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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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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Verification and Validation of Progressive Damage and Failure Analysis Methods for Intralaminar Failure Modes in Thermoplastic Composites

Current progressive damage and failure analysis (PDFA) methods were developed around thermoset material systems and their physical behavior. However, the applicability of these analysis methods has not been evaluated for use in modeling thermoplastic material systems. As part of the Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project sponsored by NASA, intralaminar failure characterization was completed on a thermoplastic material system, AS4D/PEKK-FC, with off-axis tension (OAT) and off-axis compression (OAC) testing. The experiments were able to capture matrix non-linear shear behavior and the failure envelope of the material system. Two PDFA methods, LS-DYNA MAT299 and NASA’s CompDam-DGD, were then employed to simulate individual coupon behavior and simulation results were compared to published verification and validation guidelines from the CMH-17 crashworthiness working group. The results found that the two modeling methods provided suitable representation of material behavior of thermoplastics.

PDFA↗
NASA NTRSDate not supplied

Thermal Modelling of the in-Situ Consolidation of Automated Fiber Placement of Thermoplastic Composites

NASA is developing carbon fiber reinforced thermoplastic composites processing methods under the Hi-rate Composites Aircraft Manufacturing (HiCAM) project. The in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process has high potential to increase manufacturing throughput and lower costs as it combines the repeatability and fast lay down rates of AFP with the thermoformability of thermoplastic materials to achieve part consolidation out of the autoclave. Physics-based process models are employed in the ICAT process development to understand, fundamentally, the thermal response of the carbon fiber (CF)/polyaryletherketone (PAEK) material during the rapid heating and cooling associated with laser-assisted AFP. A one-dimensional (1-D) closed-form model was developed capable of predicting the temperature profile through-the-thickness of the tape material. In addition, a two-dimensional (2-D) model was developed to predict the heat transfer through-the-thickness and in the laydown x-direction of the AFP head motion. The solution of the Fourier heat-transfer equations in the 2-D model is approximated using the explicit finite difference numerical method. The temperature profile during placement of PAEK slit-tape materials at various laser target temperatures and placement speeds were measured during ICAT process development trials at Electroimpact®, Inc. †† and the resulting experimental data is compared with the predictions of the 1-D and 2-D models.

Thermoplastics↗
NASA NTRSDate not supplied

Composites From in-Situ Consolidation Automated Fiber Placement of Thermoplastics for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.

thermoplastic composites↗
DOE OSTI2019

Methodology for Fast Iterations of Blade Designs Using Thermoplastic Composite Materials: Preprint

Tidal energy is still in the early research and development phases, therefore the ability to quickly manufacture and evaluate prototype blades with new blade designs and materials is critical. This paper investigates using a Stratasys three-dimensional printer to rapidly prototype scale-model turbine blades by printing the blade tooling and using vacuum-assisted resin transfer molding (VARTM) to manufacture blades. This work outlines a methodology for cost effectively designing and manufacturing model-scale tidal turbine blades to be used in testing campaigns, and for evaluating new thermoplastic composite materials for tidal energy applications. Demonstration blades were designed in ANSYS and manufactured using an infusible thermoplastic resin system called Elium(R). The development of scale-model thermoplastic blades enables research into their fatigue performance in realistic conditions at a cost-effective scale, and manufacturing using 3-D printed tooling enables fast and low-cost blade design iterations.

17 WIND ENERGY↗
DOE OSTI2016

High temperature thermoplastic elastomers synthesized by living anionic polymerization in hydrocarbon solvent at room temperature

We present the synthesis and characterization of a new class of high temperature thermoplastic elastomers composed of polybenzofulvene–polyisoprene–polybenzofulvene (FIF) triblock copolymers. All copolymers were prepared by living anionic polymerization in benzene at room temperature. Homopolymerization and effects of additives on the glass transition temperature (T g ) of polybenzofulvene (PBF) were also investigated. Among all triblock copolymers studied, FIF with 14 vol % of PBF exhibited a maximum stress of 14.3 ± 1.3 MPa and strain at break of 1390 ± 66% from tensile tests. The stress–strain curves of FIF-10 and 14 were analyzed by a statistical molecular approach using a nonaffine tube model to estimate the thermoplastic elastomer behavior. Dynamic mechanical analysis showed that the softening temperature of PBF in FIF was 145 °C, much higher than that of thermoplastic elastomers with polystyrene hard blocks. Microphase separation of FIF triblock copolymers was observed by small-angle X-ray scattering, even though long-range order was not achieved under the annealing conditions employed. Additionally, the microphase separation of the resulting triblock copolymers was examined by atomic force microscopy.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thermoplastic Polymer from Lignin: Creating an Extended Polyamide Network through Reactive Kraft Lignin Derivatives

