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At least 73 records · Page 4

Ceramic Matrix Composite (CMC) Materials Development

Under the former NASA EPM Program, much initial progress was made in identifying constituent materials and processes for SiC/SiC ceramic composite hot-section components. This presentation discusses the performance benefits of these approaches and elaborates on further constituent and property improvements made under NASA UEET. These include specific treatments at NASA that significantly improve the creep and environmental resistance of the Sylramic(TM) Sic fiber as well as the thermal conductivity and creep resistance of the CVI Sic matrix. Also discussed are recent findings concerning the beneficial effects of certain 2D-fabric architectures and carbon between the BN interphase coating and Sic matrix.

DiCarlo, James

Nanorod Material Developed for Use as an Optical Sensor Platform

Optical sensors are becoming increasingly important in the development of new nonintrusive or embedded sensors. The use of light and material optical properties helps us measure unknown parameters such as temperature, pressure, flow, or chemical species. The focus of this work is to develop new nanostructure platforms upon which optical sensors can be constructed. These nanorods are synthesized oxides that form a base structure to which luminescent sensing dyes or dopants can be attached or embedded. The nanorod structure allows for a much greater open area than closed or polymer-based sensors do, enabling a much faster contact of the measured species with the luminescent sensor and, thus, a potentially faster measurement.

Bencic, Timothy J.

Materials Development for Hypersonic Flight Vehicles

The DARPA/Air Force Falcon program is planning to flight test several hypersonic technology vehicles (HTV) in the next several years. A Materials Integrated Product Team (MIPT) was formed to lead the development of key thermal protection system (TPS) and hot structures technologies. The technologies being addressed by the MIPT are in the following areas: 1) less than 3000 F leading edges, 2) greater than 3000 F refractory composite materials, 3) high temperature multi-layer insulation, 4) acreage TPS, and 5) high temperature seals. Technologies being developed in each of these areas are discussed in this paper.

Glass, David E.

Reusable TPS Materials Development Activities at NASA Ames

Recent developments in low-cost access to low-earth orbit (LEO) and hypersonic flight are driving renewed demand in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Modern systems will need to consider full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance to enable this new generation of space flight. NASA Ames Research Center (ARC) has a long history of RTPS development including modern state-of-the-art materials like Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). Now, ARC is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts at ARC that span updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Adam Caldwell

Advanced Materials Development under NASA’s Hybrid Thermally Efficient Core (HyTEC) Project

The Hybrid Thermally Efficient Core (HyTEC) project aims to develop small core turbofan engine technologies that will enable fuel burn reductions, additional use of electric airplane systems through power extraction, and to advance engine operability and compatibility with sustainable aviation fuels. As such, a portfolio of technologies that contribute to raising the pressure, temperature and efficiency of turbofan engine cores needs developed. Included in HyTEC’s technology portfolio to enable these advancements are enhanced combustor liner materials and higher temperature capable turbine blades and vanes manufactured using ceramic matrix composites (CMCs) and environmental barrier coatings (EBCs). These technologies are being developed and tested in laboratory-scale relevant environments to advance the technology readiness level (TRL) to 4 or 5, before moving into an engine core demonstrator to raise the TRL to 6. A new natural gas/oxygen burner rig facility will be used to simulate turbine engine relevant environments at the laboratory/coupon scale. In addition, improvements to enable sub-element, and more complex component testing in NASA Glenn’s combustor facility (CE-5) will be presented.

Ceramic Matrix Composites (CMCs)

NASA's Additive Manufacturing Development Materials Science to Technology Infusion - Connecting the Digital Dots

At NASA, the first steps of the Journey to Mars are well underway with the development of NASA's next generation launch system and investments in research and technologies that should increase the affordability, capability, and safety of exploration activities. Additive Manufacturing presents a disruptive opportunity for NASA to design and manufacture hardware with new materials at dramatically reduced cost and schedule. Opportunities to incorporate additive manufacturing align very well with NASA missions and with most NASA programs related to space, science, and aeronautics. The Agency also relies on many partnerships with other government agencies, industry and academia.

