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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Environmental effects on graphite fiber reinforced PMR-15 polyimide

Studies were conducted to establish the effects of thermo-oxidative and hydrothermal exposure on the mechanical properties of T300 graphite fabric reinforced PMR-15 composites. The effects of hydrothermal exposure on the mechanical properties of HTS-2 continuous graphite fiber composites were also investigated. The thermo-oxidative stability characteristics of T300 fabric and T300 fabric/PMR-15 composites were determined. Flexural strengths of specimens were determined. The useful lifetime of T300 fabric/PMR-15 composites in air at 316 C was found to be about 100 hours. The useful lifetimes in air at 228 and 260 C were determined to be 500 and 1000 hours, respectively. Absorbed moisture was found to reduce the elevated temperature properties of both the T300 fabricate and HTS-2 continuous fiber composites. The moisture effect was found to be reversible. Previously announced in STAR as N81-32194

Serafini, T. T.↗
NASA NTRS1985

Polymer matrix and graphite fiber interface study

Hercules AS4 graphite fiber, unsized, or with EPON 828, PVA, or polysulfone sizing, was combined with three different polymer matrices. These included Hercules 3501-6 epoxy, Hercules 4001 bismaleimide, and Hexcel F155 rubber toughened epoxy. Unidirectional composites in all twelve combinations were fabricated and tested in transverse tension and axial compression. Quasi-isotropic laminates were tested in axial tension and compression, flexure, interlaminar shear, and tensile impact. All tests were conducted at both room temperature, dry and elevated temperature, and wet conditions. Single fiber pullout testing was also performed. Extensive scanning electron microphotographs of fracture surfaces are included, along with photographs of single fiber pullout failures. Analytical/experimental correlations are presented, based on the results of a finite element micromechanics analysis. Correlations between matrix type, fiber sizing, hygrothermal environment, and loading mode are presented. Results indicate that the various composite properties were only moderately influenced by the fiber sizings utilized.

Adams, D. F.↗
NASA NTRS2008

Fabricating Large-Area Sheets of Single-Layer Graphene by CVD

This innovation consists of a set of methodologies for preparing large area (greater than 1 cm(exp 2)) domains of single-atomic-layer graphite, also called graphene, in single (two-dimensional) crystal form. To fabricate a single graphene layer using chemical vapor deposition (CVD), the process begins with an atomically flat surface of an appropriate substrate and an appropriate precursor molecule containing carbon atoms attached to substituent atoms or groups. These molecules will be brought into contact with the substrate surface by being flowed over, or sprayed onto, the substrate, under CVD conditions of low pressure and elevated temperature. Upon contact with the surface, the precursor molecules will decompose. The substituent groups detach from the carbon atoms and form gas-phase species, leaving the unfunctionalized carbon atoms attached to the substrate surface. These carbon atoms will diffuse upon this surface and encounter and bond to other carbon atoms. If conditions are chosen carefully, the surface carbon atoms will arrange to form the lowest energy single-layer structure available, which is the graphene lattice that is sought. Another method for creating the graphene lattice includes metal-catalyzed CVD, in which the decomposition of the precursor molecules is initiated by the catalytic action of a catalytic metal upon the substrate surface. Another type of metal-catalyzed CVD has the entire substrate composed of catalytic metal, or other material, either as a bulk crystal or as a think layer of catalyst deposited upon another surface. In this case, the precursor molecules decompose directly upon contact with the substrate, releasing their atoms and forming the graphene sheet. Atomic layer deposition (ALD) can also be used. In this method, a substrate surface at low temperature is covered with exactly one monolayer of precursor molecules (which may be of more than one type). This is heated up so that the precursor molecules decompose and form one monolayer of the target material.

Bronikowski, Michael↗
NASA NTRS1987

Space environmental effects on graphite-epoxy compressive properties and epoxy tensile properties

This study characterizes the effects of electron radiation and temperature on a graphite-epoxy composite material. Compressive properties of the T300/934 material system were obtained at -250 F (-157 C), room temperature, and 250 F (121 C). Tensile specimens of the Fiberite 934 epoxy resin were fabricated and tested at room temperature and 250 F (121 C). Testing was conducted in the baseline (nonirradiated) and irradiated conditions. The radiation exposure was designed to simulate 30 year, worst-case exposure in geosynchronous Earth orbit. Mechanical properties tended to degrade at elevated temperature and improve at cryogenic temperature. Irradiation generally degraded properties at all temperatures.

