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All sources NASA NTRS DOE OSTI

NASA NTRS1993

Space environmental effects on polymer composites: Research needs and opportunities

The long-term performance of polymer-based composites in the space environment is discussed. Both thermoset and thermoplastic matrix composites are included in this discussion. Previous efforts on the space environmental effects on composites are briefly reviewed. Focus of this review is placed on the effects of hygrothermal stresses, atomic oxygen, ultraviolet (UV), and space debris/micrometeoroid impacts along with the potential synergism. Potential approaches to estimating the residual strength of polymer composites after exposure to atomic oxygen erosion or space debris/micrometeoroid impact are evaluated. New ground-based data are then utilized to illustrate the effects of atomic oxygen and thermal cycling on the failure behavior of polymer composites. Finally, research needs, challenges, and opportunities in the field of space environmental effects on composite materials are highlighted.

Jang, Bor Z.↗

NASA NTRS1989

Morphological control of inter-penetrating polymer networks

Synthetic organic polymer chemistry has been successful in producing composition of matter with thermal oxidation stability and progressively higher glass transition temperatures. In part, this was done by increasing the steric-hindrance of moieties in the chain of a macromolecule. The resulting polymers are usually quite insoluble and produce molten polymers of very high viscosities. These types of polymers are not easily processed into graphite fiber prepregs by melt or solution impregnation methods. Hence, a technological need exists to produce new knowledge of how to produce polymer-fiber composites from this class of polymers. The concept of freeze drying amic-acid prepolymers with reactive thermoplastic was proposed as a research topic for the ASEE/NASA Summer Faculty Program of 1989 as a means of producing polymer-fiber composites. This process scheme has the thermodynamic attribute that the magnitude of phase separation due to differences in solubility of two organic constituents in solution will be greatly reduced by removing a solvent not by evaporation but by sublimation. Progress to date on evaluating this polymer processing concept is briefly outlined.

Hansen, Marion↗

NASA NTRS1984

Thermoplastic composite matrices with improved solvent resistance

In order to improve solvent resistance of aromatic thermoplastic polymers, ethynyl-terminated aromatic sulfone polymers (ETS), sulfone/ester polymers (SEPE) containing pendent ethynyl groups, and phenoxy resin containing pendent ethynyl groups are synthesized. Cured polysulfones and phenoxy resins containing ethynyl groups on the ends or pendent on the molecules exhibited systematic behavior in solvent resistance, film flexibility, and toughness as a function of crosslink density. The film and composite properties of a cured solvent-resistant ETS were better than those of a commercially available solvent sensitive polysulfone. The study was part of a NASA program to better understand the trade-offs between solvent resistance, processability and mechanical properties which may be useful in designing composite structures for aerospace vehicles.

Hergenrother, P. M.↗

DOE OSTI2023

Low-Velocity Impact Performances of Healed Polymer Fiber Reinforced Plastics

Extending the lifecycle of traditional carbon or glass fiber-reinforced plastics is a complicated problem. The lack of sustainability limits the applications of the traditional composite materials in the vehicle industries where recycling and repurposing are critical issues. Alternatives for the low-stressed structural components are polymer fiber-reinforced plastics (PFRPs). In PFRPs, both the fibers and matrix are composed of thermoplastic polymers (e.g. polypropylene or polyethylene). They are lightweight, easy to manufacture, and cost-effective. Additionally, recycling and repurposing thermoplastic polymers are well understood. Therefore, the PFRPs have strong advantages compared to the traditional fiber-reinforced composites in low-stressed structural applications. In this study, we investigated the low-velocity impact (LVI) performances of the PFRPs and compared them with carbon fiber-reinforced plastics (CFRPs). A semi-spherical impactor was dropped to flat, square panels, and the absorbed impact energy was measured. The damage mechanisms were examined using a Xray µCT scan. The PFRPs outperformed the CFRPs in terms of perforation energy normalized by plate thickness and density. After the perforation, we healed the fractured plates by leveraging the recyclability of the thermoplastic polymers. The healing process of the panels was identical to the initial panel manufacturing process. No additional materials were added during the healing process. The healed PFRP panels were impacted again and substantially recovered energy absorption capability. We also conducted the repeated-impact test with several different impact energies. Unlike the CFRPs where the impact peak load decreased as the impacts repeated, the PFRPs showed an increasing trend. Such a unique mechanism was due to the strain-hardening behavior of the polymer fibers and matrix. As a result, the repeated-impact life of the PFRPs was significantly enhanced. These results are particularly interesting in the automotive or aerospace industries where repeated LVI is frequently observed.

