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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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NASA NTRS2004

Advanced Electrical Materials and Components Being Developed

All aerospace systems require power management and distribution (PMAD) between the energy and power source and the loads. The PMAD subsystem can be broadly described as the conditioning and control of unregulated power from the energy source and its transmission to a power bus for distribution to the intended loads. All power and control circuits for PMAD require electrical components for switching, energy storage, voltage-to-current transformation, filtering, regulation, protection, and isolation. Advanced electrical materials and component development technology is a key technology to increasing the power density, efficiency, reliability, and operating temperature of the PMAD. The primary means to develop advanced electrical components is to develop new and/or significantly improved electronic materials for capacitors, magnetic components, and semiconductor switches and diodes. The next important step is to develop the processing techniques to fabricate electrical and electronic components that exceed the specifications of presently available state-of-the-art components. The NASA Glenn Research Center's advanced electrical materials and component development technology task is focused on the following three areas: 1) New and/or improved dielectric materials for the development of power capacitors with increased capacitance volumetric efficiency, energy density, and operating temperature; 2) New and/or improved high-frequency, high-temperature soft magnetic materials for the development of transformers and inductors with increased power density, energy density, electrical efficiency, and operating temperature; 3) Packaged high-temperature, high-power density, high-voltage, and low-loss SiC diodes and switches.

Schwarze, Gene E.↗

NASA NTRS2006

The Cutting Edge of High-Temperature Composites

NASA s Ultra-Efficient Engine Technology (UEET) program was formed in 1999 at Glenn Research Center to manage an important national propulsion program for the Space Agency. The UEET program s focus is on developing innovative technologies to enable intelligent, environmentally friendly, and clean-burning turbine engines capable of reducing harmful emissions while maintaining high performance and increasing reliability. Seven technology projects exist under the program, with each project working towards specific goals to provide new technology for propulsion. One of these projects, Materials and Structures for High Performance, is concentrating on developing and demonstrating advanced high-temperature materials to enable high-performance, high-efficiency, and environmentally compatible propulsion systems. Materials include ceramic matrix composite (CMC) combustor liners and turbine vanes, disk alloys, turbine airfoil material systems, high-temperature polymer matrix composites, and lightweight materials for static engine structures.

Source record↗

NASA NTRS1993

Probabilistic material degradation under high temperature, fatigue, and creep

A methodology has been developed and embodied in two computer codes for quantitatively characterizing the material strength degradation of aerospace propulsion system structural components that are subjected to various random effects over the course of their service lives. The codes, PROMISS and PROMISC, constitute a material-resistance model that is used in the NESSUS aerospace structural-reliability program. NESSUS addresses the service life-reducing effects of high temperature, mechanical fatigue, and creep.

Boyce, L.↗

NASA NTRS1991

Vacuum bag bonding with a high temperature adhesive

A novel controlled molecular weight form of LARC-TPI polymide that exhibits an exceptionally high degree of melt flow in the 340-360 C temperature range has been developed. This material has been evaluated as a high-temperature adhesive, and because of its flow, cost-effective vacuum bag/oven processing can be used. Comparison of adhesive performance with higher molecular weight forms bonded at higher pressures shows this novel material to be equal in mechanical strength.

Progar, Donald J.↗

NASA NTRS2006

Mechanical Properties of T650-35/AFR-PE-4 at Elevated Temperatures for Lightweight Aeroshell Designs

Considerable efforts have been underway to develop multidisciplinary technologies for aeroshell structures that will significantly increase the allowable working temperature for the aeroshell components, and enable the system to operate at higher temperatures while sustaining performance and durability. As part of these efforts, high temperature polymer matrix composites and fabrication technologies are being developed for the primary load bearing structure (heat shield) of the spacecraft. New high-temperature resins and composite material manufacturing techniques are available that have the potential to significantly improve current aeroshell design. In order to qualify a polymer matrix composite (PMC) material as a candidate aeroshell structural material, its performance must be evaluated under realistic environments. Thus, verification testing of lightweight PMC's at aeroshell entry temperatures is needed to ensure that they will perform successfully in high-temperature environments. Towards this end, a test program was developed to characterize the mechanical properties of two candidate material systems, T650-35/AFR-PE-4 and T650-35/RP46. The two candidate high-temperature polyimide resins, AFR-PE-4 and RP46, were developed at the Air Force Research Laboratory and NASA Langley Research Center, respectively. This paper presents experimental methods, strength, and stiffness data of the T650-35/AFR-PE-4 material as a function of elevated temperatures. The properties determined during the research test program herein, included tensile strength, tensile stiffness, Poisson s ratio, compressive strength, compressive stiffness, shear modulus, and shear strength. Unidirectional laminates, a cross-ply laminate and two eight-harness satin (8HS)-weave laminates (4-ply and 10-ply) were tested according to ASTM standard methods at room and elevated temperatures (23, 316, and 343 C). All of the relevant test methods and data reduction schemes are outlined along with mechanical data. These data contribute to a database of material properties for high-temperature polyimide composites that will be used to identify the material characteristics of potential candidate materials for aeroshell structure applications.

