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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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72 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Development of 3D Woven Ablative Thermal Protection Systems (TPS) for NASA Spacecraft

The development of a new class of thermal protection system (TPS) materials known as 3D Woven TPS led by the Entry Systems and Technology Division of NASA Ames Research Center (ARC) will be discussed. This effort utilizes 3D weaving and resin infusion technologies to produce heat shield materials that are engineered and optimized for specific missions and requirements. A wide range of architectures and compositions have been produced and preliminarily tested to prove the viability and tailorability of the 3D weaving approach to TPS.

3D weaving↗
NASA NTRS2012

Woven TPS - A New Approach to TPS Design and Manufacturing

NASA's Office of the Chief Technologist (OCT) Game Changing Division recently funded an effort to advance a Woven TPS (WTPS) concept. WTPS is a new approach to producing TPS materials that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance by varying material composition and properties via the controlled placement of fibers within a woven structure. The resulting material can be designed to perform optimally for a wide range of entry conditions encompassing NASAs current and future mission needs. WTPS enables these optimized TPS designs to be translated precisely into mission-specific, manufactured materials that can substantially increase the efficiency, utility, and robustness of heat shield materials compared to the current state-of-the-art material options. By delivering improved heat shield performance and affordability, this technology will impact all future exploration missions, from the robotic in-situ science missions to Mars, Venus and Saturn to the next generation of human missions. WTPS can change the way NASA develops, certifies, and integrates TPS into mission life cycles - instead of being a mission constraint, TPS will become a mission enabler. It is anticipated that WTPS will have direct impact on SMD, HEOMD and OCT and will be of interest for DoD and COTS applications. This presentation will overview the WTPS concept and present some results from initial testing completed.

Feldman, Jay↗
NASA NTRS1994

Effects of assumed tow architecture on the predicted moduli and stresses in woven composites

This study deals with the effect of assumed tow architecture on the elastic material properties and stress distributions of plain weave woven composites. Specifically, the examination of how a cross-section is assumed to sweep-out the tows of the composite is examined in great detail. The two methods studied are extrusion and translation. This effect is also examined to determine how sensitive this assumption is to changes in waviness ratio. 3D finite elements were used to study a T300/Epoxy plain weave composite with symmetrically stacked mats. 1/32nd of the unit cell is shown to be adequate for analysis of this type of configuration with the appropriate set of boundary conditions. At low waviness, results indicate that for prediction of elastic properties, either method is adequate. At high waviness, certain elastic properties become more sensitive to the method used. Stress distributions at high waviness ratio are shown to vary greatly depending on the type of loading applied. At low waviness, both methods produce similar results.

Chapman, Clinton Dane↗
NASA NTRS1997

Handbook of Analytical Methods for Textile Composites

The purpose of this handbook is to introduce models and computer codes for predicting the properties of textile composites. The handbook includes several models for predicting the stress-strain response all the way to ultimate failure; methods for assessing work of fracture and notch sensitivity; and design rules for avoiding certain critical mechanisms of failure, such as delamination, by proper textile design. The following textiles received some treatment: 2D woven, braided, and knitted/stitched laminates and 3D interlock weaves, and braids.

Cox, Brian N.↗
NASA NTRSDate not supplied

Understanding the Durability of SiC Based Ceramic Matrix Composites (CMCs) for Gas Turbine Engine Hot Section Components

