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At least 541 records · Page 30

Cryogenic Thermal Conductivity Measurements on Candidate Materials for Space Missions

Spacecraft and instruments on space missions are built using a wide variety of carefully-chosen materials. It is common for NASA engineers to propose new candidate materials which have not been totally characterized at cryogenic temperatures. In many cases a material's cryogenic thermal conductivity must be known before selecting it for a specific space-flight application. We developed a test facility in 2004 at NASA's Goddard Space Flight Center to measure the longitudinal thermal conductivity of materials at temperatures between 4 and 300 Kelvin, and we have characterized many candidate materials since then. The measurement technique is not extremely complex, but proper care to details of the setup, data acquisition and data reduction is necessary for high precision and accuracy. We describe the thermal conductivity measurement process and present results for ten engineered materials, including alloys, polymers, composites, and a ceramic.

James Tuttle↗

High-Temperature Slurry Environmental Barrier Coating With Graded HfO 2 -HfSiO 4 Topcoat

Environmental barrier coatings (EBCs) have enabled the use of silicon carbide (SiC)-based ceramic matrix composites (CMCs) in gas turbine engines by protecting the underlying CMC from corrosive combustion species. Current-generation EBCs consist of a rare earth silicate topcoat and a silicon bond coat. The relatively low melting point of the silicon bond coat (1414°C) limits the upper use temperature of these coatings. To protect SiC-based CMCs at temperatures beyond that achievable by the current state-of-the-art, an oxide-based bond coat capable of withstanding temperatures of up to 1482°C has been developed at NASA Glenn Research Center. Hafnia (HfO2) is a promising EBC topcoat material due to its stability in high-temperature steam; however, its coefficient of thermal expansion (CTE) is highly anisotropic and much larger than that of SiC. In this study, a graded HfO2-HfSiO4 topcoat was deposited via a slurry process on the NASA-developed oxide-based bond coat. The oxidation resistance of this EBC system was evaluated at 1482°C in a steam cycling environment. The durability and stability of this slurry-deposited HfO2-HfSiO4 topcoat was compared to that of HfO2 deposited by plasma spray physical vapor deposition (PS-PVD).

EBC↗

Foreign Object Damage in Ytterbium Disilicate Based Environmental Barrier Coatings Modified for Oxidation Resistance

Environmental barrier coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites (CMCs) in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s ytterbium disilicate based EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline ytterbium disilicate EBC to that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

foreign object damage (FOD)↗

SiO2 Activity Measurements in the Gd2O3-SiO2 System Via Knudsen Effusion Mass Spectrometry (KEMS)

Environmental barrier coatings (EBCs) are required for the use of silicon carbide (SiC)-based ceramic matrix composites (CMCs) in gas turbine engines, as they protect the SiO 2 thermally grown oxide (TGO) formed at the CMC/coating interface from volatilization in a combustion environment. Current-generation EBCs consist of a silicon bond coat and a rare earth (RE) silicate topcoat. The RE silicate topcoat is exposed to high-velocity steam during engine operation, and SiO 2 within the coating can preferentially volatilize to form Si(OH) 4 gas species, albeit at a lesser degree than SiO 2 alone. Therefore, it is of interest to investigate the stability of these materials in steam as a function of their RE. In this study, SiO 2 activity, which can be related to the partial pressure of Si(OH) 4 , was measured across the Gd 2 O 3 -SiO 2 phase diagram, which includes Gd 2 SiO 5 , Gd 9.33 (SiO 4 ) 6 O 2 , and Gd 2 Si 2 O 7 as line compounds, via Knudsen Effusion Mass Spectrometry (KEMS). Values obtained for the Gd 2 O 3 -SiO 2 system were compared to those of other RE2O3-SiO2 systems and contextualized in terms of EBC viability.

