-E). In this work, the iodine-loaded PAN composites included AgI-PAN, BiI-PAN, and CuI-PAN. 5) Ceramic-metal composite waste form synthesis of polymer-containing materials using low-melting metals like bismuth, tin, or bismuth-tin alloys (32537-E). In this work, the metals evaluated included Bi, 58Bi-42Sn eutectic. 6) Cermets for immobilizing commercial sorbents loaded with radioiodine (32806-E). In this work, AgIX (iodine-loaded silver faujasite zeolite) was evaluated in cermet form.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
NASA NTRS1990

Nicalon/siliconoxycarbide ceramic composites

A number of polymers of differing molecular structure, viscosity, copolymer composition, and production procedures, screened for production of strong, tough Nicalon/siliconoxycarbide composites, are discussed. Variables during polymer synthesis include pH, water/methoxy ratio and phenyl/methyl ratio. Final processing temperatures of the composites range from 1200 deg to 1400 deg C. The filler is derived from pyrolysis of the 50 phenyl/50 methyl silsesquioxane copolymer pyrolyzed to 650 deg C, then milled to less than 1-micron powder. Composite samples were fractured to evaluate the influence of matrix composition, final fabrication temperature, and use of filler on the composite mode of failure, modulus, strain capability, and strength. Incorporation of filler was found to increase matrix compressive strength and to influence matrix shrinkage and cracking.

Hurwitz, F. I.↗
NASA NTRS1998

Scaling up the Single Transducer Thickness-Independent Ultrasonic Imaging Method for Accurate Characterization of Microstructural Gradients in Monolithic and Composite Tubular Structures

Ultrasonic velocity/time-of-flight imaging that uses back surface reflections to gauge volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse-echo ultrasonic velocity/time-of-flight imaging is that the image shows the effects of thickness as well as microstructural variations unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse-echo time-of-flight-based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples that eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material microstructure in plate-like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex-shaped structures-those having (hollow) tubular/curved geometry. The experimental inspection technique and results are described as applied to (1) monolithic mullite ceramic and polymer matrix composite 'proof-of-concept' tubular structures that contain machined patches of various depths and (2) as-manufactured monolithic silicon nitride ceramic and silicon carbide/silicon carbide composite tubular structures that might be used in 'real world' applications.

Roth, Don J.↗
NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

Ceramics↗
NASA NTRS1990

NASA's HITEMP program for UHBR engines

NASA's High Temperature Engine Materials Program (HITEMP) is concerned with the laboratory-scale technology development and feasibility demonstration of high-temperature composite materials, in conjunction with the requisite structural analysis models and test methods for their validation. HITEMP encompasses research on metallic/intermetallic, ceramic, and polymer matrix composites, and is giving attention to high-temperature component composites applicable to future widebody commercial aircraft ultrahigh bypass ratio (UHBR) engines. The UHBR components for which advanced composites are envisioned are fan, compressor, and turbine rotor blades, stator vanes, disks, and shafts, thrust bearings, gearbox bearings and linings, combustor cases and linings, nacelles, and thrust-reversers.

Stephens, Joseph R.↗
NASA NTRS2016

Stochastic-Strength-Based Damage Simulation of Ceramic Matrix Composite Laminates

The Finite Element Analysis-Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to characterize and predict the progressive damage response of silicon-carbide-fiber-reinforced reaction-bonded silicon nitride matrix (SiC/RBSN) composite laminate tensile specimens. Studied were unidirectional laminates [0] (sub 8), [10] (sub 8), [45] (sub 8), and [90] (sub 8); cross-ply laminates [0 (sub 2) divided by 90 (sub 2),]s; angled-ply laminates [plus 45 (sub 2) divided by -45 (sub 2), ]s; doubled-edge-notched [0] (sub 8), laminates; and central-hole laminates. Results correlated well with the experimental data. This work was performed as a validation and benchmarking exercise of the FEAMAC/CARES program. FEAMAC/CARES simulates stochastic-based discrete-event progressive damage of ceramic matrix composite and polymer matrix composite material structures. It couples three software programs: (1) the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC), (2) the Ceramics Analysis and Reliability Evaluation of Structures Life Prediction Program (CARES/Life), and (3) the Abaqus finite element analysis program. MAC/GMC contributes multiscale modeling capabilities and micromechanics relations to determine stresses and deformations at the microscale of the composite material repeating-unit-cell (RUC). CARES/Life contributes statistical multiaxial failure criteria that can be applied to the individual brittle-material constituents of the RUC, and Abaqus is used to model the overall composite structure. For each FEAMAC/CARES simulation trial, the stochastic nature of brittle material strength results in random, discrete damage events that incrementally progress until ultimate structural failure.

