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Adhesive and coating material formulations and manufacturing processes for lightweight low-permeability braces for use in high altitude decelerators
Various aspects of a sensitivity analysis, in particular, the impact of variations in metal sheet resistivity, metal line width, diffused layer sheet resistance, junction depth, base layer lifetime, optical coating thickness and optical coating refractive index and on process reproducibility for A's diffusion from a polymer dopant source and on module fabrication were studied. Model calculations show that acceptable process windows exist for each of these parameters.
Densification process uses brushed or sprayed coating of tetraethyl orthosilicate. Liquid is applied and cured in three steps; tile weight increase averages 0.15 g per square centimeter. TEOS liquid is prepared by mixing TEOS with hydrochloric acid and adding marking dye. TEOS application provides variable stiffness, strength, and penetration. Surface of tile shows no buidup and is more durable for additional coatings.
Inexpensive process converts architectural reflective-coated glass into electrically heated panels. Technique utilizes reflective layer as heating element in ordinary glass. Panels have many applications, including automobile windows, home-heating panels, temperature-controlled windows or containers, and food warming trays.
This paper describes the development and evaluation of chromic acid anodized (CAA) Al foil as a protective and thermal control coating for graphite/epoxy tubes designed for the Space Station truss structure. Special consideration is given to the development of solar-absorptance and thermal-emittance properties required of Al foil, the development of CAA parameters necessary to achieve these optical properties, and the atomic oxygen and UV testing of CAA Al foil. Results showed that 0.003-in CAA Al foil cocured or secondary bonded to graphite/epoxy tubes with thin epoxy film adhesive retains excellent bond strength and provides a superior protective and thermal control coating to the LEO environment. Processes were developed for CAA Al foils long enough to continuously wrap the 23-ft-long diagonal struts of the Space Station truss structure. Specifications are presented for the processes of chromic acid anodizing of Al foil and for the bonding of anodized Al foil to graphite/epoxy tubes.
The formalism for the accurate modeling of chemical vapor deposition (CVD) processes has matured based on the well established principles of transport phenomena and chemical kinetics in the gas phase and on surfaces. The utility and limitations of such models are discussed in practical applications for high temperature structural materials. Attention is drawn to the complexities and uncertainties in chemical kinetics. Traditional approaches based on only equilibrium thermochemistry and/or transport phenomena are defended as useful tools, within their validity, for engineering purposes. The role of modeling is discussed within the context of establishing the link between CVD process parameters and material microstructures/properties. It is argued that CVD modeling is an essential part of designing CVD equipment and controlling/optimizing CVD processes for the production and/or coating of high performance structural materials.
The formalism for the accurate modeling of chemical vapor deposition (CVD) processes has matured based on the well established principles of transport phenomena and chemical kinetics in the gas phase and on surfaces. The utility and limitations of such models are discussed in practical applications for high temperature structural materials. Attention is drawn to the complexities and uncertainties in chemical kinetics. Traditional approaches based on only equilibrium thermochemistry and/or transport phenomena are defended as useful tools, within their validity, for engineering purposes. The role of modeling is discussed within the context of establishing the link between CVD process parameters and material microstructures/properties. It is argued that CVD modeling is an essential part of designing CVD equipment and controlling/optimizing CVD processes for the production and/or coating of high performance structural materials.
Hydrocarbon polymer coatings used in microelectronic manufacturing processes are anisotropically etched by hyperthermal atomic oxygen beams (translational energies of 0.2 to 20 eV, preferably 1 to 10 eV). Etching with hyperthermal oxygen atom species obtains highly anisotropic etching with sharp boundaries between etched and mask protected areas.
Wire-arc spraying used to deposit protective metallic coats on thermally insulating foams. Process relatively fast and cheap, and does not damage foam or involve toxic and polluting chemicals.
The mobile communication community could significantly benefit from the availability of low-cost, large space-deployable antennas. A new class of space structures, called inflatable deployable structures, will become an option for this industry in the near future. This new technology recently made significant progress with respect to reducing the risk of flying large inflatable structures in space. This progress can be attributed to the successful space flight of the Inflatable Antenna Experiment in May of 1996, which prompted the initiation of the NASA portion of the joint NASA/DOD coordinated Space Inflatables Program, which will develop the technology to be used in future mobile communications antennas along with other users. The NASA/DOD coordinated Space Inflatables Program was initiated in 1997 as a direct result of the Inflatable Antenna Experiment. The program adds a new NASA initiative to a substantial DOD program that involves developing a series of ground test hardware, starting with 3 meter diameter units and advancing the manufacturing techniques to fabricate a 25 meter ground demonstrator unit with surface accuracy exceeding the requirements for mobile communication applications. Simultaneously, the program will be advancing the state of the art in several important inflatable technology areas, such as developing rigidizable materials for struts and tori and investigating thin film technology issues, such as application of coatings, property measurement and materials processing and assembly techniques. A very important technology area being addressed by the program is deployment control techniques. The program will sponsor activities that will lead to understanding the effects of material strain energy release, residual air in the stowed structure, and the design of the launch restraint and release system needed to control deployment dynamics. Other technology areas directly applicable to developing inflatable mobile communication antennas in the near future are analytical performance prediction tools, configuration studies and miniaturizing the inflation systems.
