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Use of expanding rubber mandrel allows for bonding of graphite/epoxy laminated parts in oven instead of expensive autoclave. Heavy-duty two-piece aluminum mold limits deflection. Manipulation of resin contact by precise control of mandrel-generated pressure eliminates complex bleeder system.
This document summarizes the experimental concepts and preliminary analyses (as of December 1975) for each of the 28 scientific experiments conducted during the Apollo-Soyuz Test Project from July 15 to 24, 1975. The scientific topics are X- ray and extreme ultraviolet astronomy, solar astronomy, gamma- ray detectors, Earth studies (including the upper atmosphere, meteorological phenomena, hydrology, oceanography, geology, desert studies, and gravity field studies), microbiology, heavy cosmic particle interaction with live cells, vestibular system studies, and materials processing (including high-temperature and ambient-temperature processing of industrial materials and electrophoretic processing of biological materials) .
Thermally-induced stresses in the foil, adhesive, and graphite-epoxy layers of composite tubes with aluminum foil bonded to the inner and outer surface are computed. The thermal effects are due to a temperature decrease from the processing temperature of the material to a temperature felt to represent the space environment, the intended operating environment of the tubes. Tubes fabricated from T300/934 and P75s/934 material systems are considered. The results indicate that the presence of the foil and adhesive have no detrimental effect on the stresses in the tube.
This paper describes the development of methodology that provides for quantification of uncertainties in lifetime strength of aerospace materials subjected to a number of diverse effects. A probabilistic material degradation model, in the form of a randomized multifactor interaction equation, has been postulated for lifetime strength degradation of structural components of aerospace propulsion systems. The model includes effects that typically reduce lifetime strength and may include temperature, mechanical fatigue, creep and others. The paper also includes the analysis of experimental data from the open literature for Inconel 718. These data are used to provide an initial check for model validity, as well as for calibration of the model's empirical material constants. The model validity check and calibration is carried out for three effects, namely, high temperature, mechanical fatigue and creep.
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Laboratory studies of cometary dust collected in the stratosphere and returned from comet 81P/Wild 2 by the Stardust spacecraft have revealed ancient interstellar grains and molecular cloud organic matter that record a range of astrophysical processes and the first steps of planetary formation. Presolar materials are rarer meteorites owing to high temperature processing in the solar nebula and hydrothermal alteration on their asteroidal parent bodies. The greater preservation of presolar materials in comets is attributed to their low accretion temperatures and limited planetary processing. Yet, comets also contain a large complement of high temperature materials from the inner Solar System. Owing to the limited and biased sampling of comets to date, the proportions of interstellar and Solar System materials within them remains highly uncertain. Interstellar materials are identified by coordinated isotopic, mineralogical, and chemical measurements at the scale of individual grains. Chondritic porous interplanetary dust particles (CP IDPs) that likely derive from comets are made up of 0.1 - 10 micron-sized silicates, Fe-Ni-sulfides, oxides, and other phases bound by organic material. As much as 1% of the silicates are interstellar grains that have exotic isotopic compositions imparted by nucleosynthetic processes in their parent stars. Crystalline silicates in CP IDPs dominantly have normal isotopic compositions and probably formed in the Solar System. 81P samples include isotopically normal refractory minerals that resemble Ca-Al rich inclusions and chondrules common in meteorites. The origins of sub-micron amorphous silicates in IDPs are not certain, but at least a few % of them are interstellar grains. The remainder have isotopic compositions consistent with Solar System origins and elemental compositions that are inconsistent with interstellar grain properties, thus favoring formation in the solar nebula [4]. The organic component in comets and primitive meteorites has large enrichments in D/H and N-15/N-14 relative to terrestrial materials. These isotopic signatures are probably due to low temperature chemical processes in cold molecular clouds or the outermost reaches of the protoplanetary disk. The greatest isotopic anomalies are found in sub-micron organic nanoglobules that show chemical signatures of interstellar chemistry. The observation that cometary dust is mostly composed of isotopically normal minerals within isotopically anomalous organic matter is difficult to reconcile with the formation models of each component. The mineral component likely formed in high temperature processes in the inner Solar System, while the organic fraction shows isotopic and chemical signatures of formation near 10 K. Studying more primitive remnants of the Solar System starting materials would help in resolving this paradox. Comets formed across a vast expanse of the outer disk under differing thermal and collisional regimes, and some are likely to be better preserved than others. Finding truly pristine aggregates of presolar materials may require return of a pristine sample of comet nucleus material.