Vickers, John

A full-scale fire program to evaluate new furnishings and textile materials developed by the National Aeronautics and Space Administration

A program of experimental fires was carried out to establish the advantages offered by new materials for improved fire safety. Four full-scale bedrooms, differing only in the materials used to furnish them, were built and burned to provide comparative data on the fire hazards produced. Cost and availability differences were not considered. The visual evidence provided by TV and photographic coverage of the four experimental room fires showed clearly that the rooms responded very differently to a common ignition condition. Resistance to the ignition and spread of fire was substantially improved in the rooms furnished completely or partially with the new materials.

Hillenbrand, L. J.

Flame Resistant Fibrous Materials Development

Since 1973, Albany International Research Co. has been engaged by NASA-JSC under Contract No. NAS9-13673 to conduct studies aimed at developing fibers and flexible structures made therefrom which would provide improved flame resistance over existing commercially available materials in oxygen enriched atmospheres. A portion of the crew bay area life support system and crew equipment for the space shuttle was initially designed to function at a 30% oxygen, 70% nitrogen atmosphere at 9 psia pressure. This oxygen concentration imposed certain fire safety and smoke generation requirements which could not be completely met by commonly accepted textiles. Potentially useful new polymers were investigated both for fire safety and mechanical properties. During the course of the work, three candidate fibers were studied and evaluated and the results of each of these efforts are summarized.

Coskren, R. J.

A Full-Scale Fire Program to Evaluate New Furnishings and Textile Materials Developed by the National Aeronautics and Space Administration

The plans for the present series of full-scale experimental fires were initiated at the suggestion of NASA following the presentation of a film and discussion illustrating Battelle-Columbus' recent work in fire research. That film showed bedroom-type fires carried out as a part of a program to determine the influence of the cyclic characteristics of real fires under limited ventilation on the burning and pyrolysis properties of the room furnishings. A new series of fires was suggested by NASA designed to show the performance of new fire resistant and fire retardant materials by providing comparative fire and smoldering environmental conditions. More recently, the goal for the new series of fires was written in a meeting with NASA personnel and others at Battelle on May 3 and 4, 1972. The goal was as follows: To establish the need for special materials of improved fire safety in domiciliary settings of public concern, and to assess, in a professionally acceptable manner, the potential of materials arising from the new space-age technology for this purpose. It was anticipated that some new materials arising from the space-age technology and not yet available through conventional commercial channels might provide significant improvements in fire safety if the best of the commercially available materials showed important shortcomings in this area. It was the intent of this program to assess the benefits that could accrue from the use of these new materials. Fire safety is a matter requiring the evaluation of a number of factors. For example, fire resistance and fire spread, visibility during the fire, toxicity of evolved gases, and the fire-fighting problem that is created must be evaluated before the relative hazard can be assessed. The plan of the program provided for sampling and instrumentation to evaluate these factors, consistent with the goal of technological utilization that has been specified. Arrangements were made with the Columbus Fire Department to use an existing six-story concrete building', designed and used as a fire training tower, as the site for the experimental fires. The visual evidence provided by TV and photographic coverage of the four experimental room fires showed clearly that the rooms responded very differently to a common ignition condition. In particular: (1) The Typical room, furnished from conventional retail sources, ignited easily and burned rapidly so that after 8 minutes the contents of the room were nearly destroyed. (2) The Improved room, furnished with materials selected as being among the best commercially available, showed substantial improvement over the Typical room in that there was slower fire spread. However, the relatively complete destruction of the room contents that resulted, and the large amounts of smoke, made it clear that substantial further improvements were needed. This fire was stopped after 29 minutes. (3) The Space-age room, furnished completely with new materials that were not yet commercially available, did not ignite under the common ignition condition and soon demonstrated the substantial improvement in fire resistance available for those components close to the ignition source. A second and larger ignition arrangement showed that this room can burn, but the difficulty with which this was brought about confirmed the improved fire resistance available with use of these materials. (4) The Mixed room ensemble, furnished with 'materials identical to the Typical room except for the substitution of the bed from the Space-age room, illustrated the improvement in control of fire spread available by careful placement of fire materials in the important paths of fire development of an otherwise ordinary room. The most significant hazards at early times in each fire were due to the rapid rise in heat flux and the abrupt obscuration of vision by smoke. The most consistent toxicity hazard was due to CO and its importance would depend on the ability of the occupant to survive the initial heat and smoke menace which characterized each fire room. Other gases and vapors were shown to reach hazardous levels in certain fire rooms and, again, their significance to an occupant, would relate to the times in which such hazards occurred, and probably to the synergistic nature of the hazard arising from mixtures of such gases. Fire retardant items in the room are caused to pyrolyze by the heat of burning from other items in the room and so contribute to combustible and toxic vapor accumulations, even though they may not have entered into the burning process. This effect of a mixture of combustible materials to produce burning and pyrolysis not characteristic of any one item individually we have chosen to call the "ensemble effect". Further full-scale fire trials may be expected to show the significant changes that control the burning and pyrolytic processes and in that event a programmed fire chamber should be developed to yield realistic laboratory results.