One of the primary obstacles to the widespread use of the direct methanol fuel cell (DMFC) is the high cost of the catalyst. Therefore, reducing the catalyst loading well below the current level of 8-12 mg/cm 2 would be important to commercialization. The current methods for preparation of catalyst layers consisting of catalyst, ionomer and sometimes a hydrophobic additive are applied by either painting, spraying, decal transfer or screen printing processes. Sputter deposition is a coating technique widely used in manufacturing and therefore particularly attractive. In this study we have begun to explore sputtering as a method for catalyst deposition. Present experiments focus on Pt-Ru catalyst layers for the anode.
F&S Inc. developed and commercialized fiber optic and microelectromechanical systems- (MEMS) based instrumentation for harsh environments encountered in the aerospace industry. The NASA SBIR programs have provided F&S the funds and the technology to develop ruggedized coatings and coating techniques that are applied during the optical fiber draw process. The F&S optical fiber fabrication facility and developed coating methods enable F&S to manufacture specialty optical fiber with custom designed refractive index profiles and protective or active coatings. F&S has demonstrated sputtered coatings using metals and ceramics and combinations of each, and has also developed techniques to apply thin coatings of specialized polyimides formulated at NASA Langley Research Center. With these capabilities, F&S has produced cost-effective, reliable instrumentation and sensors capable of withstanding temperatures up to 800? C and continues building commercial sales with corporate partners and private funding. More recently, F&S has adapted the same sensing platforms to provide the rapid detection and identification of chemical and biological agents
With the slowdown in space station construction, limiting astronaut time for scientific experiments, an effort is being made to automate certain experiments. One such experiment is production of heavy metal fluoride fibers in the microgravity environment. Previous work by this author and others have shown that microgravity inhibits crystallization of ZBLAN glass. Thus an automated experiment has been designed. This experiment will consist of several elements, one which includes the use of an autonomous robot to initiate fiber pulling. The first element will be to melt the preform to eliminate crystals. The preform tip will then be heated to the viscosity necessary for fiber drawing. The robot will initiate the draw and attach the fiber end to the take-up reel. Once fiber pulling has commenced, sensors will be used to detect a fiber break, whereupon the robot can re-initiate the pulling process. The fiber will be coated with a polymer and the polymer cured with ultraviolet light. A laser micrometer will be used to monitor fiber diameter. The experiment is designed so that up to 10 preforms can be pulled into fiber during one flight. The apparatus will be mounted on a free-flying carrier which will be placed into low-earth orbit from the cargo bay of the space shuttle by the shuttle robot arm. The experiment can be started by a signal from the shuttle or from the ground via telescience. The experiment will proceed automatically using specially designed algorithms and will be monitored from the ground. The carrier will be picked up by the shuttle before return to earth.
A prototype manufacturing technology for producing high volume efficiency and high energy density diamond-like carbon (DLC) capacitors has been developed. Unique dual ion-beam deposition and web-handling systems have been designed and constructed to deposit high quality DLC films simultaneously on both sides of capacitor grade aluminum foil and aluminum-coated polymer films. An optimized process, using inductively coupled RF ion sources, has been used to synthesize electrically robust DLC films. DLC films are amorphous and highly flexible, making them suitable for the production of wound capacitors. DLC capacitors are reliable and stable over a wide range of AC frequencies from 20 Hz to 1 MHz, and over a temperature range from .500 C to 3000 C. The compact DLC capacitors offer at least a 50% decrease in weight and volume and a greater than 50% increase in temperature handling capability over equal value capacitors built with existing technologies. The DLC capacitors will be suitable for high temperature, high voltage, pulsed power and filter applications.