The science requirements for materials processing is to provide the desired PI requirements of thermal gradient, solid/liquid interface front velocity for a given processing temperature desired by the PI. Processing is performed by translating the furnace with the sample in a stationary position to minimize any disturbances to the solid/liquid interface front during steady state processing. Typical sample materials for this metals and alloys furnace are lead-tin alloys, lead-antimony alloys, and aluminum alloys. Samples must be safe to process and therefore typically are contained with hermetically sealed cartridge tubes (gas tight) with inner ceramic liners (liquid tight) to prevent contamination and/or reaction of the sample material with the cartridge tube.
This work presents an approach to modeling the dynamic spreading and curing behavior of thermosets in nozzle-based extrusions. Thermosets cover a wide range of materials, some of which permit low-temperature processing with subsequent high-temperature and high-strength working properties. Extruding thermosets may overcome the limited working temperatures and strengths of conventional thermoplastic materials used in additive manufacturing. This project aims to produce technology for the fabrication of thermoset-based structures leveraging advances made in nozzle-based extrusion, such as fused deposition modeling (FDM), material jetting, and direct writing. Understanding the synergistic interactions between spreading and fast curing of extruded thermosetting materials will provide essential insights for applications that require accurate dimensional controls, such as additive manufacturing [1], [2] and centrifugal coating/forming [3]. Two types of thermally curing thermosets -- one being a soft silicone (Ecoflex 0050) and the other being a toughened epoxy (G/Flex) -- served as the test materials in this work to obtain models for cure kinetics and viscosity. The developed models align with extensive measurements made with differential scanning calorimetry (DSC) and rheology. DSC monitors the change in the heat of reaction, which reflects the rate and degree of cure at different crosslinking stages. Rheology measures the change in complex viscosity, shear moduli, yield stress, and other properties dictated by chemical composition. By combining DSC and rheological measurements, it is possible to establish a set of models profiling the cure kinetics and chemorheology without prior knowledge of chemical composition, which is usually necessary for sophisticated mechanistic modeling. In this work, we conducted both isothermal and dynamic measurements with both DSC and rheology. With the developed models, numerical simulations yielded predictions of diameter and height of droplets, along with width and height of extruded lines cured at varied temperatures. Experimental results carried out on a goniometric platform and a nozzle-based 3D printer showed agreement with the numerical simulations. Finally, this presentation will show how the models are adaptable to the planning of tool paths and designs in additive manufacturing.
The effects of process temperature (reforming temperature) on the overall hydrogen production process were examined. These effects are principally confined to the hydrogen production and the hydrogen purification processing units.
The responses of an unsymmetrically laminated fiber-reinforced composite cylinder to an axial compressive load, a torsional load, and the temperature change associated with cooling from the processing temperature to the service temperature are investigated. These problems are considered axisymmetric and the response is studied in the context of linear elastic material behavior and geometrically linear kinematics. Four different laminates are studied: a general unsymmetric laminate; two unsymmetric but more conventional laminates; and a conventional quasi-isotropic symmetric laminate. The responses based on closed-form solutions for different boundary conditions are computed and studied in detail. Particular emphasis is directed at understanding the influence of elastic couplings in the laminates. The influence of coupling decreased from a large effect in the general unsymmetric laminate, to practically no effect in the quasi-isotropic laminate. For example, the torsional loading of the general unsymmetric laminate resulted in a radial displacement. The temperature change also caused a significant radial displacement to occur near the ends of the cylinder. On the other hand, the more conventional unsymmetric laminate and the quasi-isotropic cylinder did not deform radially when subjected to a torsional load. From the results obtained, it is clear the degree of elastic coupling can be controlled and indeed designed into a cylinder, the degree and character of the coupling being dictated by the application.
A simulation technique has been developed for predicting the char yield of organic resins during high-temperature processing. In silico methods can aid in the screening of new advanced materials for a number of important properties, but no chemistry-sensitive protocol currently exists for predicting the important experimental value of char yield. The proposed method utilizes a reactive force field (ReaxFF) to model the chemical transformation of precursor monomers into carbonized structures during three processing stages: ramp-up to pyrolysis temperatures (~3000 K), pyrolysis, and quenching. Achieving good agreement with experimental char yields requires continuous removal of small by-product molecules to mimic outgassing, and the application of high pressure to encourage the formation of a dense, glassy network. Six different resin chemistries were investigated: an ethynyl, a phenylethynyl, a cyanate ester, a phthalonitrile, acrylonitrile, and adamantane. These candidates represent a diverse group of precursors with respect to initial cyclic content, presence of heteroatoms, and types of reactive groups. The protocol developed accurately predicts the relative char yield between the investigated chemistries and provides quantitative agreement with experimental values, especially for high char yield resins. Several simulated properties of the carbonized structures are compared with experimental results, including outgassing products, morphology of the final chemical configurations, cyclic content, and mechanical properties.