Whitley, Karen S.↗

NASA NTRS2014

Processing and Characterization of Basalt Fiber Reinforced Ceramic Composites for High Temperature Applications Using Polymer Precursors

The development of high temperature structural composite materials has been very limited due to the high cost of the materials and the processing needed. Polymer Derived Ceramics (PDCs) begin as a polymer matrix, which allows a shape to be formed prior to the cure, and is then pyrolized in order to obtain a ceramic with the associated thermal and mechanical properties. The two PDCs used in this development are polysiloxane and polycarbosilane. Basalt fibers are used for the reinforcement in the composite system. The use of basalt in structural and high temperature applications has been under development for over 50 years, yet there has been little published research on the incorporation of basalt fibers as a reinforcement in composites. Continuous basalt fiber reinforced PDCs have been fabricated and tested for the applicability of this composite system as a high temperature structural composite material.

High Temperature Composites↗

NASA NTRS1991

Progress in speckle-shift strain measurement

The Instrumentation and Control Technology Division of the Lewis Research Center has been developing an in-house capability to make one dimensional and two dimensional optical strain measurements on high temperature test specimens. The measurements are based on a two-beam speckle-shift technique. The development of composite materials for use in high temperature applications is generating interest in using the speckle-shift technique to measure strains on small diameter fibers and wires of various compositions. The results of preliminary speckle correlation tests on wire and fiber specimens are covered, and the advanced system currently under development is described.

Lant, Christian T.↗

NASA NTRS1994

High performance dielectric materials development

The mission of polymer composites materials technology is to develop materials and processing technology to meet DoD and commercial needs. The following are outlined in this presentation: high performance capacitors, high temperature aerospace insulation, rationale for choosing Foster-Miller (the reporting industry), the approach to the development and evaluation of high temperature insulation materials, and the requirements/evaluation parameters. Supporting tables and diagrams are included.

Piche, Joe↗

NASA NTRS1995

Strain-Sensing Technology For High-Temperature Applications

Paper reviews status of strain-sensing technology for high-temperature applications. Techniques discussed supported by NASA, such as those needed for applications in hypersonic vehicles and engines, advanced subsonic engines, and development of materials and structures for high temperatures. Applications involve temperatures from 540 degrees C (1,000 degrees F) to more than 1,400 degrees C (2,600 degrees F). Commercial resistance strain gauges do not give repeatable readings at temperatures above 400 degrees C (750 degrees F).

Williams, W. Dan↗

NASA NTRS2018

Levitation Experiments on ISS: Science and Applications

Levitation experiments on the International Space Station (ISS) are ongoing. The European Space Agency (ESA) Materials Science Laboratory Electromagnetic Levitator (MSL-EML) has been in operation since 2015. US investigators are on several of the European Topical Teams and have been heavily involved with the experiments since 2009. The experiments include magneto-hydrodynamic (MHD) modeling of macro-convection, the effects of convection on microstructure, investigation of metallic glass formation, and much more. Recently NASA selected four proposals to the MaterialsLab NASA Research Announcement (NRA) for experiments on the Japan Aerospace eXploration Agency (JAXA) Electrostatic Levitation Furnace (ELF), which was launched to the ISS in 2015. It is estimated that the four US investigators will have flight experiments on ELF within the next few years. The experiments range from a novel method to measure interfacial tension to investigations of thermophysical properties of metals, metal oxides, and non-linear optical materials. Using the MSL-EML and ELF, US investigators are studying a wide range of NASA exploration-relevant materials. Levitation experiments enable exploration in many ways. For example, high quality thermophysical properties of high-temperature materials are critical to develop accurate models of casting, welding, and metal additive manufacturing, which could lead to more efficient and more reliable production of metallic parts for exploration, commercial, and industrial applications. High-quality thermophysical properties could also lead to the development of functional oxide glass and optical materials. In many cases, the accuracy of available property data is the limiting factor in the predictive capabilities of the models. Many thermophysical properties can be measured in a levitator on Earth, but with convective contamination. This contamination plays a significant role in the formation of the intermediate phases. In particular, nucleation and viscosity measurements demand quiescent conditions that can only be attained in microgravity-based levitation systems. A brief overview of the ongoing and planned levitation experiments on the ISS will be presented, followed by the exploration-relevance.