An instrument for rapidly measuring the electric charges and sizes (from approximately 1 to approximately 100 micrometers) of airborne particles is undergoing development. Conceived for monitoring atmospheric dust particles on Mars, instruments like this one could also be used on Earth to monitor natural and artificial aerosols in diverse indoor and outdoor settings for example, volcanic regions, clean rooms, powder-processing machinery, and spray-coating facilities. The instrument incorporates a commercially available, low-noise, ultrasensitive charge-sensing preamplifier circuit. The input terminal of this circuit--the gate of a field-effect transistor--is connected to a Faraday-cage cylindrical electrode. The charged particles of interest are suspended in air or other suitable gas that is made to flow along the axis of the cylindrical electrode without touching the electrode. The flow can be channeled and generated by any of several alternative means; in the prototype of this instrument, the gas is drawn along a glass capillary tube (see upper part of figure) coaxial with the electrode. The size of a particle affects its rate of acceleration in the flow and thus affects the timing and shape of the corresponding signal peak generated by the charge-sensing amplifier. The charge affects the magnitude (and thus also the shape) of the signal peak. Thus, the signal peak (see figure) conveys information on both the size and electric charge of a sensed particle. In experiments thus far, the instrument has been found to be capable of measuring individual aerosol particle charges of magnitude greater than 350 e (where e is the fundamental unit of electric charge) with a precision of +/- 150 e. The instrument can sample particles at a rate as high as several thousand per second.
For some time the oxidation community has been concerned with interfacial spallation of protective alumina scales, not just upon immediate cool down, but as a time-delayed phenomenon. Moisture-induced delayed spallation (MIDS) and desktop spallation (DTS) of thermal barrier coatings (TBCs) refer to this process. It is most apparent for relatively adherent alumina scales that have survived initial cool down in a dry environment, have built up considerable thickness and strain energy, and have been somewhat damaged, such as by cyclic oxidation cracking. Indeed, a "sensitive zone" can be described that maximizes the observed effect as a function of all the relevant factors. Moisture has been postulated to serve as a source of interfacial hydrogen embrittlement. Hydrogen is derived from reaction with aluminum in the alloy at an exposed interface. The purpose of this monograph is to trace the close analogy of this phenomenon to other hydrogen-induced effects, such as embrittlement of aluminides and blistering of alloys and anodic alumina films. A formalized, top-down, logic-tree structure is presented as a guide to this discussion. A theoretical basis for interfacial weakening by hydrogen is first cited, as are demonstrations of hydrogen detection as a reaction product or interfacial species. Further support is provided by critical experiments that recreate the moisture effect, but by isolating hydrogen from other potential causative factors. These experiments include tests in H 2-containing atmospheres or cathodic hydrogen charging. Accordingly, they strongly indicate that interfacial hydrogen, derived from moisture, is the key chemical species accounting for delayed alumina scale spallation.
In the last decade, considerable progress has been made in the development and application of ceramic matrix composites consisting of silicon carbide (SiC) based matrices reinforced by small-diameter continuous-length SiC-based fibers. For example, these SiC/SiC composites are now in the early stages of implementation into hot-section components of civil aero-propulsion gas turbine engines, where in comparison to current metallic components they offer multiple advantages due to their lighter weight and higher temperature structural capability. For current production-ready SiC/SiC, this temperature capability for long time structural applications is ~1250 degC, which is better than ~1100 degC for the best metallic superalloys. Foreseeing that even higher structural reliability and temperature capability would continue to increase the advantages of SiC/SiC composites, progress in recent years has also been made at NASA toward improving the properties of SiC/SiC composites by optimizing the various constituent materials and geometries within composite microstructures. The primary objective of this chapter is to detail this latter progress, both fundamentally and practically, with particular emphasis on recent advancements in the materials and processes for the fiber, fiber coating, fiber architecture, and matrix, and in the design methods for incorporating these constituents into SiC/SiC microstructures with improved thermo-structural performance.
Controllable surface morphology is requisite across a gamut of processes, industries, and applications. The surface morphology of silica-coated polystyrene microspheres was controllably modified to enable generation of both smooth and bumpy, or raspberry-like, surfaces. Although smooth and raspberry-like silica shells on polystyrene templates have been demonstrated extensively, the method described here used readily available materials to produce radical changes in surface morphology from a single polystyrene template coated in silica through a facile sol-gel reaction processes. Silica shells were deposited via a sol-gel process (using tetraethyl orthosilicate as the silica precursor) onto 1 to 2 m diameter anionic polystyrene spheres, fabricated by emulsifier-free polymerization. By varying of the concentration of silica precursor and ammonium hydroxide catalyst and altering the electrostatic surface interactions via addition of a cationic polymeric brush, an array of surface topologies was generated. The resulting silica shells ranged from 100 to 200 nm in thickness, as measured by calcination of the polystyrene template. Empirical relations between reaction conditions and the resulting silica colloid diameter were utilized to understand the resultant silica shell topology. These results may serve as a guide to generate a versatile platform for research in the multitude of applications where polystyrene-silica core-shell particles are utilized.