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NASA NTRS1979

Advanced thermoset resins for fire-resistant composites

The thermal and flammability properties of some thermoset polymers and composites are described. The processing and evaluation of composites fabricated from currently used resins and advanced fire-resistant resins are also described. Laboratory test methodology used to qualify candidate composite materials includes thermochemical characterization of the polymeric compounds and evaluation of the glass reinforced composites for flammability and smoke evolution. The use of these test methods will be discussed in comparing advanced laminating resins and composites consisting of modified epoxies, phenolics and bismaleimide, with conventional baseline materials consisting of epoxy.

Kourtides, D. A.↗

NASA NTRS1990

A study of hydrogen environment effects on microstructure property behavior of NASA-23 alloy and related alloy systems

This work is part of the overall advanced main combustion chamber (AMCC) casting characterization program of the Materials and Processes Laboratory of the Marshall Space Flight Center. The influence of hydrogen on the tensile properties and ductility behavior of NASA-23 alloy were analyzed. NASA-23 and other referenced alloys in cast and hipped conditions were solution treated and aged under selected conditions and characterized using optical metallography, scanning electron microscopy, and electron microprobe analysis techniques. The yield strength of NASA-23 is not affected much by hydrogen under tensile tests carried at 5000 psig conditions; however, the ultimate strength and ductility properties are degraded. This implies that the physical mechanisms operating would be related to the plastic deformation process. The fracture surfaces characteristics of NASA-23 specimens tensile tested in hydrogen, helium, and air were also analyzed. These revealed surface cracks around specimen periphery with the fracture surface showing a combination of intergranular and transgranular modes of fracture. It is seen that the specimens charged in hydrogen seem to favor a more brittle fracture mode in comparison to air and helium charged specimens. The AMCC casting characterization program is to be analyzed for their hydrogen behavior. As a result of this program, the basic microstructural factors and fracture characteristics in some cases were analyzed.

Diwan, Ravinder M.↗

NASA NTRS1990

Deep space optical communications - A program update

Technological developments leading toward the use of optical communications on deep-space missions are reviewed. Developments in the characterization of atmospheric visibility and the development of advanced composite materials for use in optical communications systems are discussed. System demonstrations involving the Galileo Optical Experiment and a very lightweight optical communications package intended for the Cassini mission to Saturn are addressed. Proposed flight experiments and a deep-space optical communication long-range plan are discussed.

Lesh, James R.↗

NASA NTRS1992

Experimental characterization of nonlinear, rate-dependent behavior in advanced polymer matrix composites

In order to support materials selection for the next-generation supersonic civilian-passenger transport aircraft, a study has been undertaken to evaluate the material stress/strain relationships needed to describe advanced polymer matrix composites under conditions of high load and elevated temperature. As part of this effort, this paper describes the materials testing which was performed to investigate the viscoplastic behavior of graphite/thermoplastic and graphite/bismaleimide composites. Test procedures, results and data-reduction schemes which were developed for generating material constants for tension and compression loading, over a range of useful temperatures, are explained.

Gates, Thomas S.↗

NASA NTRS1995

Development of processing techniques for advanced thermal protection materials

The main purpose of this work has been in the development and characterization of materials for high temperature applications. Thermal Protection Systems (TPS) are constantly being tested, and evaluated for increased thermal shock resistance, high temperature dimensional stability, and tolerance to environmental effects. Materials development was carried out through the use of many different instruments and methods, ranging from extensive elemental analysis to physical attributes testing. The six main focus areas include: (1) protective coatings for carbon/carbon composites; (2) TPS material characterization; (3) improved waterproofing for TPS; (4) modified ceramic insulation for bone implants; (5) improved durability ceramic insulation blankets; and (6) ultra-high temperature ceramics. This report describes the progress made in these research areas during this contract period.

Selvaduray, Guna S.↗

NASA NTRS2024

Advanced Low Gravity Characterization and Liquid-phase Synthesis of Non-equilibrium and Glassy Oxides

Materials processing in space and the investigation, development and commercialization of non-equilibrium materials and glasses are key aspects of NASA’s BPS mission. The MATRICES project recommended by the Decadal Survey panels calls out key aspects that support development of new materials in space. These areas directly serve NASA space exploration mission and lay the basis to commercialize high value or enabling materials that can be produced in low gravity.