Silicon carbide fiber reinforced silicon carbide ceramic matrix composites (SiCf/SiC-CMCs) are being used in the fabrication of gas turbine engine hot section components due to their light weight and excellent thermal and chemical stabilities at high-temperature. These superior properties enable significant enhancements in engine efficiency and reduced fuel burn, emissions, and cooling requirements. In support of NASA’s Aeronautics Mission under various programs at Glenn Research Center, different types of composites have been developed and assessed for a high temperature (2700 °F) SiCf/SiC CMC system for turbine engine applications. These composites have creep-resistant SiC fibers, advanced 3D weaves, 2700 °F-capable hybrid SiC matrices, and durable environmental barrier coatings (EBCs). These efforts have resulted in improvements in the overall CMC thermomechanical and environmental durability. In order to study the role of different constituents and processing variables, a single fiber tow CVI (chemical vapor infiltration) SiC/SiC mini-composite can be considered the basic architectural feature of woven and laminate SiC/SiC CMCs. Moreover, the mini-composite mechanical and tensile creep damage behavior represents the creep behavior of 0° fiber tows in the axial loading direction of a macro-composite or component. In addition, a large number of mini-composite samples can be fabricated at relatively low cost within a short time, which makes them attractive for obtaining a robust set of experimental data and studying constituent behavior. In this presentation, the mini-composite approach to study damage mechanisms that limit CMC life in extreme environments including exposure to steam will be presented. The effects of constituent type and volume fraction on the CMC durability, which will help influence CMC design, will be discussed.

Ceramic Matrix Composites (CMCs)↗
NASA NTRSDate not supplied

Response of Ablative Thermal Protection Materials to Degradation in Low Earth Orbit –Characterization of Specimens from MISSE-13

The environment of low Earth orbit presents unique material interactions due to the presence of atomic oxygen and solar spectrum UV. A variety of degradation mechanisms can occur depending, inlarge part, on the specific material system involved. This talk will review the characterization of two ablative materials, PICA-D and HEEET, as well as relevant adhesive joints and coatings. PICA-D is a variant of the phenolic impregnated carbon ablator (PICA) and is the baseline thermal protection system (TPS) on Dragonfly and the lander for Mars Sample Return (MSR). HEEET is a 3D woven system from which MSR’s Earth entry TPS is derived. The samples for these materials were flown in orbit during the Materials International Space Station Experiment-13 (MISSE-13) which launched on March 6, 2020 and returned to Earth on January 13, 2021. Changes to surface microstructure and reflectivity will be presented along with tomographic analysis. The effect of differential erosion rates on the composites and the impacts of the orbit environment on coating performances will be discussed in the context of TPS performance and mission design aspects.

MISSE↗
NASA NTRSDate not supplied

Response of Ablative Thermal Protection Materials to Degradation in Low Earth Orbit – Characterization of Specimens from MISSE-13

The environment of low Earth orbit presents unique material interactions due to the presence of atomic oxygen and solar spectrum UV. A variety of degradation mechanisms can occur depending, in large part, on the specific material system involved. This talk will review the characterization of two ablative materials, PICA-D and HEEET, as well as relevant adhesive joints and coatings. PICA-D is a variant of the phenolic impregnated carbon ablator (PICA) and is the baseline thermal protection system (TPS) on Dragonfly and the lander for Mars Sample Return (MSR). HEEET is a 3D woven system from which MSR’s Earth entry TPS is derived. The samples for these materials were flown in orbit during the Materials International Space Station Experiment-13 (MISSE-13) which launched on March 6, 2020 and returned to Earth on January 13, 2021. Changes to surface microstructure and reflectivity will be presented along with tomographic analysis. The effect of differential erosion rates on the composites and the impacts of the orbit environment on coating performances will be discussed in the context of TPS performance and mission design aspects.

MISSE↗
NASA NTRS1993

Cross-stiffened continuous fiber structures

Under NASA's Novel Composites for Wing and Fuselage Applications (NCWFA) program, Contract NAS1-18784, Grumman is evaluating the structural efficiency of graphite/epoxy cross-stiffened panel elements fabricated using innovative textile preforms and cost effective Resin Transfer Molding (RTM) and Resin Film Infusion (RFI) processes. Two three-dimensional woven preform assembly concepts have been defined for application to a representative window belt design typically found in a commercial transport airframe. The 3D woven architecture for each of these concepts is different; one is vertically woven in the plane of the window belt geometry and the other is loom woven in a compressed state similar to an unfolded eggcrate. The feasibility of both designs has been demonstrated in the fabrication of small test element assemblies. These elements and the final window belt assemblies will be structurally tested, and results compared.