Fox, Derek J.↗
NASA NTRS1987

Crosslinking-property relationships in PMR polyimide composites. I

The thermooxidatively-induced crosslinking/ physical and mechanical property relationships of graphite fiber-reinforced PMR polyimide-matrix composites were studied during isothermal exposure of the composite specimens at 288 C in air for periods of up to 5000 hr. The crosslinking densities due to this treatment were estimated on the basis of the kinetic theory of rubber elasticity and shifts in the glass transition temperature T(g). Several linear relationships are noted between crosslink density and physical and mechanical properties: T(g), initial weight loss, and elevated temperature interlaminar shear strength increase with crosslink density, while initial moisture absorption decreases. After achieving the highest crosslink density, several of the composite properties begin to decrease from their maximum values.

Pater, R. H.↗
DOE OSTI2025

Rational Electrolyte Design for Elevated-Temperature and Thermally Stable Lithium-Ion Batteries with Nickel-Rich Cathodes

As the energy density of lithium-ion batteries (LIBs) increases, the shortened cycle life and the increased safety hazard of LIBs are drawing increasing concerns. To address such challenges, a series of localized high-concentration electrolytes (LHCEs) based on a solvating-solvent mixture of tetramethylene sulfone and trimethyl phosphate and a high flash-point diluent 1H,1H,5H-octafluoropentyl 1,1,2,2-tetrafluoroethyl ether were designed. The LHCEs exhibited non-flammability and greatly suppressed heat release at high temperatures, which would potentially improve the safety performance of the LIBs. Moreover, the optimal LHCE achieved capacity retentions of 87.1% and 81.7% in graphite||LiNi 0.8 Mn 0.1 Co 0.1 O 2 cells after 500 cycles at 25 °C and 45 °C, respectively, which were significantly better than the conventional electrolyte, whose capacity retentions were only 75.2% and 38.5% under the same condition. Mechanistic studies revealed that the LHCE not only formed a more robust solid electrolyte interphase, but also exhibited improved anodic stability, compared with the conventional electrolyte. Further, this work sheds light in rational electrolyte design for high energy density LIBs with high battery performance and low safety concerns.

25 ENERGY STORAGE↗
NASA NTRS1998

Thermal Output of WK-Type Strain Gauges on Various Materials at Cryogenic and Elevated Temperatures

Strain gage apparent strain (thermal output) is one of the largest sources of error associated with the measurement of strain when temperatures and mechanical loads are varied. In this paper, experimentally determined apparent strains of WK-type strain gages, installed on both metallic and composite-laminate materials of various lay-ups and resin systems for temperatures ranging from -450 F to 230 F are presented. For the composite materials apparent strain in both the 0 ply orientation angle and the 90 ply orientation angle were measured. Metal specimens tested included: aluminum-lithium alloy (Al-LI 2195-T87), aluminum alloy (Al 2219-T87), and titanium alloy. Composite materials tested include: graphite-toughened-epoxy (IM7/997- 2), graphite-bismaleimide (IM7/5260), and graphite-K3 (IM7/K3B). The experimentally determined apparent strain data are curve fit with a fourth-order polynomial for each of the materials studied. The apparent strain data and the polynomials that are fit to the data are compared with those produced by the strain gage manufacturer, and the results and comparisons are presented. Unacceptably high errors between the manufacture's data and the experimentally determined data were observed (especially at temperatures below - 270-F).

Kowalkowski, Matthew K.↗
NASA NTRS2010

Development and Testing of High Surface Area Iridium Anodes for Molten Oxide Electrolysis

Processing of lunar regolith into oxygen for habitat and propulsion is needed to support future space missions. Direct electrochemical reduction of molten regolith is an attractive method of processing, because no additional chemical reagents are needed. The electrochemical processing of molten oxides requires high surface area, inert anodes. Such electrodes need to be structurally robust at elevated temperatures (1400-1600 C), be resistant to thermal shock, have good electrical conductivity, be resistant to attack by molten oxide (silicate), be electrochemically stable and support high current density. Iridium with its high melting point, good oxidation resistance, superior high temperature strength and ductility is the most promising candidate for anodes in high temperature electrochemical processes. Several innovative concepts for manufacturing such anodes by electrodeposition of iridium from molten salt electrolyte (EL-Form process) were evaluated. Iridium electrodeposition to form of complex shape components and coating was investigated. Iridium coated graphite, porous iridium structure and solid iridium anodes were fabricated. Testing of electroformed iridium anodes shows no visible degradation. The result of development, manufacturing and testing of high surface, inert iridium anodes will be presented.