Chris Benmore↗

NASA NTRS2017

Electric Potential and Electric Field Imaging with Dynamic Applications: 2017 Research Award Innovation

The technology and methods for remote quantitative imaging of electrostatic potentials and electrostatic fields in and around objects and in free space is presented. Electric field imaging (EFI) technology may be applied to characterize intrinsic or existing electric potentials and electric fields, or an externally generated electrostatic field may be used for illuminating volumes to be inspected with EFI. The baseline sensor technology (e-Sensor) and its construction, optional electric field generation (quasi-static generator), and current e- Sensor enhancements (ephemeral e-Sensor) are discussed. Critical design elements of current linear and real-time two-dimensional (2D) measurement systems are highlighted, and the development of a three dimensional (3D) EFI system is presented. Demonstrations for structural, electronic, human, and memory applications are shown. Recent work demonstrates that phonons may be used to create and annihilate electric dipoles within structures. Phonon induced dipoles are ephemeral and their polarization, strength, and location may be quantitatively characterized by EFI providing a new subsurface Phonon-EFI imaging technology. Initial results from real-time imaging of combustion and ion flow, and their measurement complications, will be discussed. These new EFI capabilities are demonstrated to characterize electric charge distribution creating a new field of study embracing areas of interest including electrostatic discharge (ESD) mitigation, crime scene forensics, design and materials selection for advanced sensors, combustion science, on-orbit space potential, container inspection, remote characterization of electronic circuits and level of activation, dielectric morphology of structures, tether integrity, organic molecular memory, atmospheric science, and medical diagnostic and treatment efficacy applications such as cardiac polarization wave propagation and electromyography imaging.

Generazio, Ed↗

NASA NTRS2016

Advanced Laser Architecture for Two-Step Laser Tandem Mass Spectrometer

Future astrobiology missions will focus on planets with significant astrochemical or potential astrobiological features, such as small, primitive bodies and the icy moons of the outer planets that may host diverse organic compounds. These missions require advanced instrument techniques to fully and unambiguously characterize the composition of surface and dust materials. Laser desorptionionization mass spectrometry (LDMS) is an emerging instrument technology for in situ mass analysis of non-volatile sample composition. A recent Goddard LDMS advancement is the two-step laser tandem mass spectrometer (L2MS) instrument to address the need for future flight instrumentation to deconvolve complex organic signatures. The L2MS prototype uses a resonance enhanced multi-photon laser ionization mechanism to selectively detect aromatic species from a more complex sample. By neglecting the aliphatic and inorganic mineral signatures in the two-step mass spectrum, the L2MS approach can provide both mass assignments and clues to structural information for an in situ investigation of non-volatile sample composition. In this paper we will describe our development effort on a new laser architecture that is based on the previously flown Lunar Orbiter Laser Altimeter (LOLA) laser transmitter for the L2MS instrument. The laser provides two discrete midinfrared wavelengths (2.8 m and 3.4 m) using monolithic optical parametric oscillators and ultraviolet (UV) wavelength (266 nm) on a single laser bench with a straightforward development path toward flight readiness.

Laser↗

NASA NTRS1986

Mechanical properties characterization of composite sandwich materials intended for space antenna applications

The composite materials proposed for use in the Advanced Communications Technology Satellite (ACTS) Program contains a new, high modulus graphite fiber as the reinforcement. A study was conducted to measure certain mechanical properties of the new fiber-reinforced material as well as of a composite-faced aluminum honeycomb sandwich structure. Properties were measured at -157, 22, and 121 C. Complete characterization of this material was not intended. Longitudinal tensile, picture-frame shear, short-beam shear, and flexural tests were performed on specimens of the composite face-sheet materials. Unidirectional, cross-plied, and quasi-isotropic fiber composite ply layup designs were fabricated and tested. These designs had been studied by using NASA's Integrated Composite Analyzer (ICAN) computer program. Flexural tests were conducted on (+/- 60/0 deg) sub s composite-faced sandwich structure material. Resistance strain gages were used to measure strains in the tensile, picture-frame, and sandwich flexural tests. The sandwich flexural strength was limited by the core strength at -157 and 22 C. The adhesive bond strength was the limiting factor at 121 C. Adhesive mechanical properties are reflected in sandwich structure flexural properties when the span-to-depth ratio is great enough to allow a significant shear effect on the load-deflection behavior of the sandwich beam. Most measured properties agreed satisfactorily with the properties predicted by ICAN.