Hillenbrand, L. J.

Materials Development for Auxiliary Components for Large Compact Mo/Au TES Arrays

We describe our current fabrication process for arrays of superconducting transition edge sensor microcalorimeters, which incorporates superconducting Mo/Au bilayers and micromachined silicon structures. We focus on materials and integration methods for array heatsinking with our bilayer and micromachining processes. The thin superconducting molybdenum bottom layer strongly influences the superconducting behavior and overall film characteristics of our molybdenum/gold transition-edge sensors (TES). Concurrent with our successful TES microcalorimeter array development, we have started to investigate the thin film properties of molybdenum monolayers within a given phase space of several important process parameters. The monolayers are sputtered or electron-beam deposited exclusively on LPCVD silicon nitride coated silicon wafers. In our current bilayer process, molybdenum is electron-beam deposited at high wafer temperatures in excess of 500 degrees C. Identifying process parameters that yield high quality bilayers at a significantly lower temperature will increase options for incorporating process-sensitive auxiliary array components (AAC) such as array heat sinking and electrical interconnects into our overall device process. We are currently developing two competing technical approaches for heat sinking large compact TES microcalorimeter arrays. Our efforts to improve array heat sinking and mitigate thermal cross-talk between pixels include copper backside deposition on completed device chips and copper-filled micro-trenches surface-machined into wafers. In addition, we fabricated prototypes of copper through-wafer microvias as a potential way to read out the arrays. We present an overview on the results of our molybdenum monolayer study and its implications concerning our device fabrication. We discuss the design, fabrication process, and recent test results of our AAC development.

Finkbeiner, F. m.

Low-Thermal-Conductivity Pyrochlore Oxide Materials Developed for Advanced Thermal Barrier Coatings

When turbine engines operate at higher temperatures, they consume less fuel, have higher efficiencies, and have lower emissions. The upper-use temperatures of the base materials (superalloys, silicon-based ceramics, etc.) used for the hot-section components of turbine engines are limited by the physical, mechanical, and corrosion characteristics of these materials. Thermal barrier coatings (TBCs) are applied as thin layers on the surfaces of these materials to further increase the operating temperatures. The current state-of-the-art TBC material in commercial use is partially yttria-stabilized zirconia (YSZ), which is applied on engine components by plasma spraying or by electron-beam physical vapor deposition. At temperatures higher than 1000 C, YSZ layers are prone to sintering, which increases thermal conductivity and makes them less effective. The sintered and densified coatings can also reduce thermal stress and strain tolerance, which can reduce the coating s durability significantly. Alternate TBC materials with lower thermal conductivity and better sintering resistance are needed to further increase the operating temperature of turbine engines.

Bansal, Narottam P.

Investigative study of holographic recording materials development

The potential of certain cis-trans isomers and doped LiNbO3 for the holographic read/write/erase memory application was investigated. The cis-trans work involved the photochemical investigation of a number of potential materials as well as specific molecular engineering efforts on alpha-methyl stilbene and its derivatives. These efforts resulted in an increase in the change in index of refraction, and thereby, in potential recording utility, of an order of magnitude. The work on LiNbO3 was directed toward a preliminary investigation of the dynamics of the writing process. Several samples and a variety of writing conditions were investigated. An unexpected and as yet unexplained improvement in material behavior with continued recycling was observed. In addition, some effort was devoted to an analysis of the physical conditions under which several current theories of the optical damage process are valid.