Thermoplastic polymers have many desirable properties for consumer applications and are complemented by efficient thermal processing techniques, reducing the cost of manufacturing. Lignin exists as an immense biobased carbon source but has largely been researched for its use in thermoset materials due to its own cross-linked, polyfunctional nature. In this study, a new reaction design is employed to create a thermoplastic polyamide network incorporating lignin that is tested to be 99% biobased carbon by radiocarbon analysis. Chemical analysis reveals the nature of lignin incorporation based on chain extension and cross-linking models. The thermal and rheological properties of the new polymers are thoroughly investigated to demonstrate the higher melt-strength capability of the lignin-based polymers facilitating their use in modern processing equipment. This analysis results in finding an optimal lignin loading ratio in the polymer composition reflected by improved tensile strength and stiffness. The results point to a promising polymer design for applying industrial kraft lignin in high-value thermoplastic polymer applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1975

Analytical and experimental evaluation of techniques for the fabrication of thermoplastic hologram storage devices

The results of an experimental investigation on recording information on thermoplastic are given. A description was given of a typical fabrication configuration, the recording sequence, and the samples which were examined. There are basically three configurations which can be used for the recording of information on thermoplastic. The most popular technique uses corona which furnishes free charge. The necessary energy for deformation is derived from a charge layer atop the thermoplastic. The other two techniques simply use a dc potential in place of the corona for deformation energy.

Rogers, J. W.↗
NASA NTRS1977

Graphite fiber reinforced thermoplastic resins

The results of a program designed to optimize the fabrication procedures for graphite thermoplastic composites are described. The properties of the composites as a function of temperature were measured and graphite thermoplastic fan exit guide vanes were fabricated and tested. Three thermoplastics were included in the investigation: polysulfone, polyethersulfone, and polyarylsulfone. Type HMS graphite was used as the reinforcement. Bending fatigue tests of HMS graphite/polyethersulfone demonstrated a gradual shear failure mode which resulted in a loss of stiffness in the specimens. Preliminary curves were generated to show the loss in stiffness as a function of stress and number of cycles. Fan exit guide vanes of HMS graphite polyethersulfone were satisfactorily fabricated in the final phase of the program. These were found to have stiffness and better fatigue behavior than graphite epoxy vanes which were formerly bill of material.

Navak, R. C.↗
NASA NTRS1978

The relative fire resistance of select thermoplastic materials

The relative thermal stability, flammability, and related thermochemical properties of some thermoplastic materials currently used in aircraft interiors as well as of some candidate thermoplastics were investigated. Currently used materials that were evaluated include acrylonitrile butadiene styrene, bisphenol A polycarbonate, polyphenylene oxide, and polyvinyl fluoride. Candidate thermoplastic materials evaluated include: 9,9-bis(4-hydroxyphenyl)fluorene polycarbonate-poly(dimethylsiloxane) block polymer, chlorinated polyvinylchloride homopolymer, phenolphthalein polycarbonate, polyethersulfone, polyphenylene sulfide, polyarylsulfone, and polyvinylidene fluoride.

Kourtides, D. A.↗
NASA NTRS1978

Applicability of thermoplastic composites for space structures

The discussion defines a thermoplastic resin and compares the structural and environmental properties and the fabrication and repairability of the thermoplastic composite with a typical epoxy composite. Low labor costs exhibited by the thermoplastic composites make them a priority consideration for use in space structure.

Hoggatt, J. T.↗
NASA NTRS1983

A Solvent-Resistant, Thermoplastic Poly(imidesulfone)

Process for preparing thermoplastic poly(imidesulfone) results in material having excellent thermoplastic properties generally associated with polysulfones and excellent solvent resistance generally associated with polyimides. New thermoplastic, solvent-resistant polymer is used as molding resin, as adhesive, and as matrix resin for fiber reinforced composites.

St. Clair, T. L.↗
NASA NTRS1982

Positron lifetime studies in thermoplastic polyimide test specimens

Positron lifetime measurements were made in two thermoplastic polyimide materials recently developed at Langley. The long component lifetime values in polyimidesulfone samples are 847 + or - 81 Ps (dry) and 764 + or - 91 Ps (saturated). The corresponding values in LARC thermoplastic imides are 1080 + or - 139 Ps (dry) and 711 + or - 96 Ps (saturated). Clearly, the presence of moisture has greater effect on positron lifetime in LARC thermoplastic imides than in the case of polyimidesulfones. This result is consistent with the photomicrographic observations made on frozen water saturated specimens of these materials.