Bowles, Kenneth J.↗

NASA NTRS1989

Mechanical properties characterization of composite sandwich materials intended for space antenna applications

The composite materials proposed for use in the Advanced Communications Technology Satellite (ACTS) program contains a new, high modulus graphite fiber as the reinforcement. A study was conducted to measure certain mechanical properties of the new fiber-reinforced material as well as of a composite-faced aluminum honeycomb sandwich structure. Properties were measured at -157, 22, and 121 C. Complete characterization of this material was not intended. Longitudinal tensile, picture-frame shear, short-beam shear, and flexural tests were performed on specimens of the composite face-sheet materials. Unidirectional, cross-plied, and quasi-isotropic fiber composite ply layup designs were fabricated and tested. These designs had been studied by using NASA's Integrated Composite Analyzer (ICAN) computer program. Flexural tests were conducted on (+/- 60/0 deg) sub s composite-faced sandwich structure material. Resistance strain gages were used to measure strains in the tensile, picture-frame, and sandwich flexural tests. The sandwich flexural strength was limited by the core strength at 157 and 22 c. The adhesive bond strength was the limiting factor at 121 C. Adhesive mechanical properties are reflected in sandwich structure flexural properties when the span-to-depth ratio is great enough to allow a significant shear effect on the load-deflection behavior of the sandwich beam. Most measured properties agreed satisfactorily with the properties predicted by ICAN.

Bowles, Kenneth J.↗

NASA NTRS2017

Electric Potential and Electric Field Imaging with Dynamic Applications & Extensions

The technology and methods for remote quantitative imaging of electrostatic potentials and electrostatic fields in and around objects and in free space is presented. Electric field imaging (EFI) technology may be applied to characterize intrinsic or existing electric potentials and electric fields, or an externally generated electrostatic field made be used for volumes to be inspected with EFI. The baseline sensor technology (e-Sensor) and its construction, optional electric field generation (quasi-static generator), and current e- Sensor enhancements (ephemeral e-Sensor) are discussed. Critical design elements of current linear and real-time two-dimensional (2D) measurement systems are highlighted, and the development of a three dimensional (3D) EFI system is presented. Demonstrations for structural, electronic, human, and memory applications are shown. Recent work demonstrates that phonons may be used to create and annihilate electric dipoles within structures. Phonon induced dipoles are ephemeral and their polarization, strength, and location may be quantitatively characterized by EFI providing a new subsurface Phonon-EFI imaging technology. Results from real-time imaging of combustion and ion flow, and their measurement complications, will be discussed. Extensions to environment, Space and subterranean applications will be presented, and initial results for quantitative characterizing material properties are shown. A wearable EFI system has been developed by using fundamental EFI concepts. These new EFI capabilities are demonstrated to characterize electric charge distribution creating a new field of study embracing areas of interest including electrostatic discharge (ESD) mitigation, manufacturing quality control, crime scene forensics, design and materials selection for advanced sensors, combustion science, on-orbit space potential, container inspection, remote characterization of electronic circuits and level of activation, dielectric morphology of structures, tether integrity, organic molecular memory, atmospheric science, weather prediction, earth quake prediction, and medical diagnostic and treatment efficacy applications such as cardiac polarization wave propagation and electromyography imaging.

Generazio, Ed↗

NASA NTRS1988

Elevated temperature durability of ceramic materials

Fast fracture, stress rupture, and cyclic high temperature durability characterizations have been conducted for advanced silicon carbide and silicon nitride ceramics applicable to gas turbine hot section components. The fast fracture and stress rupture tests were conducted in four-point flexure at temperatures of up to 1540 C; the durability tests involved cycling specimens to temperatures of 1370 C and air quenching at 200 C for up to 3500 hrs. Materials with further reliability improvements are noted to be required for gas turbine hot section component applications.

Lindberg, Laura J.↗

NASA NTRS1991

Advanced materials for space nuclear power systems

The overall philosophy of the research was to develop and characterize new high temperature power conversion and radiator materials and to provide spacecraft designers with material selection options and design information. Research on three candidate materials (carbide strengthened niobium alloy PWC-11 for fuel cladding, graphite fiber reinforced copper matrix composites for heat rejection fins, and tungsten fiber reinforced niobium matrix composites for fuel containment and structural supports considered for space power system applications is discussed. Each of these types of materials offers unique advantages for space power applications.

