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At least 109 records · Page 6

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NASA NTRS2003

Torque Limit for Bolted Joint for Composites: TTTC Properties of Laminated Composites - Part A

The existing design code for torque limit of bolted joints for composites at Marshall Space Flight Center is MSFC-STD-486B, which was originally developed in 1960s for metallic materials. The theoretical basis for this code was a simplified mechanics analysis, which takes into account only the bolt, nut and washers, but not the structural members to be connected. The assumption was that metallic materials would not fail due to the bearing stress at the contact area between washer and the mechanical member. This is true for metallic materials; but for composite materials the results could be completely different. Unlike most metallic materials, laminated composite materials have superior mechanical properties (such as modulus and strength) in the in-plane direction, but not in the out-of-plane, or through-the-thickness (TTT) direction. During the torquing, TTT properties (particularly compressive modulus and compressive strength) play a dominant role in composite failure. Because of this concern, structural design engineers at Marshall are currently using a compromised empirical approach: using 50% of the torque value for composite members. Companies like Boeing is using a similar approach. An initial study was conducted last summer on this topic to develop theoretical model(s) that takes into consideration of composite members. Two simplified models were developed based on stress failure criterion and strain failure criterion, respective. However, these models could not be used to predict the torque limit because of the unavailability of material data, specifically, through-the-thickness compression (TTTC) modulus and strength. Therefore, the task for this summer is to experimentally determine the TTTC properties. Due to the time limitation, only one material has been tested: IM7/8552 with [0 degrees,plus or minus 45 degrees, 90 degree ] configuration. This report focuses the test results and their significance, while the experimentation will be described in a separate report by Mr. Kris Kostreva.

Zhao, Yi↗

NASA NTRS2008

Application of Pi Preform Composite Joints in Fabrication of NASA Composite Crew Module Demonstration Structure

This paper will describe unique and extensive use of pre-woven and impregnated pi cross-sections in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a) To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This paper will focus on the design and fabrication issues supporting selection of the Lockheed Martin patented Pi pre-form to provide sound composite joints a numerous locations in the structure. This abstract is based on Preliminary Design data. The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date.

Higgins, John E.↗

NASA NTRS2012

Voluntary Consensus Organization Standards for Nondestructive Evaluation of Thin-Walled Metallic Liners and Composite Overwraps in Composite Overwrapped Pressure Vessels

NASA fracture control requirements outlined in NASA-STD-5009 and NASA-STD-5014 are predicated on the availability and use of sensitive nondestructive evaluation (NDE) methods that can detect and monitor defects, thereby providing data that can be used to predict failure or reduce the risk of failure in fracture critical components. However, in the case of composite materials and components, including composite overwrapped pressure vessels (COPVs), the effect of defects is poorly understood, the NDE methods used to evaluate locate and size defects are typically at lower technical readiness level than analogous NDE methods used for metals, and demonstration studies to verify the probability of detection (POD) are generally lacking or unavailable. These factors together make failure prediction of fracture critical composite materials and components based on size, quantity, or orientation of defects nearly impossible. Also, when inspecting metal liners in as-manufactured COPVs, sensitivity is lost and only the inner surface of the liner is accessible. Also, NDE of COPVs as applied during manufacturing varies significantly from manufacturer to manufacturer and has not yet been standardized. Although requirements exist to perform NDE immediately after manufacturing to establish initial integrity of the parts, procedural detail for NDE of composites is still nonexistent or under development. For example, in practice, only a visual inspection of COPVs is performed during manufacturing and service, leaving in question whether defects of concern, for example, bridging, overwrap winding anomalies, impact damage below visible threshold, out-of-family strain growth, and liner buckling have been adequately detected and monitored. To address these shortcomings, in 2005 the NASA Nondestructive Evaluation Working Group (NNWG) began funding work to develop and adopt standards for nondestructive evaluation of aerospace composites in collaboration with the American Society for Testing and Materials (ASTM) Committee E07 on Nondestructive Testing. Similarly, in 2006 the NASA Engineering and Safety Center (NESC) recommended that nondestructive evaluation methods that can predict composite failure in COPVs should be developed and verified, and integrated into the damage control plan for these vessels