Singh, J. J.↗
NASA NTRS1983

Solvent resistant thermoplastic aromatic poly(imidesulfone) and process for preparing same

A process for preparing a thermoplastic poly(imidesulfone) is disclosed. This resulting material has thermoplastic properties which are generally associated with polysulfones but not polyimides, and solvent resistance which is generally associated with polyimides but not polysulfones. This system is processable in the 250 to 350 C range for molding, adhesive and laminating applications. This unique thermoplastic poly(imidesulfone) is obtained by incorporating an aromatic sulfone moiety into the backbone of an aromatic linear polyimide by dissolving a quantity of a 3,3',4,4'-benzophenonetetracarboxylic dianhydride (BTDA) in a solution of 3,3'-diaminodiphenylsulfone and bis(2-methoxyethyl)ether, precipitating the reactant product in water, filtering and drying the recovered poly(amide-acid sulfone) and converting it to the poly(imidesulfone) by heating.

St.clair, T. L.↗
NASA NTRS1984

Aliphatic-Aromatic Heterocyclics as Potential Thermoplastics for Composite Matrices

The successful development of impact- and solvent-resistant thermoplastic systems for glass graphite composites is particularly attractive because of the demonstrated streamlined manufacturability of such composites. Hypothetically, thermoplastics only require simple heating and cooling cycles for component manufacture, whereas thermosets require precise, and possibly extended heating schedules which must be consistent with the cure chemistry. The sensitivity of the majority of existing thermoplastics to aircraft fluids and other solvents preempts their serious consideration in aircraft components. This is the basic reason that Acurex proposed insolubility in common solvents as the starting point. The target properties are summarized as follows: (1) prepreg properties (use of conventional prepregging equipment, 6+ months shelf stability, processability, and thermoformability); and (2) composite properties (-54 C to 93 C capability, good mechanical properties, good environmental properties, and impact resistance).

Delano, C. B.↗
NASA NTRS1984

Process for preparing solvent resistant, thermoplastic aromatic poly(imidesulfone)

A process for preparing a thermoplastic poly(midesulfone) is disclosed. This resulting material has thermoplastic properties which are generally associated with polysulfones but not polyimides, and solvent resistant which is generally associated with polyimides but not polysulfones. This system is processable in the 250 to 350 C range for molding, adhesive and laminating applications. This unique thermoplastic poly(imidesulfone) is obtained by incorporating an aromatic sulfone moiety into the backbone of an aromatic linear polyimide by dissolving a quantity of a 3,3',4,4'-benzophenonetetracarboxylic dianhydride (BTDA) in a solution of 3,3'-diaminodiphenylsulfone and bis(2-methoxyethyl)ether, precipitating the reactant product in water, filtering and drying the recovered poly(amide-acid sulfone) and converting it to the poly(imidesulfone) by heating.

St.clair, T. L.↗
NASA NTRS1988

Annealing Reduces Free Volumes In Thermoplastics

Investigation conducted to determine free volumes and water-absorption characteristics of two types of thermoplastic polymide as functions of annealing histories. Reductions reach asymptotic values after several annealing cycles. High-temperature thermoplastics excellent candidates for use in aerospace applications. Graphite-fiber composites containing thermoplastic matrices have wide applicability.

Singh, Jag J.↗
NASA NTRS1988

Reinforcing of thermoplastic polycarbonate and polysulfone with carbon fibers: Production and characteristics of UD-compound objects

The production and characteristics of the carbon fiber reinforced thermoplastics polycarbonate and polysulfone are described. The production of prepregs from defined polymer solutions is emphasized along with methods of optimizing the production of compounds. The characteristics of unidirectionally reinforced thermoplastics, such as shear strength, bending strength, and impact resistance are compared with regard to fracture behavior, the influence of intermediate layers, and the behavior under cryogenic conditions and under slightly elevated temperatures. The problem of adhesion between high strength carbon fibers and thermoplastics is examined, taking into account the effect of moisture on the shear strength and the impact resistance.

Fitzer, E.↗
NASA NTRS1988

Thermoplastic coated carbon fibers for textile preforms

A continuous process for producing prepreg from carbon fiber and thermoplastic matrix is described. After the tow has been spread using a pneumatic device, the process utilizes a fluidized bed to apply thermoplastic powder to the bundle. Finally, direct electrical heating of the coated fiber tow melts the polymer on the individual fibers, creating a uniform and extremely flexible prepreg. The efficiency of the process was evaluated during initial trials in which a thermoplastic polyimide, LaRC-TPI, was applied to T-300, 3K (3000 filament) carbon fiber tow. The physical properties of unidirectional composite specimens fabricated from this prepreg were measured, and the matrix uniformity and void content of the samples was determined. The results of these evaluations are detailed and discussed.

Allen, L. E.↗