Shchetkovskiy, Anatoliy↗
NASA NTRS2010

Development and Testing of High Surface Area Iridium Anodes for Molten Oxide Electrolysis

Processing of lunar regolith into oxygen for habitat and propulsion is needed to support future space missions. Direct electrochemical reduction of molten regolith is an attractive method of processing, because no additional chemical reagents are needed. The electrochemical processing of molten oxides requires high surface area, inert anodes. Such electrodes need to be structurally robust at elevated temperatures (1400-1600?C), be resistant to thermal shock, have good electrical conductivity, be resistant to attack by molten oxide (silicate), be electrochemically stable and support high current density. Iridium with its high melting point, good oxidation resistance, superior high temperature strength and ductility is the most promising candidate for anodes in high temperature electrochemical processes. Several innovative concepts for manufacturing such anodes by electrodeposition of iridium from molten salt electrolyte (EL-Form? process) were evaluated. Iridium electrodeposition to form of complex shape components and coating was investigated. Iridium coated graphite, porous iridium structure and solid iridium anodes were fabricated. Testing of electroformed iridium anodes shows no visible degradation. The result of development, manufacturing and testing of high surface, inert iridium anodes will be presented.

Shchetkovskiy, Anatoliy↗
NASA NTRS2000

Erosion Coatings for High-Temperature Polymer Composites: A Collaborative Project With Allison Advanced Development Company

The advantages of replacing metals in aircraft turbine engines with high-temperature polymer matrix composites (PMC's) include weight savings accompanied by strength improvements, reduced part count, and lower manufacturing costs. Successfully integrating high-temperature PMC's into turbine engines requires several long-term characteristics. Resistance to surface erosion is one rarely reported property of PMC's in engine applications because PMC's are generally softer than metals and their erosion resistance suffers. Airflow rates in stationary turbine engine components typically exceed 2.3 kg/sec at elevated temperatures and pressures. In engine applications, as shown in the following photos, the survivability of PMC components is clearly a concern, especially when engine and component life-cycle requirements become longer. Although very few publications regarding the performance of erosion coatings on PMC's are available particularly in high-temperature applications the use of erosion-resistant coatings to significantly reduce wear on metallic substrates is well documented. In this study initiated by the NASA Glenn Research Center at Lewis Field, a low-cost (less than $140/kg) graphite-fiber-reinforced T650 35/PMR 15 sheet-molding compound was investigated with various coatings. This sheet-molding compound has been compression molded into many structurally complicated components, such as shrouds for gas turbine inlet housings and gearboxes. Erosion coatings developed for PMC s in this study consisted of a two-layered system: a bondcoat sprayed onto a cleaned PMC surface, followed by an erosion-resistant, hard topcoat sprayed onto the bondcoat as shown in following photomicrograph. Six erosion coating systems were evaluated for their ability to withstand harsh thermal cycles, erosion resistance (ASTM G76 83 "Standard Practice for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets") using Al2O3, and adhesion to the graphite fiber polyimide composite (ASTM D 4541 95 "Pull Off Strength of Coatings"). Glenn and Allison Advanced Development Company collaborated to optimize erosion coatings for gas turbine fan and compressor applications. All the coating systems survived aggressive thermal cycling without spalling. During erosion tests (see the final photo), the most promising coating systems tested had Cr3C2-NiCr and WC-Co as the hard topcoats. In all cases, these coating systems performed significantly better than that with a TiN hard topcoat. When material depth (thickness) loss is considered, the Cr3C2-NiCr and WC-Co coating systems provided, on average, an erosion resistance 8.5 times greater than that for the uncoated PMR 15/T650 35 composite. Similarly, Cr3C2-NiCr and WC-Co coating systems adhered to the PMC substrate during tensile tests significantly better than systems containing a TiN topcoat. Differences in topcoats of Cr3C2-NiCr and WC-Co were determined by considering issues such as cost and environmental impact. The preferred erosion-resistant coating system for PMR 15/T650 35 has WC-Co as the hard topcoat. This system provides the following benefits in comparison to the coating system with Cr3C2-NiCr topcoat: lower powder material cost (15 to 20 percent), environmentally friendly materials (Cr3C2-NiCr is hazardous), and higher deposition yield (10 to 15 percent), which results in less waste.