Ewen, John R.↗
NASA NTRS2018

Pterodactyl: Integrated Control Design for Precision Targeting of Deployable Entry Vehicles

Deployable Entry Vehicles (DEVs) enable in-situ scientific exploration at destinations with atmospheres across the solar system. Because they stow in a compact form and deploy only when ready to enter the atmosphere, DEVs relax the volume constraint imposed by rigid aeroshells. This work seeks to do for a DEV what the Wright Brothers did to propel modern day aviation: develop the guidance and control (G&C) methods that will make maneuvering and precision landing of DEV a reality. The Pterodactyl project objective is to deliver an integrated G&C methodology for a DEV, based on a detailed analysis that utilizes a Multi-disciplinary, Design, Analysis and Optimization (MDAO) framework. The current state-of-the-art for blunt body entry, G&C is rooted in the precision landing of vehicles such as Mars Science Laboratory (MSL) and Apollo, which used a propulsive reaction control system (RCS) to steer. Recent research has taken a particular interest in non-propulsive control for DEVs, including direct force control (angle of attack modulation via control surfaces or mass movement) and drag modulation (discrete change in ballistic coefficient). Using the MDAO framework that includes a guidance and control model to explore multiple control concepts for a DEV will shed light on the best design approach for these vehicles. In Pterodactyl, we will complete this study for a novel DEV concept, and then we will fabricate a functional prototype to help validate the design. The project is expected to down-select to a final control architecture by the end of 2018, and complete fabrication of the prototype by the end of 2019.The DEV chosen for detailed study in this project is the Adaptable Deployable Entry and Placement Technology (ADEPT). ADEPT uses a revolutionary 3D-woven carbon fabric that is foldable, can serve as primary structure, and can survive the extreme heating environment of atmospheric entry. The specific configuration of ADEPT under investigation is called Lifting Nano-ADEPT (LNA). LNA is designed for secondary payloads missions that require precision landing either for scientific objectives at a target destination or for payload recovery at Earth.The MDAO framework being created through this research, called COBRA-Pt (Composite Beam Roll-Up Solar Array-Prototype), will combine three critical elements of the system design: a guidance algorithm with Monte Carlo, a parametric control model, and vehicle geometry details. Novel control models being studied are deployable aerodynamic surfaces as well as shape morphing. These concepts will be compared at the system level with a more traditional propulsive RCS by comparing several key performance parameters. Upon completion of the design study, a functional prototype of LNA will be fabricated that will include the integration of guidance software and relevant control actuators. We expect this study will provide critical data that could feed into the development of an Earth-based flight test of LNA. The COBRA-Pt framework will provide a modular system by which to study any DEV concept in any atmosphere.

Smith, Brandon↗
NASA NTRSDate not supplied

The Porous Microstructure Analysis (PuMA) software

The open-source Porous Microstructure Analysis (PuMA) software was implemented to offer an efficient framework for determining material characteristics from 3D microstructures. Its development was inspired by progress in X-ray microtomography, an imaging technology that captures the internal structure of materials in 3D, and even in a 4D temporal context. Over recent years, this method has transformed the domain of materials science due to its capability to non-destructively examine material microstructures while presenting digital data about their geometrical details. It has provided insights into materials relevant to several NASA missions, including heatshields, parachute fabrics, meteorites, and other advanced composites. PuMA, in its current version 3, delivers an array of features, spanning from basic geometric insights of a microstructure to intricate anisotropic thermo-elastic and chemical behavior. Specifically, the software evaluates morphological attributes (specific surface area, volume fractions, mean intercept lengths, orientation) and physical characteristics (conductivity, elasticity, permeability, and tortuosity). Additionally, it can model material degradation processes, such as oxidation and surface chemistry interactions. The software can generate synthetic microstructures, from straightforward geometrical designs to intricate woven and non-woven geometries. Coupling material generation and characterization enable parametric studies and sensitivity analysis to optimize the microstructural performance and inform design decisions and reliability assessment based on uncertainty quantification. A recent addition to PuMA includes the TomoSAM plugin, devised to incorporate the cutting-edge Segment Anything Model (SAM). SAM is a promptable deep learning model that can identify objects and create image masks in a zero-shot manner, based only on a few user clicks. The synergy between these tools aids in the segmentation of complex 3D datasets from tomography or other imaging techniques, which would otherwise require a laborious manual segmentation process.