composite structures↗
NASA NTRS2007

Novel Nanotube Manufacturing Streamlines Production

Nanotubes have novel qualities that make them uniquely qualified for a plethora of uses, including applications in electronics, optics, and other scientific and industrial fields. The NASA process for creating these nanostructures involves using helium arc welding to vaporize an amorphous carbon rod and then form nanotubes by depositing the vapor onto a water-cooled carbon cathode, which then yields bundles, or ropes, of single-walled nanotubes at a rate of 2 grams per hour using a single setup. This eliminates costs associated with the use of metal catalysts, including the cost of product purification, resulting in a relatively inexpensive, high-quality, very pure end product. While managing to be less expensive, safer, and simpler, the process also increases the quality of the nanotubes. Goddard's Innovative Partnerships Program (IPP) Office promoted the technology, and in 2005, Boise-based Idaho Space Materials Inc. (ISM) was formed and applied for a nonexclusive license for the single-walled carbon nanotube (SWCNT) manufacturing technology. ISM commercialized its products, and the inexpensive, robust nanotubes are now in the hands of the scientists who will create the next generation of composite polymers, metals, and ceramics that will impact the way we live. In fact, researchers are examining ways for these newfound materials to be used in the manufacture of transistors and fuel cells, large screen televisions, ultra-sensitive sensors, high-resolution atomic force microscopy probes, supercapacitors, transparent conducting films, drug carriers, catalysts, and advanced composite materials, to name just a few of the myriad technologies to benefit.

Source record↗
NASA NTRS2014

The Effect of General Statistical Fiber Misalignment on Predicted Damage Initiation in Composites

A micromechanical method is employed for the prediction of unidirectional composites in which the fiber orientation can possess various statistical misalignment distributions. The method relies on the probability-weighted averaging of the appropriate concentration tensor, which is established by the micromechanical procedure. This approach provides access to the local field quantities throughout the constituents, from which initiation of damage in the composite can be predicted. In contrast, a typical macromechanical procedure can determine the effective composite elastic properties in the presence of statistical fiber misalignment, but cannot provide the local fields. Fully random fiber distribution is presented as a special case using the proposed micromechanical method. Results are given that illustrate the effects of various amounts of fiber misalignment in terms of the standard deviations of in-plane and out-of-plane misalignment angles, where normal distributions have been employed. Damage initiation envelopes, local fields, effective moduli, and strengths are predicted for polymer and ceramic matrix composites with given normal distributions of misalignment angles, as well as fully random fiber orientation.

Micromechanical↗
NASA NTRS1980

The materials processing research base of the Materials Processing Center

The goals and activities of the center are discussed. The center activities encompass all engineering materials including metals, ceramics, polymers, electronic materials, composites, superconductors, and thin films. Processes include crystallization, solidification, nucleation, and polymer synthesis.

Flemings, M. C.↗
NASA NTRS1989

Materials properties numerical database system established and operational at CINDAS/Purdue University

A computerized comprehensive numerical database system on the mechanical, thermophysical, electronic, electrical, magnetic, optical, and other properties of various types of technologically important materials such as metals, alloys, composites, dielectrics, polymers, and ceramics has been established and operational at the Center for Information and Numerical Data Analysis and Synthesis (CINDAS) of Purdue University. This is an on-line, interactive, menu-driven, user-friendly database system. Users can easily search, retrieve, and manipulate the data from the database system without learning special query language, special commands, standardized names of materials, properties, variables, etc. It enables both the direct mode of search/retrieval of data for specified materials, properties, independent variables, etc., and the inverted mode of search/retrieval of candidate materials that meet a set of specified requirements (which is the computer-aided materials selection). It enables also tabular and graphical displays and on-line data manipulations such as units conversion, variables transformation, statistical analysis, etc., of the retrieved data. The development, content, accessibility, etc., of the database system are presented and discussed.

Ho, C. Y.↗
NASA NTRS1992

LDEF Materials Workshop 1991, part 2

The LDEF Materials Workshop 1991 was a follow-on to the Materials Sessions at the First LDEF Post-Retrieval Symposium held in Kissimmee, Florida, June 1991. 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 coating and surface treatments; polymers and films; polymer matrix composites; metals, ceramics, and optical materials; lubricants adhesives, seals, fasteners, solar cells, and batteries. This document continues the LDEF Space Environmental Effects on Materials Special Investigation Group (MSIG) pursuit to investigate the effects of LEO exposure on materials which were not originally planned to be test specimens. Papers from the technical sessions are presented.

Stein, Bland A.↗
NASA NTRS1992

LDEF Materials Workshop 1991, part 1

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.