Waller, Jess↗

NASA NTRS2015

Structural CNT Composites Part II: Assessment of CNT Yarns as Reinforcement for Composite Overwrapped Pressure Vessels

Carbon nanotubes (CNTs) are one-dimensional nanomaterials with outstanding electrical and thermal conductivities and mechanical properties. This combination of properties offers routes to enable lightweight structural aerospace components. Recent advances in the manufacturing of CNTs have made bulk forms such as yarns, tapes and sheets available in commercial quantities to permit the evaluation of these materials for aerospace use, where the superior tensile properties of CNT composites can be exploited in tension dominated applications such as composite overwrapped pressure vessels (COPVs). To investigate their utility in this application, aluminum rings were overwrapped with thermoset/CNT yarn composite and their mechanical properties measured. CNT composite overwrap characteristics such as processing method, CNT/resin ratio, and applied tension during CNT yarn winding were varied to determine their effects on the mechanical performance of the CNT composite overwrapped Al rings (CCOARs). Mechanical properties of the CCOARs were measured under static and cyclic loads at room, elevated, and cryogenic temperatures to evaluate their mechanical performance relative to bare Al rings. At room temperature, the breaking load of CCOARs with a 10.8% additional weight due to the CNT yarn/thermoset overwrap increased by over 200% compared to the bare Al ring. The quality of the wound CNT composites was also investigated using x-ray computed tomography.

Kim, Jae-Woo↗

DOE OSTI2016

Ceramic matrix composite article and process of fabricating a ceramic matrix composite article

A ceramic matrix composite article and a process of fabricating a ceramic matrix composite are disclosed. The ceramic matrix composite article includes a matrix distribution pattern formed by a manifold and ceramic matrix composite plies laid up on the matrix distribution pattern, includes the manifold, or a combination thereof. The manifold includes one or more matrix distribution channels operably connected to a delivery interface, the delivery interface configured for providing matrix material to one or more of the ceramic matrix composite plies. The process includes providing the manifold, forming the matrix distribution pattern by transporting the matrix material through the manifold, and contacting the ceramic matrix composite plies with the matrix material.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2018

Ceramic matrix composite article and process of fabricating a ceramic matrix composite article

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2019

Ceramic matrix composite component and process of producing a ceramic matrix composite component

A process of producing a ceramic matrix composite component. The process includes positioning core plies on a mandrel. At least partially rigidizing the core plies to form a preform ceramic matrix composite arrangement defining a tip cavity and a hollow region. Ceramic matrix composite tip plies are positioned on the preform ceramic matrix composite arrangement and within the tip cavity. The ceramic matrix composite tip plies are densified to form a tip region of the composite component.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Atomic Origins of the Self-Healing Function in Cement–Polymer Composites

Motivated by recent advances in self-healing cement and epoxy polymer composites, we present a combined ab initio molecular dynamics and sum frequency generation (SFG) spectroscopy study of a calcium-silicate-hydrate/polymer interface. On stable, low-defect surfaces, the polymer only weakly adheres through coordination and hydrogen bonding interactions and can be easily mobilized towards defected surfaces. Conversely, on fractured surfaces, the polymer strongly anchors through ionic Ca-O bonds resulting from the deprotonation of polymer hydroxyl groups. In addition, polymer S-S groups are turned away from the cement/polymer interface, allowing for the self-healing function within the polymer. The overall elasticity and healing properties of these composites stem from a flexible hydrogen bonding network that can readily adapt to surface morphology. The theoretical vibrational signals associated with the proposed cement-polymer interfacial chemistry were confirmed experimentally by SFG spectroscopy.