Tomography↗
NASA NTRSDate not supplied

The Porous Microstructure Analysis (PuMA) software

The open-source Porous Microstructure Analysis (PuMA) software was created to offer an efficient framework for determining material properties from 3D microstructures. Its development was inspired by progress in X-ray microtomography, an imaging technology that captures the internal structure of materials in 3D, and even in a 4D temporal context. Over recent years, this method has transformed the domain of materials science due to its capability to non-destructively examine material microstructures while presenting digital data about their geometrical details. It has provided insights into materials relevant to several NASA missions, including heatshields, parachute fabrics, meteorites, and other advanced composites. PuMA, in its current version 3, delivers an array of features, spanning from basic geometric insights of a microstructure to intricate anisotropic thermo-elastic and chemical behavior. Specifically, the software evaluates morphological attributes (specific surface area, volume fractions, mean intercept lengths, orientation) and physical characteristics (conductivity, elasticity, permeability, and tortuosity). Additionally, it can model material degradation processes, such as oxidation and surface chemistry interactions. The software can generate synthetic microstructures, from straightforward geometrical designs to intricate woven and non-woven geometries. Coupling material generation and characterization enables parametric studies and sensitivity analysis to optimize the microstructural performance and inform design decisions and reliability assessment based on uncertainty quantification. A recent addition to PuMA includes the TomoSAM plugin, devised to incorporate the cutting-edge Segment Anything Model (SAM) into our image segmentation workflow. SAM is a promptable deep learning model that can identify objects and create image masks in a zero-shot manner, based only on a few user clicks. The synergy between these tools aids in the segmentation of complex 3D datasets from tomography and other imaging techniques, which would otherwise require a laborious manual segmentation process.

Tomography↗
NASA NTRSDate not supplied

Computation of Effective Mechanical Properties and Mechanical Erosion Modeling of TPS Materials

The goal of this presentation is to provide a general overview of the multi-scale modeling formulation to determine if there is additional surface recession in Thermal Protection Systems (TPS) materials as a result of mechanical erosion due to high shear conditions during atmospheric entry. This modeling process is performed at different scales by leveraging two computational frameworks developed at NASA: the Porous Microstructure Analysis (PuMA) software, and the Porous material Analysis Toolbox based on OpenFOAM (PATO). PuMA specializes in computing effective macro-scale material properties by performing material response simulations on 3D digital micro-scale representations of porous micro-structures. The modeling of TPS materials at the micro-scale is essential to understand how they behave as part of a heat shield assembly. The first part of the presentation will detail the implementation of PuMA’s cell-centered finite volume elasticity solver, which allows the computation of macro-scale effective mechanical properties of heterogeneous and anisotropic materials such as fibrous and woven TPS composites. These homogenized mechanical properties are used by PATO’s mechanical erosion model to predict the TPS material’s recession at a larger scale. This work will also provide some examples of multi-scale analysis from the fiber level up to the unit cell. The second part of the presentation will focus on the macro-scale approach to determine if erosion at the heat shield’s surface occurs due to mechanical and thermal loads experienced during atmospheric entry. To accomplish this, a solid mechanics module was integrated within PATO enabling it to model the potential mechanical erosion in three steps: first, after obtaining the effective mechanical properties with PuMA, the implemented stress analysis solver computes the stress and the displacement fields for the TPS material using the wall shear stress tensor, computed using a CFD solver, as boundary conditions; then, regions on the surface where the stress meets the failure criteria are identified; finally, the failed material is removed and the mesh is redistributed accordingly. The outcome is a model capable of predicting the total recession in the material due to surface chemistry and mechanical erosion.