Sutter, James K.↗
NASA NTRS1985

SEM/XPS analysis of fractured adhesively bonded graphite fibre-reinforced polyimide composites

The surfaces of the graphite fiber-reinforced polyimide composites presently pretreated prior to bonding with polyimide adhesive contained variable amounts of a fluoropolymer, as determined by X-ray photoelectron spectroscopy. Lap shear strengths were determined for unaged samples and for those aged over 500- and 1000-hour periods at 177 and 232 C. Unaged sample lap strengths, which were the highest obtained, exhibited no variation with surface pretreatment, but a significant decrease is noted with increasing aging temperature. These thermally aged samples, however, had increased surface fluorine concentration, while a minimal concentration was found in unaged samples. SEM demonstrated a progressive shift from cohesive to adhesive failure for elevated temperature-aged composites.

Devilbiss, T. A.↗
DOE OSTI2025

Fuel performance analysis of fully-resolved TRISO compact

The TRi-structural ISOtropic (TRISO) fuel multilayered coating structure offers multiple barriers to fission product release, enhancing safety and performance. The heterogeneous nature of TRISO fuel compacts, comprising thousands of randomly distributed coated fuel particles embedded in a graphite matrix, creates intricate stress fields and thermal gradients that cannot be accurately modeled using simplified one-dimensional or homogenized approaches. Consequently, three-dimensional modeling enables the prediction of fuel compact dimensional changes, internal pressure buildup, and fission product transport pathways under diverse irradiation and thermal conditions. This capability facilitates detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating failures, which directly impact fuel performance and safety margins. This capability is particularly critical for advanced reactors, such as high-temperature gas-cooled reactors and other Generation IV reactor designs where TRISO fuel operates at elevated temperatures and burn-up levels. This work introduces a novel method to generate an optimized packing of TRISO compacts and a complete 3D mesh with random distribution of TRISO particles, which are discretized into each coating component layer.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1986

Space radiation effects on the thermo-mechanical behavior of graphite-epoxy composites

This investigation of composite material properties utilized T300/934 graphite-epoxy that was subjected to 1.0 MeV electron radiation for a total dose of 1.0 x 10 to the 10th rads at a rate of 5.0 x 10 to the 7th rads/hour, simulating a worst-case exposure equivalent to 30 years in space. Mechanical testing was performed on 4-ply unidirectional laminates over the temperature range of -250 F (116 K) to +250 F (394 K). In-plane elastic tensile and shear properties as well as strength were obtained. The results show that electron radiation degrades the epoxy matrix and produces products that volatilize at the temperatures considered. These degradation products plasticize the epoxy at elevated temperatures and embrittle it at low temperatures, thereby altering the mechanical properties of the composite.

Milkovich, Scott M.↗
NASA NTRS2017

Examining the Possibility of Carbon as a Light Element in the Core of Mercury

Results from the MErcury Surface, Space ENvironment, GEochemistry and Ranging (MESSENGER) spacecraft have shown elevated abundances of C on the surface of Mercury. Peplowski et al. used GRS data from MESSENGER to show an average northern hemisphere abundance of C on the planet of 0 to 4.1 wt% C at the three-sigma detection limit. Confirmation of C on the planet prompts many questions regarding the role of C during the differentiation and evolution of Mercury. The elevated abundances of both S and C on Mercury's surface, coupled with the low abundances of iron, suggest that the oxygen fugacity of the planet is several log10 units below the Iron-Wustite buffer. These observations spark questions about the bulk composition of Mercury's core. This experimental study seeks to understand the impact of C as a light element on potential mercurian core compositions. In order to address this question, experiments were conducted at 1 GPa and a variety of temperatures (700 - 1500 C) on metal compositions ranging from Si5Fe95 to Si22Fe78, possibly representative of the mercurian core. All starting metals were completely enclosed in a graphite capsule to ensure C saturation at a given set of run conditions. All elements, including C, were analyzed using electron probe microanalysis. Precautions were taken to ensure accurate measurements of C with this technique including using the LDE2 crystal, the cold finger on the microprobe to minimize contamination and increase the vacuum, and an instrument with no oil based pumps. Based on the superliquidus experimental results in the present study, as Fe-rich cores become more Si-rich, the C content of that core composition will decrease. Furthermore, although C concentration at graphite saturation (CCGS) varies from a liquid to a solid, temperature does not seem to play a substantial role in CCGS, at least at 1 GPa.