EBCs↗

Structural similitude and design of scaled down laminated models

The excellent mechanical properties of laminated composite structures make them prime candidates for wide variety of applications in aerospace, mechanical and other branches of engineering. The enormous design flexibility of advanced composites is obtained at the cost of large number of design parameters. Due to complexity of the systems and lack of complete design based informations, designers tend to be conservative in their design. Furthermore, any new design is extensively evaluated experimentally until it achieves the necessary reliability, performance and safety. However, the experimental evaluation of composite structures are costly and time consuming. Consequently, it is extremely useful if a full-scale structure can be replaced by a similar scaled-down model which is much easier to work with. Furthermore, a dramatic reduction in cost and time can be achieved, if available experimental data of a specific structure can be used to predict the behavior of a group of similar systems. This study investigates problems associated with the design of scaled models. Such study is important since it provides the necessary scaling laws, and the factors which affect the accuracy of the scale models. Similitude theory is employed to develop the necessary similarity conditions (scaling laws). Scaling laws provide relationship between a full-scale structure and its scale model, and can be used to extrapolate the experimental data of a small, inexpensive, and testable model into design information for a large prototype. Due to large number of design parameters, the identification of the principal scaling laws by conventional method (dimensional analysis) is tedious. Similitude theory based on governing equations of the structural system is more direct and simpler in execution. The difficulty of making completely similar scale models often leads to accept certain type of distortion from exact duplication of the prototype (partial similarity). Both complete and partial similarity are discussed. The procedure consists of systematically observing the effect of each parameter and corresponding scaling laws. Then acceptable intervals and limitations for these parameters and scaling laws are discussed. In each case, a set of valid scaling factors and corresponding response scaling laws that accurately predict the response of prototypes from experimental models is introduced. The examples used include rectangular laminated plates under destabilizing loads, applied individually, vibrational characteristics of same plates, as well as cylindrical bending of beam-plates.

Simitses, G. J.↗

Thermodynamics of the Lu2O3 – SiO2 system and comparison to other Rare Earth Silicates

Environmental barrier coatings are necessary to protect SiC based ceramics and composites from water vapor degradation in harsh engine environments. Currently, rare earth (RE) silicates are the most promising systems to protect SiC based ceramics and composites. This protection is largely based on reduced silica activity in these rare earth silicates which results in a lowered reactivity with water vapor. To that end, previous Knudsen effusion mass spectrometry (KEMS) studies have explored RE = Yb, Y silicates to measure the reduced silica activity and subsequent water vapor reactivity. Similarly, this work employs the KEMS technique to measure the SiO(g) vapor pressure in Lu containing RE silicates to calculate the activity of silica within the monosilicate [log(a(SiO2)) = -2351.1*1/T-1.6731] and the disilicate (log(a(SiO2)) = -4884.0*1/T + 2.2208) as a function of temperature. The enthalpies of formation for Lu monosilicate from the oxides and the elements were calculated to be -45±3 kJ/mol at 1550 K and -2831.1±12 kJ/mol at 298 K, respectively. The measured enthalpy of formation and those found in literature are compared to modeled values from density functional theory and those estimated using electronegativity.

Knudesen Effusion Mass Spectrometry↗

Improving Turbine Performance with Ceramic Matrix Composites

Under the new NASA Fundamental Aeronautics Program, efforts are on-going within the Supersonics Project aimed at the implementation of advanced SiC/SiC ceramic composites into hot section components of future gas turbine engines. Due to recent NASA advancements in SiC-based fibers and matrices, these composites are lighter and capable of much higher service temperatures than current metallic superalloys, which in turn will allow the engines to operate at higher efficiencies and reduced emissions. This presentation briefly reviews studies within Task 6.3.3 that are primarily aimed at developing physics-based concepts, tools, and process/property models for micro- and macro-structural design, fabrication, and lifing of SiC/SiC turbine components in general and airfoils in particular. Particular emphasis is currently being placed on understanding and modeling (1) creep effects on residual stress development within the component, (2) fiber architecture effects on key composite properties such as design strength, and (3) preform formation processes so that the optimum architectures can be implemented into complex-shaped components, such as turbine vanes and blades.