Source record

Holographic recording materials development

The area of organic cis-trans photoisomerization systems for holographic memory applications was examined. Photochemical studies were made of stilbene, indigo, and thioindigo derivatives in solution and in a variety of polymer matrix materials, to optimize the photorefractive behavior of the chemical system as a whole. Lithium niobate was used to study the writing and reading efficiencies of thick phase holograms. Both phase-wave holograms and Fourier-transform holograms were employed, and a number of reconstruction techniques are discussed. The possibility of using cis-trans photoisomerization of appropriate organic chemicals as the basis for a holographic recording system is confirmed.

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Cryoinsulation Material Development to Mitigate Obsolescence Risk for Global Warming Potential Foams

Cryoinsulation foams currently being qualified for the Space Launch System (SLS) core stage are nonozone- depleting substances (ODP) and are compliant with current environmental regulations. However, these materials contain the blowing agent HFC-245fa, a hydrofluorocarbon (HFC), which is a Global Warming Potential (GWP) substance. In August 2014, the Environmental Protection Agency (EPA) proposed a policy change to reduce or eliminate certain HFCs, including HFC-245fa, in end-use categories including foam blowing agents beginning in 2017. The policy proposes a limited exception to allow continued use of HFC and HFC-blend foam blowing agents for military or space- and aeronautics-related applications, including rigid polyurethane spray foams, but only until 2022.

Protz, Alison

Achieving Innovation and Affordability Through Standardization of Materials Development and Testing

The successful expansion of development, innovation, and production within the aeronautics industry during the 20th century was facilitated by collaboration of government agencies with the commercial aviation companies. One of the initial products conceived from the collaboration was the ANC-5 Bulletin, first published in 1937. The ANC-5 Bulletin had intended to standardize the requirements of various government agencies in the design of aircraft structure. The national space policy shift in priority for NASA with an emphasis on transferring the travel to low earth orbit to commercial space providers highlights an opportunity and a need for the national and global space industries. The same collaboration and standardization that is documented and maintained by the industry within MIL-HDBK-5 (MMPDS-01) and MIL-HBDK-17 (nonmetallic mechanical properties) can also be exploited to standardize the thermal performance properties, processing methods, test methods, and analytical methods for use in aircraft and spacecraft design and associated propulsion systems. In addition to the definition of thermal performance description and standardization, the standardization for test methods and analysis for extreme environments (high temperature, cryogenics, deep space radiation, etc) would also be highly valuable to the industry. Its subsequent revisions and conversion to MIL-HDBK-5 and then MMPDS-01 established and then expanded to contain standardized mechanical property design values and other related design information for metallic materials used in aircraft, missiles, and space vehicles. It also includes guidance on standardization of composition, processing, and analytical methods for presentation and inclusion into the handbook. This standardization enabled an expansion of the technologies to provide efficiency and reliability to the consumers. It can be established that many individual programs within the government agencies have been overcome with development costs generated from these nonstandard requirements. Without industry standardization and acceptance, the programs are driven to shoulder the costs of determining design requirements, performance criteria, and then material qualification and certification. A significant investment that the industry could make to both reduce individual program development costs and schedules while expanding commercial space flight capabilities would be to invest in standardizing material performance properties for high temperature, cryogenic, and deep space environments for both metallic and nonmetallic materials.

Bray, M. H.

Technology update: Tethered aerostat structural design and material developments

Requirements exist for an extremely stable, high performance, all-weather tethered aerostat system. This requirement has been satisfied by a 250,000 cubic foot captive buoyant vehicle as demonstrated by over a year of successful field operations. This achievement required significant advancements in several technology areas including composite materials design, aerostatics and aerodynamics, structural design, electro-mechanical design, vehicle fabrication and mooring operations. This paper specifically addresses the materials and structural design aspects of pressurized buoyant vehicles as related to the general class of Lighter Than Air vehicles.

Witherow, R. G.

Fire-resistant aircraft materials development and evaluation program

The overall objectives of this program are to provide a more fire-resistant commercial aircraft interior and to improve the fuselage insulation barrier between the cabin interior and an exterior fuel fire. Significant secondary objectives are to reduce the smoke and toxic gas production of the materials and to meet the end item use requirements pertaining to wearability, color fastness, and aesthetic appeal. It is shown that the fuselage insulation materials must meet stringent requirements pertaining to acoustic attenuation, low density, and water repellency.

Bricker, R. W.