Stein, Bland A.↗
NASA NTRS1992

LDEF materials: An overview of the interim findings

The flight and retrieval of the National Aeronautics and Space Administration's Long Duration Exposure Facility (LDEF) provided an opportunity for the study of the low-Earth orbit (LEO) environment and long-duration space environmental effect (SEE) on materials that are unparalleled in the history of the U.S. space program. The 5.8-year flight of LDEF greatly enhanced the potential value of materials data from LDEF to the international SEE community, compared to that of the original 1-year flight plan. The remarkable flight attitude stability of LDEF enables specific analyses of various individual and combined effects of LEO environmental parameters on identical materials of the same space vehicle. NASA recognized the potential by forming the LDEF Space Environmental Effects on Materials Special Investigation Group (MSIG) to address the greatly expanded materials and LEO space environment parameter analysis opportunities available in the LDEF structure, experiment trays, and corollary measurements, so that the combined value of all LDEF materials data to current and future space missions will be assessed and documented. This paper provides an overview of the interim LDEF materials findings of the Principal Investigators and the Materials Special Investigation Group. These revelations are based on observations of LEO environmental effects on materials made in-space during LDEF retrieval and during LDEF tray deintegration at the Kennedy Space Center, and on findings of approximately 1.5 years of laboratory analyses of LDEF materials by the LDEF materials scientists. These findings were extensively reviewed and discussed at the MSIG-sponsored LDEF Materials Workshop '91. The results are presented in a format which categorizes the revelations as 'clear findings' or 'confusing/unexplained findings' and resultant needs for new space materials developments and ground simulation testing/analytical modeling in seven categories: environmental parameters and data bases; LDEF contamination; thermal control coatings and protective treatments; polymers and films; polymer-matrix composites; metals, ceramics, and optical materials; and systems-related materials. General outlines of findings of the other LDEF Special Investigation Groups (Ionizing Radiation, Meteoroid and Debris, and Systems) are also included. The utilization of LDEF materials data for future low-earth orbit missions is also discussed, concentrating on Space Station Freedom. Some directions for continuing studies of LDEF materials are outlined. In general, the LDEF data is remarkable consistent; LDEF will provide a 'benchmark' for materials design data bases for satellites in low-Earth orbit. Some materials were identified to be encouragingly resistant to LEO SEE for 5.8-years; other 'space qualified' materials displayed significant environmental degradation. Molecular contamination was widespread; LDEF offers an unprecedented opportunity to provide a unified perspective of unmanned LEO spacecraft contamination mechanisms. New material development requirements for long-term LEO missions have been identified and current ground simulation testing methods/data for new, durable materials concepts can be validated with LDEF results. LDEF findings are already being integrated into the design of Space Station Freedom.

Stein, Bland A.↗
NASA NTRS1993

LDEF materials overview

The flight and retrieval of the National Aeronautics and Space Administration's Long Duration Exposure Facility (LDEF) provided an opportunity for the study of the low-Earth orbit (LEO) environment and long-duration space environmental effects (SEE) on materials that is unparalleled in the history of the U.S. Space Program. The 5-year, 9-month flight of LDEF greatly enhanced the potential value of all materials on LDEF to the international SEE community, compared to that of the original 1-year flight plan. The remarkable flight attitude stability of LDEF enables specific analyses of individual and combined effects of LEO environmental parameters on identical materials on the same space vehicle. NASA recognized this potential by forming the LDEF Space Environmental Effects on Materials Special Investigation Group (MSIG) to address the greatly expanded materials and LEO space environment analysis opportunities available in the LDEF structure, experiment trays, and corollary measurements so that the combined value of all LDEF materials data to current and future space missions will be addressed and documented. An overview of the interim LDEF materials findings of the principal investigators and the Materials Special Investigation Group is provided. These revelations are based on observations of LEO environmental effects on materials made in space during LDEF retrieval and during LDEF tray deintegration at the Kennedy Space Center, and on findings of approximately 1.5 years of laboratory analyses of LDEF materials by the LDEF materials scientists. These findings were extensively reviewed and discussed at the MSIG-sponsored LDEF Materials Workshop '91. The results are presented in a format that categorizes the revelations as 'clear findings' or 'obscure preliminary findings' (and progress toward their resolution), plus resultant needs for new space materials developments and ground simulation testing/analytical modeling, in seven categories: materials/environmental parameters and data bases; LDEF contamination; thermal control coatings and protective treatments; polymers and films; polymer-matrix composites; metals, ceramics, and optical materials; and systems-related materials. The utilization of LDEF materials data for future low-Earth orbit missions is also discussed, concentrating on Space Station Freedom. In general, the LDEF data is remarkably consistent; LDEF will provide a 'benchmark' for materials design data bases for satellites in low-Earth orbit. Some materials were identified to be encouragingly resistant to LEO SEE for 5.8-years; other 'space qualified' materials displayed significant environmental degradation. General contamination levels on LDEF were low, but molecular contamination was widespread; LDEF offers an unprecedented opportunity to provide a unified perspective of unmanned LEO spacecraft contamination mechanisms. New material development requirements for long-term LEO missions were identified and current ground simulation testing methods/data for new, durable materials concepts can be validated with LDEF results. LDEF findings are already being integrated into the design of Space Station Freedom.