Mechanical Properties↗
NASA NTRSDate not supplied

An Automated Meshing Framework for Progressive Damage Analysis of Fabrics Using CompDam

A meshing and model construction framework for progressive damage analysis of fabric composites is proposed. A mesoscale idealization is used such that the fiber tows are considered homogeneous and transversely isotropic continua, and the matrix is a homogeneous isotropic continuum. By using this idealization, relatively mature damage modeling techniques developed for laminates of unidirectional plies are transferrable to fabrics. Cohesive interface elements and a continuum damage mechanics (CDM) model implemented in the software CompDam are used to account for the key damage modes including cracking at the tow/matrix interface, transverse matrix cracking in the tows, and fiber breakage in the tows. Matrix degradation is accounted for by plasticity. The modeling approach is demonstrated for a 3D orthogonal woven fabric. The main novelty of the proposed model construction framework is in its flexibility resulting from a formulation that is agnostic to the fabric architecture and implementation using mesh based operations. The algorithm does not make any assumptions about the tow sizes, shape, path, or proximity to other tows, thus it is applicable to a broad range of fabric architectures. The matrix region mesh surrounding the tows is constructed from domain boundary and tow surface meshes (i.e. through a series of mesh-based operations) such that the model domain can be arbitrarily shaped.

Andrew Cole Bergan↗
NASA NTRSDate not supplied

Modeling the Effective Elasticity of Anisotropic Porous Materials

The development and optimization of composite materials designed for thermal protection of NASA’s spacecraft require understanding their physical response to high-enthalpy environments. To predict their macro-scale properties and behavior, high-fidelity 3D simulations are performed at the microscale on realistic representations of these composites. The digital microstructures are generated either synthetically or through X-ray micro-computed tomography reconstructions. One of the main challenges in the prediction of the structural response of heatshield materials is the computation of the effective elasticity of the fibrous composite, as well as the understanding of the deformation and stresses generated at the microscale. These are driven by the fiber layout within the microstructure and the distribution of the infused matrix. In this effort, the micro-mechanical linear elastic behavior of fibrous ablators is modeled using a numerical method based on the Multi-Point Stress Approximation (MPSA) finite volume scheme, a generalization of the more commonly used Multi-Point Flux Approximation (MPFA) that was presented at the 10th Ablation Workshop. To predict the behavior of fibrous and woven architectures, algorithms that compute the local fiber orientation are used. The implementation of the MPSA was verified using analytical solutions, engineering test cases, and compared against legacy Finite Element Analysis (FEA) software. The stress analysis models were then applied to real geometries used by NASA in thermal protection systems such as fibrous preforms and woven materials and the results were compared to experimental data.

Elasticity↗
NASA NTRSDate not supplied

Computing the effective elasticity of anisotropic porous media from X-ray computed micro-tomography images

Development and optimization of composite materials designed for thermal protection of NASA’s spacecraft requires the understanding of their physical response to high-enthalpy environments. To predict their macro-scale properties and behavior, high-fidelity 3D simulations are performed at the micro-scale on realistic representations of these composites. The digital micro-structures are generated either synthetically or through X-ray micro-tomography reconstructions. One of the main challenges in the prediction of heatshield material structural response is the computation of the effective elasticity of the fibrous composite, as well as the understanding of the deformation and stresses generated at the micro-scale. These are driven by the fiber layout within the micro-structure and the distribution of the infused matrix. In this effort, the micro-mechanical linear elastic behavior of fibrous ablators is modeled through the use of a numerical method based on the Multi-Point Stress Approximation (MPSA) finite volume scheme. The MPSA, a generalization of the more commonly used Multi-Point Flux Approximation (MPFA), was discussed in a previous presentation at the 15th USCCN and in reference. To predict the behavior of fibrous and woven architectures, algorithms that compute the local fiber orientation are used. The implementation of the MPSA was verified using analytical solutions, engineering test cases and compared against legacy Finite Element Analysis (FEA) software. The stress analysis models were then applied to real geometries used by NASA in thermal protection systems such as fibrous preforms and woven materials and the results were compared to experimental data.