Ko, Seunghyun↗

NASA NTRS2008

Organic/Inorganic Polymeric Composites for Heat-Transfer Reduction

Organic/inorganic polymeric composite materials have been invented with significant reduction in heat-transfer properties. Measured decreases of 20-50 percent in thermal conductivity versus that of the unmodified polymer matrix have been attained. These novel composite materials also maintain mechanical properties of the unmodified polymer matrix. The present embodiments are applicable, but not limited to: racing applications, aerospace applications, textile industry, electronic applications, military hardware improvements, and even food service industries. One specific application of the polymeric composition is for use in tanks, pipes, valves, structural supports, and components for hot or cold fluid process systems where heat flow through materials is problematic and not desired. With respect to thermal conductivity and physical properties, these materials are superior alternatives to prior composite materials. These materials may prove useful as substitutes for metals in some cryogenic applications. A material of this type can be made from a blend of thermoplastics, elastomers, and appropriate additives and processed on normal polymer processing equipment. The resulting processed organic/inorganic composite can be made into fibers, molded, or otherwise processed into useable articles.

Smith, Trent↗

NASA NTRS2012

Processing and Damage Tolerance of Continuous Carbon Fiber Composites Containing Puncture Self-Healing Thermoplastic Matrix

Research at NASA Langley Research Center (NASA LaRC) has identified several commercially available thermoplastic polymers that self-heal after ballistic impact and through-penetration. One of these resins, polybutadiene graft copolymer (PB(sub g)), was processed with unsized IM7 carbon fibers to fabricate reinforced composite material for further evaluation. Temperature dependent characteristics, such as the degradation point, glass transition (T(sub g)), and viscosity of the PBg polymer were characterized by thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and dynamic parallel plate rheology. The PBg resin was processed into approximately equal to 22.0 cm wide unidirectional prepreg tape in the NASA LaRC Advanced Composites Processing Research Laboratory. Data from polymer thermal characterization guided the determination of a processing cycle used to fabricate quasi-isotropic 32-ply laminate panels in various dimensions up to 30.5cm x 30.5cm in a vacuum press. The consolidation quality of these panels was analyzed by optical microscopy and acid digestion. The process cycle was further optimized based on these results and quasi-isotropic, [45/0/-45/90]4S, 15.24cm x 15.24cm laminate panels were fabricated for mechanical property characterization. The compression strength after impact (CAI) of the IM7/pBG composites was measured both before and after an elevated temperature and pressure healing cycle. The results of the processing development effort of this composite material as well as the results of the mechanical property characterization are presented in this paper.