Titran, Robert H.↗

NASA NTRS1991

Advanced materials for space nuclear power systems

The overall philosophy of the research was to develop and characterize new high temperature power conversion and radiator materials and to provide spacecraft designers with material selection options and design information. Research on three candidate materials (carbide strengthened niobium alloy PWC-11 for fuel cladding, graphite fiber reinforced copper matrix composites for heat rejection fins, and tungsten fiber reinforced niobium matrix composites for fuel containment and structural supports) considered for space power system applications is discussed. Each of these types of materials offers unique advantages for space power applications.

Titran, Robert H.↗

NASA NTRSDate not supplied

Quantitative Characterization of 3D Woven Composites Via Fourier Analysis and Structure Tensors Applied to CT Scans

NASA's development of advanced 3D woven carbon composites, such as HEEET and 3MDCP, represents a significant leap in materials designed to endure extreme atmospheric entry conditions. However, the internal complexity of these materials introduces a variety of structures and novel defect types. Traditional characterization methods rely on labor-intensive, manual examination of X-ray CT scans, demanding considerable time and expertise. This process, while thorough, is not sustainable for large-scale analysis and defect tracking. Addressing this critical challenge, this presentation introduces an innovative suite of automated tools and analytical techniques, pioneered by the Mars Sample Return (MSR) Earth Entry System (EES) Thermal Protection System (TPS) project. These advancements offer a more efficient and accurate approach for quantifying CT data and characterizing the defects of 3D woven composites.

3D Woven↗

NASA NTRS1997

A Novel Microcharacterization Technique in the Measurement of Strain and Orientation Gradient in Advanced Materials

Representation of morphology and evolution of the microstructure during processing and their relation to properties requires proper experimental techniques. Residual strains, lattice distortion, and texture (micro-texture) at the interface and the matrix of a layered structure or a functionally gradient material and their variation are among parameters important in materials characterization but hard to measure with present experimental techniques. Current techniques available to measure changes in interred material parameters (residual stress, micro-texture, microplasticity) produce results which are either qualitative or unreliable. This problem becomes even more complicated in the case of a temperature variation. These parameters affect many of the mechanical properties of advanced materials including stress-strain relation, ductility, creep, and fatigue. A review of some novel experimental techniques using recent advances in electron microscopy is presented here to measure internal stress, (micro)texture, interracial strength and (sub)grain formation and realignment. Two of these techniques are combined in the chamber of an Environmental Scanning Electron Microscope to measure strain and orientation gradients in advanced materials. These techniques which include Backscattered Kikuchi Diffractometry (BKD) and Microscopic Strain Field Analysis are used to characterize metallic and intermetallic matrix composites and superplastic materials. These techniques are compared with the more conventional x-ray diffraction and indentation techniques.

Garmestai, H.↗

NASA NTRS2016

Subscale Carbon-Carbon Nozzle Extension Development and Hot Fire Testing in Support of Upper Stage Liquid Rocket Engines

Upper stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures increasing exhaust velocities. Due to the large size of such nozzles and the related engine performance requirements, carbon-carbon (C/C) composite nozzle extensions are being considered for use in order to reduce weight impacts. NASA and industry partner Carbon-Carbon Advanced Technologies (C-CAT) are working towards advancing the technology readiness level of large-scale, domestically-fabricated, C/C nozzle extensions. These C/C extensions have the ability to reduce the overall costs of extensions relative to heritage metallic and composite extensions and to decrease weight by 50%. Material process and coating developments have advanced over the last several years, but hot fire testing to fully evaluate C/C nozzle extensions in relevant environments has been very limited. NASA and C-CAT have designed, fabricated and hot fire tested multiple subscale nozzle extension test articles of various C/C material systems, with the goal of assessing and advancing the manufacturability of these domestically producible materials as well as characterizing their performance when subjected to the typical environments found in a variety of liquid rocket and scramjet engines. Testing at the MSFC Test Stand 115 evaluated heritage and state-of-the-art C/C materials and coatings, demonstrating the capabilities of the high temperature materials and their fabrication methods. This paper discusses the design and fabrication of the 1.2k-lbf sized carbon-carbon nozzle extensions, provides an overview of the test campaign, presents results of the hot fire testing, and discusses potential follow-on development work.

Gradl, Paul↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

DED↗