Experimental results are shown which demonstrate that the properties of plasma sprayed fully stabilized zirconia are strongly influenced by the process parameters. Properties of the coatings in the as-sprayed condition are shown to be additionally influenced by environmental exposure. This behavior is dependent on raw material considerations and processing conditions as well as exposure time and temperature. Process control methodology is described which can take into consideration these complex interactions and help to produce thermal barrier coatings in a cost effective way while meeting coating technical requirements.
Experimental results are shown which demonstrate that the properties of plasma sprayed fully stabilized zirconia are strongly influenced by the process parameters. Properties of the coatings in the as-sprayed condition are shown to be additionally influenced by environmental exposure. This behavior is dependent on raw material considerations and processing conditions as well as exposure time and temperature. Process control methodology is described which can take into consideration these complex interactions and help to produce thermal barrier coatings in a cost effective way while meeting coating technical requirements.
It has widely been ascertained that doping of lead in Bi:Sr:Ca:Cu:O systems promotes the growth of high T(sub c) (110 K) phase, improves critical current density, and lowers processing temperature. A systematic investigation is undertaken to determine optimum lead content and processing conditions to achieve these. A large number of samples with cationic compositions of Bi(2-x)Pb(x)Sr2Ca2Cu3 (x = 0.2 to 2.0) were prepared by conventional solid state reaction technique. Samples of all compositions were annealed together at a temperature and characterized through resistance-temperature (R-T) measurements and x ray diffraction (XRD) to determine the zero resistance temperature, T(sub c)(0) and to identify presence of phases, respectively. The annealing temperature was varied between 790 C to optimize processing parameters. Results are given. In brief, an optimum process is reported along with composition of leaded bismuth cuprate superconductor which yields nearly a high T(sub c) single phase with highly stable superconducting properties.
It has been widely ascertained that doping of lead in Bi-Sr-Ca-Cu-O systems promotes the growth of high T sub c (110 K) phase, improves critical current density, and lowers processing temperature. A systematic study was undertaken to determine optimum lead content and processing conditions to achieve these properties. A large number of samples with cationic compositions of Bi(2-x)Pb(x)Sr2Ca2Cu3 (x = 0.2 to 2.0) were prepared by conventional solid state reaction technique. Samples of all compositions were annealed together at a temperature and characterized through resistance temperature (R-T) measurements and x ray diffraction to determine the zero resistance temperature, T sub c(0) and to identify presence of phases, respectively. The annealing temperature was varied between 790 and 880 C to optimize processing parameters. Results are given. In brief, an optimum process is reported along with composition of leaded bismuth cuprate superconductor which yields nearly a high T sub c single phase with highly stable superconducting properties.
A radiation hardened version of the C2L process has been developed that utilizes all-low-temperature processes subsequent to channel oxidation. This process has been used on 1K RAMS. The RAMs functioned reliably at a dose of 200,000 rads (Si) and failed at a dose of 500,000 rads (Si). The 1K RAM is capable of operating from 7.5 to 12 volts and has an access time from address change of 160 nsec at 10 volts
An MOCVD-based atomic-layer epitaxy process is being developed as a potential solution to the problems of film-thickness and interface-abruptness control which are encountered when fabricating superconductor-insulator-superconductor devices using YBa2Cu3O(7-x). In initial studies, the atomic-layer MOCVD process yields superconducting YBa2Cu3O(7-x) films with substrate temperatures of 605 C during film growth, and no postdeposition anneal. The low temperature process yields a smooth film surface and can reduce interface degradation due to diffusion.
A series of silsesquioxane copolymers was synthesized by acid hydrolysis and condensation of trimethoxysilanes of the form RSi(OCH3)3, where R = methyl or phenyl. By varying pH, water/methoxy and methyl/phenyl ratios, the molecular structure, polymer rheology and ceramic composition can be controlled. The polymers form an amorphous siliconoxycarbide on pyrolysis. Composites of Nicalon/siliconoxycarbide were fractured in four-point flexure and in tension to evaluate the influence of matrix composition, final fabrication temperature and use of filler on composite mode of failure, modulus, strain capability and strength. Incorporation of filler was found to increase matrix compressive strength. Employment of processing temperatures of 1375 to 1400 C enhanced strain to failure and reduced the tendency toward brittle fracture. Mixed mode (compression/shear and tension/shear) failures were observed in flexural samples processed to the higher temperatures, giving rise to nonlinear stress-strain curves. Tensile samples pyrolyzed to 1400 C showed linear-elastic behavior and failed by fracture of fiber bundles. Matrix material was found to be adherent to the fiber surface after failure. These results demonstrate the need for tensile testing to establish composite behavior.