SanSoucie, Michael P.↗

NASA NTRS1975

Synthesis and development of low cost, high temperature N-arylene polybenzimidazole foam material

Polymer (and foam) studies followed two basic routes: (1) formation of high molecular weight uncyclized polyamide followed by subsequent fusion and cyclodehydration to yield NABI (foam) and (2) polymer and foam formation by reaction of diphenyl esters (or anhydrides) with the tetramine. The latter route was found much more attractive since considerable versatility in both basic polymer structure and crosslinkability is achievable. Preliminary studies on BAB, phthalic anhydride (PA), and 3, 3 (prime), 4, 4(prime) benzo pheno netetracarboxylic acid dianhydride (BTDA) as crosslinked polymer precursors were conducted. Nonmelting rigid char forming foams with densities as low as 2.7 lb/cubic ft. were achieved. The program was successful in the preparation of a potentially low cost, low density, high char yield, high temperature foam material.

Harrison, E. S.↗

NASA NTRS2014

Development and Performance Evaluations of HfO2-Si and Rare Earth-Si Based Environmental Barrier Bond Coat Systems for SiC/SiC Ceramic Matrix Composites

Ceramic environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft propulsion systems because of their ability to significantly increase engine operating temperatures, improve component durability, reduce engine weight and cooling requirements. Advanced EBC systems for SiCSiC CMC turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant material development challenges for the high temperature CMC components is to develop prime-reliant, high strength and high temperature capable environmental barrier coating bond coat systems, since the current silicon bond coat cannot meet the advanced EBC-CMC temperature and stability requirements. In this paper, advanced NASA HfO2-Si based EBC bond coat systems for SiCSiC CMC combustor and turbine airfoil applications are investigated. The coating design approach and stability requirements are specifically emphasized, with the development and implementation focusing on Plasma Sprayed (PS) and Electron Beam-Physic Vapor Deposited (EB-PVD) coating systems and the composition optimizations. High temperature properties of the HfO2-Si based bond coat systems, including the strength, fracture toughness, creep resistance, and oxidation resistance were evaluated in the temperature range of 1200 to 1500 C. Thermal gradient heat flux low cycle fatigue and furnace cyclic oxidation durability tests were also performed at temperatures up to 1500 C. The coating strength improvements, degradation and failure modes of the environmental barrier coating bond coat systems on SiCSiC CMCs tested in simulated stress-environment interactions are briefly discussed and supported by modeling. The performance enhancements of the HfO2-Si bond coat systems with rare earth element dopants and rare earth-silicon based bond coats are also highlighted. The advanced bond coat systems, when integrated with advanced EBC top coats, showed promise to achieve 1500 C temperature capability, helping enable next generation turbine engines with significantly improved engine component temperature capability and long-term durability.

HfO2-Si bond coat↗

NASA NTRS2016

Development and Property Evaluation of Selected HfO2-Silicon and Rare Earth-Silicon Based Bond Coats and Environmental Barrier Coating Systems for SiC/SiC Ceramic Matrix Composites

Ceramic environmental barrier coatings (EBC) and SiC/SiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft propulsion systems because of their ability to significantly increase engine operating temperatures, improve component durability, reduce engine weight and cooling requirements. Advanced EBC systems for SiC/SiC CMC turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant material development challenges for the high temperature CMC components is to develop prime-reliant, high strength and high temperature capable environmental barrier coating bond coat systems, since the current silicon bond coat cannot meet the advanced EBC-CMC temperature and stability requirements. In this paper, advanced NASA HfO2-Si and rare earth Si based EBC bond coat EBC systems for SiC/SiC CMC combustor and turbine airfoil applications are investigated. High temperature properties of the advanced EBC systems, including the strength, fracture toughness, creep and oxidation resistance have been studied and summarized. The advanced NASA EBC systems showed some promise to achieve 1500C temperature capability, helping enable next generation turbine engines with significantly improved engine component temperature capability and durability.