Grimsley, Brian W.↗

NASA NTRS2012

High-Temperature Shape Memory Polymers

physical conformation changes when exposed to an external stimulus, such as a change in temperature. Such materials have a permanent shape, but can be reshaped above a critical temperature and fixed into a temporary shape when cooled under stress to below the critical temperature. When reheated above the critical temperature (Tc, also sometimes called the triggering or switching temperature), the materials revert to the permanent shape. The current innovation involves a chemically treated (sulfonated, carboxylated, phosphonated, or other polar function group), high-temperature, semicrystalline thermoplastic poly(ether ether ketone) (Tg .140 C, Tm = 340 C) mix containing organometallic complexes (Zn++, Li+, or other metal, ammonium, or phosphonium salts), or high-temperature ionic liquids (e.g. hexafluorosilicate salt with 1-propyl-3- methyl imidazolium, Tm = 210 C) to form a network where dipolar or ionic interactions between the polymer and the low-molecular-weight or inorganic compound forms a complex that provides a physical crosslink. Hereafter, these compounds will be referred to as "additives". The polymer is semicrystalline, and the high-melt-point crystals provide a temporary crosslink that acts as a permanent crosslink just so long as the melting temperature is not exceeded. In this example case, the melting point is .340 C, and the shape memory critical temperature is between 150 and 250 C. PEEK is an engineering thermoplastic with a high Young fs modulus, nominally 3.6 GPa. An important aspect of the invention is the control of the PEEK functionalization (in this example, the sulfonation degree), and the thermal properties (i.e. melting point) of the additive, which determines the switching temperature. Because the compound is thermoplastic, it can be formed into the "permanent" shape by conventional plastics processing operations. In addition, the compound may be covalently cross - linked after forming the permanent shape by S-PEEK by applying ionizing radiation ( radiation, neutrons), or by chemical crosslinking to form a covalent permanent network. With respect to other shape memory polymers, this invention is novel in that it describes the use of a thermoplastic composition that can be thermally molded or solution-cast into complex "permanent" shapes, and then reheated or redissolved and recast from solution to prepare another shape. It is also unique in that the shape memory behavior is provided by a non-polymer additive.

Yoonessi, Mitra↗

DOE OSTI2022

Understanding the Elastic, Plastic, and Damage Features in Fracturing of Self-reinforced Thermoplastic Composites via Non-destructive Digital Imaging Correlation

This work demonstrated the utilization of non-destructive Digital Imaging Correlation (DIC) method to characterize the elastic, plastic, and damage features during the Mode I intra-laminar fracturing process of self-reinforced thermoplastic composites by using a self-reinforced polypropylene (PP) composite as an example. The DIC results clearly showed the development of huge plastic zone (PZ) and non-negligible Fracture Process Zone (FPZ) in front of the notch tip during the fracturing process, and the geometries and sizes of the foregoing zones at the peak load were further quantified. Such an interesting fracturing behavior of self-reinforced thermoplastic composites is way different from brittle materials (e.g., glass, acrylic, etc.), ductile materials (e.g., aluminum, steel, etc.), and even quasi-brittle materials (e.g., concrete, nanoparticle-reinforced composites, tough ceramics, wood, cement, carbon/glass fiber-reinforced polymers, etc.). Thus, understanding the elastic, plastic, and damage features is the first step before better characterizing the material fracture properties of self-reinforced thermoplastic composites through new analytical methods and computational modeling. These efforts are of utmost importance for wide applications of self-reinforced thermoplastic composites in various engineering fields in the future.

Lightweight Composites, Self-reinforced Thermoplas↗

NASA NTRS1994

Society of the plastic industry process emission initiatives

At first view, plastics process emissions research may not seem to have much bearing on outgassing considerations relative to advanced composite materials; however, several parallel issues and cross currents are of mutual interest. The following topics are discussed: relevance of plastics industry research to aerospace composites; impact of clean air act amendment requirements; scope of the Society of the Plastics Industry, Inc. activities in thermoplastic process emissions and reinforced plastics/composites process emissions; and utility of SPI research for advanced polymer composites audiences.

Mcdermott, Joseph↗

NASA NTRS2015

Puncture-Healing Thermoplastic Resin Carbon-Fiber-Reinforced Composites

A composite comprising a combination of a self-healing polymer matrix and a carbon fiber reinforcement is described. In one embodiment, the matrix is a polybutadiene graft copolymer matrix, such as polybutadiene graft copolymer comprising poly(butadiene)-graft-poly(methyl acrylate-co-acrylonitrile). A method of fabricating the composite is also described, comprising the steps of manufacturing a pre-impregnated unidirectional carbon fiber preform by wetting a plurality of carbon fibers with a solution, the solution comprising a self-healing polymer and a solvent, and curing the preform. A method of repairing a structure made from the composite of the invention is described. A novel prepreg material used to manufacture the composite of the invention is described.