Vander Kaaden, Kathleen↗
NASA NTRS1982

Effects of fiber/matrix interactions on the properties of graphite/epoxy composites

A state-of-the-art literature review of the interactions between fibers and resin within graphite epoxy composite materials was performed. Emphasis centered on: adhesion theory; wetting characteristics of carbon fiber; load transfer mechanisms; methods to evaluate and measure interfacial bond strengths; environmental influence at the interface; and the effect of the interface/interphase on composite performance, with particular attention to impact toughness. In conjunction with the literature review, efforts were made to design experiments to study the wetting behavior of carbon fibers with various finish variants and their effect on adhesion joint strength. The properties of composites with various fiber finishes were measured and compared to the base-line properties of a control. It was shown that by tailoring the interphase properties, a 30% increase in impact toughness was achieved without loss of mechanical properties at both room and elevated temperatures.

Mcmahon, P. E.↗
NASA NTRS1993

The effects of aircraft fuel and fluids on the strength properties of Resin Transfer Molded (RTM) composites

The resin transfer molding (RTM) process offers important advantages for cost-effective composites manufacturing, and consequently has become the subject of intense research and development efforts. Several new matrix resins have been formulated specifically for RTM applications in aircraft and aerospace vehicles. For successful use on aircraft, composite materials must withstand exposure to the fluids in common use. The present study was conducted to obtain comparative screening data on several state-ofthe-art RTM resins after environmental exposures were performed on RTM composite specimens. Four graphite/epoxy composites and one graphite/bismaleimide composite were tested; testing of two additional graphite epoxy composites is in progress. Zero-deg tension tests were conducted on specimens machined from eight-ply (+45-deg, -45-deg) laminates, and interlaminar shear tests were conducted on 32-ply 0-deg laminate specimens. In these tests, the various RTM resins demonstrated widely different strengths, with 3501-6 epoxy being the strongest. As expected, all of the matrix resins suffered severe strength degradation from exposure to methylene chloride (paint stripper). The 3501-6 epoxy composites exhibited about a 30 percent drop in tensile strength in hot, wet tests. The E905-L epoxy exhibited little loss of tensile strength (less than 8 percent) after exposure to water. The CET-2 and 862 epoxies as well as the bismaleimide exhibited reduced strengths at elevated temperature after exposure to oils and fuel. In terms of the percentage strength reductions, all of the RTM matrix resins compared favorably with 3501-6 epoxy.

Falcone, Anthony↗
NASA NTRS1984

Space Radiation Effects on Graphite-Epoxy Composite Materials

Radiation effects on engineering properties, dimensional stability, and chemistry on state of the art composite systems were characterized. T300/934 graphite-epoxy composite was subjected to 1.0 MeV electron radiation for a total dose of 1.0 x 10(10) rads at a rate of 5.0 x 10(7) rads/hour. This simulates a worst case exposure equivalent to 30 years in space. Mechanical testing was performed on he 4-ply unidirectional laminates over the temperature range of -250 F (116K) to +250 F (394K). A complete set of in-plane tensile elastic and strength properties were obtained (E sub 1, E sub 2, nu sub 12, G sub 12, X sub T, Y sub T, and S). In addition electron microscopy was used to study and analyze the fracture surfaces of all specimens tested. Results indicate that little difference in properties is noted at room temperature, but significant differences are observed at both low and elevated temperatures.

Milkovich, S. M.↗
NASA NTRS1972

Improved oxidation-resistant carbon and graphite materials

A variety of silicon-carbide treated carbon and graphite products were prepared, and oxidation and strength properties determined. Carbon and graphite materials used in the preliminary study include fiber, tape, felt, foam, bulk, and laminar configurations. The silicon-carbide treatment used in preparing the oxidation resistant specimens employs either vacuum or ultrasonic impregnation of various silicone-silicon mixtures into the matrix material. The impregnation phase is followed by controlled thermal reaction at which time the silicon carbide is synthesized and takes the form of an integral protective boundary layer. Thickness of the layer ranges from a fraction of a mil to 10 mils, depending on the matrix material and processing parameters. Oxidation resistance of all the silicon-carbide-treated specimens investigated was found to be significantly improved. Mechanical strengths of the laminar composites were also found to be somewhat improved. At room temperature the specific strength of the silicon-carbide treated fibers and tapes was degraded to some extent; however, their relative strengths were significantly increased at elevated temperatures in oxidizing atmosphere.

Muir, H. M.↗