DiCarlo, James A.↗

Metal-matrix composites: Status and prospects

Applications of metal matrix composites for air frames and jet engine components are discussed. The current state of the art in primary and secondary fabrication is presented. The present and projected costs were analyzed to determine the cost effectiveness of metal matrix composites. The various types of metal matrix composites and their characteristics are described.

Source record↗

NASA's engineering research centers and interdisciplinary education

A new program of interactive education between NASA and the academic community aims to improve research and education, provide long-term, stable funding, and support cross-disciplinary and multi-disciplinary research. The mission of NASA's Office of Aeronautics, Exploration and Technology (OAET) is discussed and it is pointed out that the OAET conducts about 10 percent of its total R&D program at U.S. universities. Other NASA university-based programs are listed including the Office of Commercial Programs Centers for the Commercial Development of Space (CCDS) and the National Space Grant program. The importance of university space engineering centers and the selection of the nine current centers are discussed. A detailed composite description is provided of the University Space Engineering Research Centers. Other specialized centers are described such as the Center for Space Construction, the Mars Mission Research Center, and the Center for Intelligent Robotic Systems for Space Exploration. Approaches to educational outreach are discussed.

Johnston, Gordon I.↗

Aircraft Engine Particle Emissions during the 2023 NASA-Boeing ecoDemonstrator Field Measurements

Aerosol aircraft emissions are responsible for the formation of contrail cirrus clouds which can alter Earth’s radiation and water budgets exerting substantial effects on climate. However, at present, the impact of aviation on climate forcing remaining uncertain. Recently, NASA has collaborated with Boeing ecoDemonstrator program to improve the understanding of air traffic emissions and the impact of different jet fuel compositions on contrail microphysics. As part of the program, in October 2023 the NASA DC-8 aircraft was used to sample engine exhausts emitted by a Boeing ecoDemonstrator Explorer 737-10 burning sustainable aviation fuel (SAF) and conventional jet fuel over the north western US. In this study, we present unique observations of aerosols properties relevant for contrail-cirrus cloud formation collected during the 2023 ecoDemonstrator research flights and we will discuss the variations of key microphysical contrail parameters in function of different jet fuel compositions and engine conditions.

Francesca Gallo↗

Chemical recycling of scrap composites

There are no well-developed technologies for recycling composite materials other than grinding to produce fillers. New approaches are needed to reclaim these valuable resources. Chemical or tertiary recycling, conversion of polymers into low molecular weight hydrocarbons for reuse as chemicals or fuels, is emerging as the most practical means for obtaining value from waste plastics and composites. Adherent Technologies is exploring a low-temperature catalytic process for recycling plastics and composites. Laboratory results show that all types of plastics, thermosets as well as thermoplastics, can be converted in high yields to valuable hydrocarbon products. This novel catalytic process runs at 200 C, conversion times are rapid, the process is closed and, thus, nonpolluting, and no highly toxic gas or liquid products have been observed so no negative environmental impact will result from its implementation. Tests on reclamation of composite materials show that epoxy, imide, and engineering thermoplastic matrices can be converted to low molecular weight hydrocarbons leaving behind the reinforcing fibers for reuse as composite reinforcements in secondary, lower-performance applications. Chemical recycling is also a means to dispose of sensitive or classified organic materials without incineration and provides a means to eliminate or reduce mixed hazardous wastes containing organic materials.