Federico Semeraro↗
NASA NTRS2003

Fabrication And Evaluation Of Sic/Sic Tubes With Various Fiber Architectures

SiC/SiC composites are excellent material candidates for high temperature applications where the performance requirements are high strength, high creep-rupture resistance, high environmental durability, and high thermal conductivity. In the past, the NASA UEET program has demonstrated fabrication of high-performance SiC/SiC flat panels reinforced by Sylramic-iBN SiC fibers. Currently NASA UEET is scaling up this SiC/SiC system by fabrication of more complex shaped components using the same fiber type. This paper reports the effects of various fiber architectures on the processing, mechanical, and durability behavior of small-diameter 0.5" ID SiC/SiC tubes, which are potential sub-elements for leading edges and cooling channels in turbine vanes and blades. Nine different fiber architectures were utilized for construction of seamless tube preforms, from simple 2D jelly-rolling to complex braiding, pin-weaving, filament-winding and 3D orthogonal weaving with approximately 5% fibers in the thru-thickness direction. Using the BN interphase and Sic matrix processing steps established for the flat panels, SiC/SiC tubes were fabricated with wall thicknesses of approximately 60 mils and total fiber fractions of approximately 35%. The "D" split ring tests for hoop tensile properties, micro-structural examinations for relationship between fiber architecture formation and matrix infiltration, and the low-pressure burner rig tests for the high temperature durability under thru-thickness thermal gradient were conducted. The better matrix infiltration and higher hoop strength were achieved using the tri-axial braided and the three-float pin woven SiC/SiC tubes. In general, it needs not only higher hoop direction fibers but also axial direction fibers for the higher hoop strength and the better infiltration, respectively. These results are analyzed to offer general guidelines for selecting fiber pre-form architectures and SiC/SiC processes that maximize tube hoop strength, thru-thickness thermal conductivity, and burner-rig durability under a high thermal gradient.

Yun, H. M.↗
NASA NTRSDate not supplied

Effect of Boundary Conditions on Process-Induced Stresses in a Plain Weave Unit Cell

Woven polymer matrix composites (PMCs) are leveraged in aerospace applications for their desirable specific properties, yet they are vulnerable to high residual stresses during manufacturing and their complex geometry makes experimental results difficult to observe. Process modeling is needed to characterize the effects of the curing and predict end stress states. Finite element software can be used to model woven architectures, however accurate representation of processing conditions remains a challenge when it comes to selecting boundary conditions. The effect of BCs on process-induced stress within woven PMCs is studied. The commercial Finite Element Analysis (FEA) software Abaqus is coupled with user-written subroutines in a process modeling framework. A two-dimensionally (2D) woven PMC repeating unit cell (RUC) is modeled with TexGen and Abaqus. Virtual curing is imposed on the bulk matrix. The BC study is conducted with Free, Periodic, Flat, and Flat-Free configurations. Results show that the end stress state is sensitive to the boundary condition assumptions. Flat BC results show great agreement with Periodic BCs. Residual stress results from process modeling are then compared with a linear-elastic thermal cooldown analysis in Abaqus. Cooldown results indicate an overestimation in matrix stresses compared with process modeling.

micromechanics↗
NASA NTRSDate not supplied

Experimental Observations of Damage States in Unnotched and Notched 3D Orthogonal Woven Coupons Loaded in Tension

This paper describes a series of unnotched and notched tensile tests on two 3D orthogonal woven architectures loaded in the warp direction. Dogbone specimens were used for the unnotched tests, and open-hole specimens were used for the notched tests. For each architecture and test type, two specimens were loaded under monotonic displacement control to failure, and two specimens were incrementally loaded to failure in five steps. X-ray computed tomography (CT) was used to characterize the woven architecture and defects on each specimen prior to testing. Digital image correlation (DIC) images were obtained from both sides of the specimen throughout the loading and unloading. For the incremental tests, X-ray CT was used to document the damage progression after each load increment. The results for both architectures and test specimens followed a similar pattern where matrix cracks formed perpendicular to the load direction and were primarily located between the stacks of warp tows. Two-piece failure path always occurred perpendicular to the loading direction, along the through-thickness segments of the Z-tows. The combination of stress concentrations due to the specimen geometry, weave geometry, and cut tows created stress concentrations that appear to initiate failure.

Woven materials↗