Gordon, Keith L.↗

NASA NTRS2017

Puncture-Healing Thermoplastic Resin Carbon-Fiber Reinforced Composites

Gordon, Keith L.↗

NASA NTRS1989

A petrographic thin sectioning technique for evaluating composite materials

Petrographic thin sectioning by a low-speed diamond saw has been used in conjunction with transmission polarized light microscopy for the characterization of the microstructure and deformation mechanisms of a variety of polymer systems. It has proven possible by these means to study three types of thermoplastic matrices for composite applications: PEEK, BPA-based polycarbonate (PC), and a rubber-modified PC. The reinforcing fibers for these matrices were in all cases AS4 carbon fibers, unidirectionally arrayed. Superior analyzability of matrix morphology and subsurface fracture processes is achieved by thin sectioning.

Parker, D. S.↗

DOE OSTI2020

Polymer composites for fused filament fabrication and methods of making the same

Disclosed are compositions of a fused filament fabrication (FFF) composite filament having embedded functional materials in a thermoplastic matrix. Methods of making the composite filaments are also disclosed. In one example, a FFF composite filament incorporates a MOF, in an amount greater than 10% by mass, dispersed in a matrix polymer. One example of a method of synthesizing FFF composite filaments involves mixing a suspension that has a MOF with a matrix polymer solution to yield a polymer-MOF mixture. The mixture is cast and dried into a solid composite material, which is formed a FFF composite filament having the MOF in an amount greater than 10% by mass.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Solvent Resistant Thermoplastic Composite Matrices

The following approaches improved the solvent resistance and raised the Tg of thermoplastics: end-capping aligomers with ethynyl groups; incorporating ethynyl groups pendent along the polymer chain; and correcting polymers containing pendent ethynyl groups with a low molecular weight diethynyl compound. The following conclusions were reached: (1) film and composite properties off an ethynyl-terminated sulfone were better than those of UDEL (trademark); (2) fracture energy of an ethynyl-terminated sulfone was lower than that of UDEL (trademark); (3) residual palladium in the cured ethynyl-terminated sulfone lower the thermooxidative stability of the cured resin; (4) the properties of a phenoxy resin were altered considerably by placing pendent ethynyl groups along the polymer chain; and (5) property trade-offs must be considered when thermoplastics are modified via reactant groups.

Hergenrother, P. M.↗

NASA NTRS1994

Laminated thermoplastic composite material from recycled high density polyethylene

The design of a materials-science, educational experiment is presented. The student should understand the fundamentals of polymer processing and mechanical property testing of materials. The ability to use American Society for Testing and Materials (ASTM) standards is also necessary for designing material test specimens and testing procedures. The objectives of the experiment are (1) to understand the concept of laminated composite materials, processing, testing, and quality assurance of thermoplastic composites and (2) to observe an application example of recycled plastics.

Liu, Ping↗

DOE OSTI2020

Internal arcing and lightning strike damage in short carbon fiber reinforced thermoplastic composites