Allred, Ronald E.↗

Impact Resistance of Lightweight Hybrid Structures for Gas Turbine Engine Fan Containment Applications

The ballistic impact resistance of hybrid composite sandwich structures was evaluated with the ultimate goal of developing new materials or structures for potential gas turbine engine fan containment applications. The sandwich structures investigated consisted of GLARE-5 laminates as face sheets with lightweight cellular metallic materials such as honeycomb, foam, and lattice block as a core material. The impact resistance of these hybrid sandwich structures was compared to GLARE-5 laminates and 2024-T3 Al sheet, which were tested as a function of areal weight (material thickness). The GLARE-5 laminates exhibited comparable impact properties to that of 2024-T3 Al at low areal weights, even though there were significant differences in the static tensile properties of these materials. The GLARE-5, however, did have a greater ballistic limit than straight aluminum sheet at higher areal weights. Furthermore, there is up to a 25% advantage in ballistic limit for the GLARE-5/foam sandwich structures compared to straight 2024-T3 Al. But no advantage in ballistic limit was observed between any of the hybrid sandwich structures and thicker versions of GLARE-5. Recommendations for future work are provided, based on these preliminary data.

Hebsur, Mohan G.↗

A preliminary design study of a laminar flow control wing of composite materials for long range transport aircraft

The results of an aircraft wing design study are reported. The selected study airplane configuration is defined. The suction surface, ducting, and compressor systems are described. Techniques of manufacturing suction surfaces are identified and discussed. A wing box of graphite/epoxy composite is defined. Leading and trailing edge structures of composite construction are described. Control surfaces, engine installation, and landing gear are illustrated and discussed. The preliminary wing design is appraised from the standpoint of manufacturing, weight, operations, and durability. It is concluded that a practical laminar flow control (LFC) wing of composite material can be built, and that such a wing will be lighter than an equivalent metal wing. As a result, a program of suction surface evaluation and other studies of configuration, aerodynamics, structural design and manufacturing, and suction systems are recommended.

Swinford, G. R.↗

Empirical Model Development for Predicting Shock Response on Composite Materials Subjected to Pyroshock Loading: Appendices

The NASA Engineering and Safety Center (NESC) received a request to develop an analysis model based on both frequency response and wave propagation analyses for predicting shock response spectrum (SRS) on composite materials subjected to pyroshock loading. The model would account for near-field environment (approx. 9 inches from the source) dominated by direct wave propagation, mid-field environment (approx. 2 feet from the source) characterized by wave propagation and structural resonances, and far-field environment dominated by lower frequency bending waves in the structure. This document contains appendices to the Volume I report.

Gentz, Steven J.↗

The tribology of PS212 coatings and PM212 composites for the lubrication of titanium 6Al-4V components of a Stirling engine space power system

The Stirling space power machine incorporates a linear alternator to generate electrical power. The alternator is a reciprocating device that is driven by a solar or nuclear-powered Stirling engine. The power piston and cylinder are made of titanium 6Al-4V (Ti6-4) alloy, and are designed to be lubricated by a hydrodynamically-generated gas film. Rubbing occurs during starts and stops and there is the possibility of an occasional high speed rub. Since titanium is known to have a severe galling tendency in sliding contacts, a 'back-up', self-lubricating coating on the cylinder and/or the piston is needed. This report describes the results of a research program to study the lubrication of Ti6-4 with the following chromium carbide based materials: plasma-sprayed PS212 coatings and sintered PM212 counterfaces. Program objectives are to achieve adherent coatings on Ti6-4 and to measure the friction and wear characteristics of the following sliding combinations under conditions simulative of the Stirling-driven space power linear alternator: Ti6-4/Ti6-4 baseline, Ti6-4/PS212-coated Ti6-4, and PS212-coated Ti6-4/PM212.

Sliney, Harold E.↗

The tribology of PS212 coatings and PM212 composites for the lubrication of titanium 6A1-4V components of a Stirling engine space power system

The Stirling space power machine incorporates a linear alternator to generate electrical power. The alternator is a reciprocating device that is driven by a solar or nuclear-powered Stirling engine. The power piston and cylinder are made of titanium 6A1-4V (Ti6-4) alloy, and are designed to be lubricated by a hydrodynamically-generated gas film. Rubbing occurs during starts and stops and there is a possibility of an occasional high speed rub. Since titanium is known to have a severe galling tendency in sliding contacts, a 'backup,' self-lubricating coating on the cylinder and/or the piston is needed. This report describes the results of a research program to study the lubrication of Ti6-4 with the following chromium carbide based materials: plasma-sprayed PS212 coatings and sintered PM212 counterfaces. Program objectives are to achieve adherent coatings on Ti6-4 and to measure the friction and wear characteristics of the following sliding combinations under conditions simulative of the Stirling-driven space power linear alternator: Ti6-4/Ti6-4 baseline, Ti6-4/PS212 coated Ti6-4, and Ps212 coated Ti6-4/PM212