ab initio molecular 8 dynamics↗

DOE OSTI2021

Engineering Graphene-Ceramic 3D Composite Foams by Freeze Drying

A 3D graphene foam produced by the chemical vapor deposition (CVD) technique is recognized as an effective nanofiller material, as it does not agglomerate in the matrix. Though CVD facilitates pristine graphene foam production, the method poses limitations in developing large-scale 3D graphene composite foams as advanced engineering materials. In this paper, a freeze-drying (FD) process is used to produce a composite 3D foam, which is a mixture of graphene nanoplatelet (GNP) and a low-temperature co-fired ceramic (LTCC). The freeze-dried GNP-LTCC reticulated 3D composite foam has an average pore size ranging from 70 to 100 μm. Pore size is varied by regulating the heat transfer rate during the freezing process using a thermally conductive aluminum (Al) mold and a thermally insulating acrylonitrile butadiene styrene (ABS) mold. Computational thermal modeling is used to visualize the heat transfer and its effect on foam pore size. Subsequently, a freeze-dried GNP-LTCC composite foam is embedded into the LTCC matrix to form a hierarchical assembly by a spark plasma technique without compromising the 3D structure of the FD foam. This study established that a simple, eco-friendly, and scalable processing methodology can produce advanced graphene-based 3D composite foams as the future tailorable nanofillers for designing multimatrix materials.

36 MATERIALS SCIENCE↗

DOE OSTI2020

A step forward from high-entropy ceramics to compositionally complex ceramics: a new perspective

High-entropy ceramics (HECs) have quickly gained attention since 2015. To date, nearly all work has focused on five-component, equimolar compositions. This perspective article briefly reviews different families of HECs and selected properties. Following a couple of our most recent studies, we propose a step forward to expand HECs to compositionally-complex ceramics (CCCs) to include medium-entropy and/or non-equimolar compositions. Here, using defective fluorite and ordered pyrochlore oxides as two primary examples, we further consider the complexities of aliovalent cations and anion vacancies as well as ordered structures with two cation sublattices. Better thermally-insulating yet stiff CCCs have been found in non-equimolar compositions with optimal amounts of oxygen vacancies and in ordered pyrochlores with large size disorder; it is demonstrated that medium-entropy ceramics (MECs) can prevail over their high-entropy counterparts. The diversifying classes of CCCs provide even more possibilities than HECs to tailor the composition, defects, disorder/order, and consequently various properties.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Remarkable enhancement in thermal conductivity of stainless-steel leveraging metal composite via laser powder bed fusion: 316L-Cu composite

This work aimed to significantly enhance the thermal conductivity of the SS matrix by fabricating a metal composite SS-Cu system utilizing a laser powder bed fusion process. The impact of process parameters on the microstructure of SS-Cu samples is investigated. Here, the processing and post-processing factors that influence the effective thermal conductivity of the metal composite SS-Cu system are discussed. Then, the effective thermal conductivity and mechanical properties of the SS-Cu composite are measured at room temperature and operating temperature of 300 °C. The optimized laser powder bed fusion parameters led to low Marangoni convection, high cooling rate, greater macro-segregation, and higher thermal conductivity values albeit at the cost of ductility in SS-Cu metal composite likely due to the presence of the unmelted powder particles. As-printed SS-60 vol % Cu and annealed SS-60 vol % Cu had 2.5X and 6.6X thermal conductivity enhancement, respectively. During annealing, phase separation, partial melting of Cu, and formation of a continuous network of Cu surrounding SS play a key role in enhancing the thermal conductivity of the SS-Cu metal composite structure.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Hybrid Bio-Based Composites: Enabling Cellulose Nanofiber (CNF) Incorporation into Composites via Macroscale Natural Fiber Carriers