Oxidation and cyclic durability↗

NASA NTRS2017

Environmental Stability and Oxidation Behavior of HfO2-Si and YbGd(O) Based Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites

Ceramic Matrix Composites↗

NASA NTRS2005

Fabrication of High Temperature Cermet Materials for Nuclear Thermal Propulsion

Processing techniques are being developed to fabricate refractory metal and ceramic cermet materials for Nuclear Thermal Propulsion (NTP). Significant advances have been made in the area of high-temperature cermet fuel processing since RoverNERVA. Cermet materials offer several advantages such as retention of fission products and fuels, thermal shock resistance, hydrogen compatibility, high conductivity, and high strength. Recent NASA h d e d research has demonstrated the net shape fabrication of W-Re-HfC and other refractory metal and ceramic components that are similar to UN/W-Re cermet fuels. This effort is focused on basic research and characterization to identify the most promising compositions and processing techniques. A particular emphasis is being placed on low cost processes to fabricate near net shape parts of practical size. Several processing methods including Vacuum Plasma Spray (VPS) and conventional PM processes are being evaluated to fabricate material property samples and components. Surrogate W-Re/ZrN cermet fuel materials are being used to develop processing techniques for both coated and uncoated ceramic particles. After process optimization, depleted uranium-based cermets will be fabricated and tested to evaluate mechanical, thermal, and hot H2 erosion properties. This paper provides details on the current results of the project.

Hickman, Robert↗

NASA NTRS1992

Low thrust chemical rocket technology

An on-going technology program to improve the performance of low thrust chemical rockets for spacecraft on-board propulsion applications is reviewed. Improved performance and lifetime is sought by the development of new predictive tools to understand the combustion and flow physics, introduction of high temperature materials and improved component designs to optimize performance, and use of higher performance propellants. Improved predictive technology is sought through the comparison of both local and global predictions with experimental data. Predictions are based on both the RPLUS Navier-Stokes code with finite rate kinetics and the JANNAF methodology. Data were obtained with laser-based diagnostics along with global performance measurements. Results indicate that the modeling of the injector and the combustion process needs improvement in these codes and flow visualization with a technique such as 2-D laser induced fluorescence (LIF) would aid in resolving issues of flow symmetry and shear layer combustion processes. High temperature material fabrication processes are under development and small rockets are being designed, fabricated, and tested using these new materials. Rhenium coated with iridium for oxidation protection was produced by the Chemical Vapor Deposition (CVD) process and enabled an 800 K increase in rocket operating temperature. Performance gains with this material in rockets using Earth storable propellants (nitrogen tetroxide and monomethylhydrazine or hydrazine) were obtained through component redesign to eliminate fuel film cooling and its associated combustion inefficiency while managing head end thermal soakback. Material interdiffusion and oxidation characteristics indicated that the requisite lifetimes of tens of hours were available for thruster applications. Rockets were designed, fabricated, and tested with thrusts of 22, 62, 440 and 550 N. Performance improvements of 10 to 20 seconds specific impulse were demonstrated. Higher performance propellants were evaluated: Space storable propellants, including liquid oxygen (LOX) as the oxidizer with nitrogen hydrides or hydrocarbon as fuels. Specifically, a LOX/hydrazine engine was designed, fabricated, and shown to have a 95 pct theoretical c-star which translates into a projected vacuum specific impulse of 345 seconds at an area ratio of 204:1. Further performance improvment can be obtained by the use of LOX/hydrogen propellants, especially for manned spacecraft applications, and specific designs must be developed and advanced through flight qualification.

Schneider, Steven J.↗

NASA NTRS1961

Rapid-Rate Compression Testing of Sheet Materials at High Temperatures

This Report describes the test equipment that was developed and the procedures that were used to evaluate structural sheet-material compression properties at preselected constant strain rates and/or loads. Electrical self-resistance was used to achieve a rapid heating rate of 200 F/sec. Four materials were tested at maximum temperatures which ranged from 600 F for the aluminum alloy to 2000 F for the Ni-Cr-Co iron-base alloy. Tests at 0.1, 0.001, and 0.00001 in./in./sec showed that strain rate has a major effect on the measured strength, especially at the high temperatures. The tests, under conditions of constant temperature and constant compression stress, showed that creep deformation can be a critical factor even when the time involved is on the order of a few seconds or less. The theoretical and practical aspects of rapid-rate compression testing are presented, and suggestions are made regarding possible modifications of the equipment which would improve the over-all capabilities.

Bernett, E. C.↗

NASA NTRS1987

High temperature superconductors

The two principle objectives are to develop materials that superconduct at higher temperatures and to better understand the mechanisms behind high temperature superconductivity. Experiments on the thermal reaction, structure, and physical properties of materials that exhibit superconductivity at high temperatures are discussed.

Wu, Maw-Kuen↗