Sliney, Harold E.↗

The OFP-6M transport jet

This report presents a preliminary design of a commercial jet transport that meets the criteria of the Request For Proposal presented by the American Institute of Aeronautics and Astronauts (AIAA). The proposal requires an innovative design of a low cost domestic commercial transport that will reduce operating costs for airline companies while still meeting present and future requirements of the Federal Aviation Regulations for this type of aircraft. Specifications for the design include a mixed class, 153 passenger aircraft, traveling a range of 3000 nm. The intent of the project is to identify factors that reduce cost and to design within the limits of these constraints. The project includes techniques or options that incorporate new technologies but do not override practicality, alternative design approaches, and a comparison between the new design and current aircraft in its class. The OFP-6M is an alternative design approach to the conventional commercial transport jet and is geared towards customer satisfaction through efficiency and reliability. The goals of the OFP-6M transport design are to provide original, sensible, and practical solutions by combining essential preliminary design factors with growing technology. The design focus of the OFP-6M reduces costs by simplifying systems where significant weight or maintenance savings can be achieved, and by integrating advanced technology for improved performance. Key aspects of the OFP-6M design are efficient use of materials like composites, and efficient advanced ducted high bypass turbofan engines. The high bypass engines lower fuel consumption and aid in reducing costs and meeting future noise emission restrictions. Composites are used for most structural components, including flooring and wing box. Although composites are an emerging technology and presently, a high maintenance material, they can be cost effective and an alternative to aluminum structures when correct manufacturing and design strategies are applied. Since, composites are lighter and require less manufacturing of complex parts, they can significantly reduce structural weight. Because of the large 17 ft. diameter, sophisticated aerodynamic considerations were implemented to significantly lower the drag. Supercritical airfoils were chosen with simple control surface design which allows for less maintenance and manufacturing costs. The interior configuration accommodates either all passenger, dual and single class flights or complete cargo. Also, a relaxed conventional stability is integrated with a stability augmentation system. As a result of these design implementations, the OFP-6M bottom line direct operating costs, compare favorably with the Boeing 737 and 757, at 3.49 cents per available seat mile and costs are expected to reduce when improved manufacturing and maintenance methods are implemented.

Alexander, Kelly↗

Improving Interlaminar Shear Strength

To achieve NASA's mission of space exploration, innovative manufacturing processes are being applied to the fabrication of complex propulsion elements.1 Use of fiber-reinforced, polymeric composite tanks are known to reduce weight while increasing performance of propulsion vehicles. Maximizing the performance of these materials is needed to reduce the hardware weight to result in increased performance in support of NASA's missions. NASA has partnered with the Mississippi State University (MSU) to utilize a unique scalable approach of locally improving the critical properties needed for composite structures. MSU is responsible for the primary development of the concept with material and engineering support provided by NASA. The all-composite tank shown in figure 1 is fabricated using a prepreg system of IM7 carbon fiber/CYCOM 5320-1 epoxy resin. This is a resin system developed for out-of-autoclave applications. This new technology is needed to support the fabrication of large, all composite structures and is currently being evaluated on a joint project with Boeing for the Space Launch System (SLS) program. In initial efforts to form an all composite pressure vessel using this prepreg system, a 60% decrease in properties was observed in scarf joint regions. Inspection of these areas identified interlaminar failure in the adjacent laminated structure as the main failure mechanism. This project seeks to improve the interlaminar shear strength (ILSS) within the prepreg layup by locally modifying the interply region shown in figure 2.2

Jackson, Justin↗