Cellulose nanofibers (CNFs) have significant potential in composites as additives to improve mechanical properties, melt rheology, and more. However, agglomeration of CNFs is a key challenge in composite melt processing as obtaining nano-level dispersion of CNFs often requires cost- and energy-intensive processes (e.g., solvent exchange or freeze drying) due to the strong hornification tendencies of CNF. Herein, we avoid these challenges by using a natural fiber carrier method to integrate CNF into thermoplastic composites. Fibers are co-dried to create a hybrid fiber feedstock for compounding in which natural fibers are decorated with dispersed nanofibers. The hybridized fibers result in up to a 24% increase in tensile strength and up to a 35% increase in Young’s modulus compared to composites only containing natural fibers. The lignocellulosic nanofibers are found to outperform their purely cellulosic counterpart, which is theorized to be due to either an increased propensity for fibrillation of the lignocellulosic fibers or the increased hydrophobicity of the fibers due to the presence of lignin. Surface analysis of fiber feedstocks, via streaming potential measurements and dynamic light scattering (DLS), confirmed a significant change in the feedstock hydrophobicity before and after hybridization. While mild additions of CNF (1 wt.% on the macroscale fiber) do not impact the composite melt viscosity, the viscosity is found to increase at higher CNF loadings (5 wt.% on the macroscale fiber), indicating its utility as a rheology modifier. Lastly, use of these materials as novel feedstocks for medium-scale additive manufacturing in high-fidelity part production was demonstrated.

bio-based↗

DOE OSTI2022

DISCOVR strain pipeline screening – Part II: Winter and summer season areal productivities and biomass compositional shifts in climate-simulation photobioreactor cultures

Assessing the seasonal biomass productivity and compositional shift dynamics under simulated outdoor culture conditions of the top 22 algae strains selected during Tier I flask screening is an important step in the further prioritization of strains with regard to outdoor pond cultivation. These top 22 strains were subjected to Tier II testing in the PNNL Laboratory Environmental Algae Pond Simulator (LEAPS) photobioreactors, simulating light and temperature conditions of 20 cm deep outdoor ponds during the Arizona winter and summer season. All strains were grown in two consecutive nutrient-replete batch culture experiments at their particular optimal medium salinity to quantify their respective seasonal linear-phase areal biomass productivities. To determine biomass compositional shifts in response to nutrient-depletion, the LEAPS cultures were allowed to enter a 9-day nutrient depletion phase at the end of the second batch run. The following strains were evaluated in winter-season climate-simulated cultures and are listed in the order from highest (7.9 g m -2 day -1 ) to lowest (2.3 g m -2 day -1 ) areal N-replete biomass productivity: Monoraphidium minutum 26B-AM, Tetraselmis striata LANL1001, Chlorella vulgaris LRB AZ-1201, Micractinium reisseri NREL14-F2, Monoraphidium sp. MONOR1, Chlorella vulgaris NREL4-C12, Scenedesmus obliquus UTEX393, Scenedesmus acutus LRB-AP-0401, Nannochloropsis oceanica CCAP849/10, and Stichococcus minutus CCALA727. The following strains were evaluated in summer-season climate-simulated cultures and are listed in the order from highest (31.8 g m -2 day -1 ) to lowest (14.2 g m -2 day -1 ) areal N-replete biomass productivity: Picochlorum renovo NREL39-A8, Scenedesmus obliquus UTEX393, Porphyridium cruentum CCMP675, Picochlorum celeri TG2-WT-CSM/EMRE, Chlorella sorokiniana DOE1116, Stichococcus minor CCMP819, Picochlorum oklahomensis CCMP2329, Chlorella sorokiniana DOE1412 (UTEXB3016), Scenedesmus rubescens NREL46B-D3, Picochlorum soloecismus DOE101, Tetraselmis striata LANL1001, Scenedesmus obliquus DOE 0152.z, and Agmenellum quadruplicatum UTEX2268. All LEAPS cultures experienced a significant reduction in areal biomass productivity in response to nutrient-depletion, from 7-16% in the winter season simulation and up to 1-60% in the summer season simulation. Finally, for 10 of the strains tested, the carbohydrate content more than doubled upon nutrient depletion, and for 9 strains, the lipid content increased by over 50% of the initial content.

09 BIOMASS FUELS↗

DOE OSTI2018