Stein, Bland A.↗
NASA NTRS1993

Near net shape processing: A necessity for advanced materials applications

High quality discrete parts are the backbones for successful operation of equipment used in transportation, communication, construction, manufacturing, and appliances. Traditional shapemaking for discrete parts is carried out predominantly by machining, or removing unwanted material to produce the desired shape. As the cost and complexity of modern materials escalates, coupled with the expense and environmental hazards associated with handling of scrap, it is increasingly important to develop near net shape processes for these materials. Such processes involve casting of liquid materials, consolidation of powder materials, or deformation processing of simple solid shapes into the desired shape. Frequently, several of these operations may be used in sequence to produce a finished part. The processes for near net shape forming may be applied to any type of material, including metals, polymers, ceramics, and their composites. The ability to produce shapes is the key to implementation of laboratory developments in materials science into real world applications. This seminar presents an overview of near net shapemaking processes, some application examples, current developments, and future research opportunities.

Kuhn, Howard A.↗
NASA NTRS1995

Space environmental effects on spacecraft: LEO materials selection guide, part 1

This document provides performance properties on major spacecraft materials and subsystems that have been exposed to the low-Earth orbit (LEO) space environment. Spacecraft materials include metals, polymers, composites, white and black paints, thermal-control blankets, adhesives, and lubricants. Spacecraft subsystems include optical components, solar cells, and electronics. Information has been compiled from LEO short-term spaceflight experiments (e.g., space shuttle) and from retrieved satellites of longer mission durations (e.g., Long Duration Exposure Facility). Major space environment effects include atomic oxygen (AO), ultraviolet radiation, micrometeoroids and debris, contamination, and particle radiation. The main objective of this document is to provide a decision tool to designers for designing spacecraft and structures. This document identifies the space environments that will affect the performance of materials and components, e.g., thermal-optical property changes of paints due to UV exposures, AO-induced surface erosion of composites, dimensional changes due to thermal cycling, vacuum-induced moisture outgassing, and surface optical changes due to AO/UV exposures. Where appropriate, relationships between the space environment and the attendant material/system effects are identified. Part 1 covers spacecraft design considerations for the space environment; advanced composites; polymers; adhesives; metals; ceramics; protective coatings; and lubricants, greases, and seals.

Silverman, Edward M.↗
NASA NTRS2002

Airframe Research and Technology for Hypersonic Airbreathing Vehicles

The Hypersonics Investment Area (HIA) within NASA's Advanced Space Transportation Program (ASTP) has the responsibility to develop hypersonic airbreathing vehicles for access to space. The Airframe Research and Technology (AR and T) Project, as one of six projects in the HIA, will push the state-of-the-art in airframe and vehicle systems for low-cost, reliable, and safe space transportation. The individual technologies within the project are focused on advanced, breakthrough technologies in airframe and vehicle systems and cross-cutting activities that are the basis for improvements in these disciplines. Both low and medium technology readiness level (TRL) activities are being pursued. The key technical areas that will be addressed by the project include analysis and design tools, integrated vehicle health management (IVHM), composite (polymer, metal, and ceramic matrix) materials development, thermal/structural wall concepts, thermal protection systems, seals, leading edges, aerothermodynamics, and airframe/propulsion flowpath technology. Each of the technical areas or sub-projects within the Airframe R and T Project is described in this paper.

Glass, David E.↗
NASA NTRS2010

Pyroelectric Materials for Uncooled Infrared Detectors: Processing, Properties, and Applications

Uncooled pyroelectric detectors find applications in diverse and wide areas such as industrial production; automotive; aerospace applications for satellite-borne ozone sensors assembled with an infrared spectrometer; health care; space exploration; imaging systems for ships, cars, and aircraft; and military and security surveillance systems. These detectors are the prime candidates for NASA s thermal infrared detector requirements. In this Technical Memorandum, the physical phenomena underlying the operation and advantages of pyroelectric infrared detectors is introduced. A list and applications of important ferroelectrics is given, which is a subclass of pyroelectrics. The basic concepts of processing of important pyroelectrics in various forms are described: single crystal growth, ceramic processing, polymer-composites preparation, and thin- and thick-film fabrications. The present status of materials and their characteristics and detectors figures-of-merit are presented in detail. In the end, the unique techniques demonstrated for improving/enhancing the performance of pyroelectric detectors are illustrated. Emphasis is placed on recent advances and emerging technologies such as thin-film array devices and novel single crystal sensors.

Aggarwal, M. D.↗