Short carbon fiber reinforced thermoplastic composites (S-CFRTP) are currently used in interior parts of aircraft such as electronic circuitry and assemblies, and their usage in aircraft's exterior is also being studied. In this paper, we present a lightning strike study on S-CFRTPs. High performance thermoplastics such as a polyphenylene sulfide (PPS) reinforced with 50% weight (wt.) short carbon fiber (CF), a polyphenyl sulfone (PPSU) reinforced with 25 % wt. Short CF and a acrylonitrile butadiene styrene (ABS) with 20 % wt. short CF were tested against artificial lightning strikes. All samples were prepared using an extrusion compression molding (ECM) technique. A modified component A (100 kA) of lightning waveform, as defined by SAE ARP 5412-B, was applied. High speed imaging, thermography, scanning electron microscopy (SEM) and ultrasonic non-destructive evaluation were performed to understand the effect of lightning strikes on the thermoplastic panels. The results show that electrical conductivity of the composite, thermal stability of the polymers, and CF orientation significantly affected the damage from artificial lightning strikes. PPS composite had the highest resilience against lightning strike damage, retaining 95% and 89% residual flexural strength and modulus, respectively. CF exfoliation due to internal arcing was observed in the carbon fiber-reinforced ABS polymer (CF-ABS) composite. CF exfoliation damage has been reported for the first time.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Mechanical properties of several neat polymer matrix materials and unidirectional carbon fiber-reinforced composites

The mechanical and physical properties of three neat matrix materials, i.e., PEEK (polyetheretherketone) thermoplastic, Hexcel F155 rubber-toughened epoxy and Hercules 8551-7 rubber-toughened epoxy, were experimentally determined. Twelve unidirectional carbon fiber composites, incorporating matrix materials characterized in this or earlier studies (with one exception; the PISO(sub 2)-TPI matrix itself was not characterized), were also tested. These composite systems included AS4/2220-1, AS4/2220-3, T500/R914, IM6/HX1504, T300/4901A (MDA), T700/4901A (MDA), T300/4901B (MPDA), T700/4901B (MPDA), APC2 (AS4/PEEK, ICI), APC2 (AS4/PEEK, Langley Research Center), AS4/8551-7, and AS4/PISO(sub 2)-TPI. For the neat matrix materials, the tensile, shear, fracture toughness, coefficient of thermal expansion, and coefficient of moisture expansion properties were measured as a function of both temperature and moisture content. For the unidirectional composites, axial and transverse tensile, longitudinal shear, coefficient of thermal expansion, and coefficient of moisture expansion properties were determined, at room temperature and 100 C.

Coguill, Scott L.↗

NASA NTRSDate not supplied

Design Considerations for Practical Li-S Batteries for Electric Aviation

The development of high-energy, high-safety, and high-power batteries beyond electric automotive standards is critical for future electric aviation applications. Non-volatile solid-state electrolytes (SSE) offer many promising advantages over traditional flammable liquid electrolytes. Solid-state electrolytes may be an enabling technology for certain battery chemistries by preventing detrimental interactions with liquid electrolytes, for example prevention of the dissolution of intermediates in lithium-sulfur common in traditional liquid organic solvents. However, significant manufacturing challenges must be overcome before the adoption of such technology. This research was conducted to identify processing techniques for producing solid-state battery components with practical dimensions and weights for enabling high specific energy cells. Traditional research has identified a range of very high theoretical ionic conductivities but are impractical due to their instability or inability to be manufactured. Electrolytes explored in this study were produced as sulfide-polymer composites with densified thicknesses below 40 micron using a tape-casting technique and thermoplastic elastomer binder. The combination of high chemical compatibility and flexibility produced robust films that had moderate impact on the ionic conductivity but was capable of dramatically reducing the parasitic mass. Despite minimal conductivity losses, films were produced 10-15 times thinner than comparable bulk powder electrolytes thus leading to overall lower film resistance. Conductivity is maintained above 0.2mS/cm for composite electrolytes. Through the analysis of materials based on their physical properties, such as density, practical cells can be designed. Based on this, low density sulfide-solid-state electrolytes are a promising candidate for achieving the energy and safety metrics for electric aviation, however, further optimization of cathode microstructure and composite processing will be required to achieve the high power metrics and will be the focus of further studies. Additionally, fabrication challenges arise when utilizing metallic lithium foil, due to its soft nature, as overflow and mechanical short circuit can occur on assembly which remains a challenge to overcome before metallic lithium anodes can be fully realized.

batteries↗