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At least 127 records · Page 7

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NASA NTRS2005

Multilayer Composite Pressure Vessels

A method has been devised to enable the fabrication of lightweight pressure vessels from multilayer composite materials. This method is related to, but not the same as, the method described in gMaking a Metal- Lined Composite-Overwrapped Pressure Vessel h (MFS-31814), NASA Tech Briefs, Vol. 29, No. 3 (March 2005), page 59. The method is flexible in that it poses no major impediment to changes in tank design and is applicable to a wide range of tank sizes. The figure depicts a finished tank fabricated by this method, showing layers added at various stages of the fabrication process. In the first step of the process, a mandrel that defines the size and shape of the interior of the tank is machined from a polyurethane foam or other suitable lightweight tooling material. The mandrel is outfitted with metallic end fittings on a shaft. Each end fitting includes an outer flange that has a small step to accommodate a thin layer of graphite/epoxy or other suitable composite material. The outer surface of the mandrel (but not the fittings) is covered with a suitable release material. The composite material is filament- wound so as to cover the entire surface of the mandrel from the step on one end fitting to the step on the other end fitting. The composite material is then cured in place. The entire workpiece is cut in half in a plane perpendicular to the axis of symmetry at its mid-length point, yielding two composite-material half shells, each containing half of the foam mandrel. The halves of the mandrel are removed from within the composite shells, then the shells are reassembled and bonded together with a belly band of cured composite material. The resulting composite shell becomes a mandrel for the subsequent steps of the fabrication process and remains inside the final tank. The outer surface of the composite shell is covered with a layer of material designed to be impermeable by the pressurized fluid to be contained in the tank. A second step on the outer flange of each end fitting accommodates this layer. Depending on the application, this layer could be, for example, a layer of rubber, a polymer film, or an electrodeposited layer of metal. If the fluid to be contained in the tank is a gas, then the best permeation barrier is electrodeposited metal (typically copper or nickel), which can be effective at a thickness of as little as 0.005 in (.0.13 mm). The electrodeposited metal becomes molecularly bonded to the second step on each metallic end fitting. The permeation-barrier layer is covered with many layers of filament-wound composite material, which could be the same as, or different from, the composite material of the inner shell. Finally, the filament-wound composite material is cured in an ov

DeLay, Tom↗

NASA NTRS2001

NASA/University JOint VEnture (JOVE) Program: Transverse Shear Moduli Using the Torsional Responses of Rectangular Laminates

The first year included a study of the non-visible damage of composite overwrapped pressure vessels with B. Poe of the Materials Branch of Nasa-Langley. Early determinations showed a clear reduction in non-visible damage for thin COPVs when partially pressurized rather than unpressurized. Literature searches on Thicker-wall COPVs revealed surface damage but clearly visible. Analysis of current Analytic modeling indicated that that current COPV models lacked sufficient thickness corrections to predict impact damage. After a comprehensive study of available published data and numerous numerical studies based on observed data from Langley, the analytic framework for modeling the behavior was determined lacking and both Poe and Bogan suggested any short term (3yr) result for Jove would be overly ambitious and emphasis should be placed on transverse shear moduli studies. Transverse shear moduli determination is relevant to the study of fatigue, fracture and aging effects in composite structures. Based on the techniques developed by Daniel & Tsai, Bogan and Gates determined to verify the results for K3B and 8320. A detailed analytic and experimental plan was established and carried out that included variations in layup, width, thickness, and length. As well as loading rate variations to determine effects and relaxation moduli. The additional axial loads during the torsion testing were studied as was the placement of gages along the composite specimen. Of the proposed tasks, all of tasks I and 2 were completed with presentations given at Langley, SEM conferences and ASME/AIAA conferences. Sensitivity issues with the technique associated with the use of servohydraulic test systems for applying the torsional load to the composite specimen limited the torsion range for predictable and repeatable transverse shear properties. Bogan and Gates determined to diverge on research efforts with Gates continuing the experimental testing at Langley and Bogan modeling the apparent non-linear behavior at low torque & angles apparent from the tests.

Bogan, Sam↗

DOE OSTI2024

Rational design of semi-interpenetrating network based on hyperbranched polyglycerol grafted MXene/polyurethane–epoxy for compressed hydrogen storage

Here, hydrogen (H 2 ) energy has emerged as a promising alternative in the automotive sector to replace fossil fuel; however, its storage with volumetric efficiency remains a challenge. The latest type IV storage vessel featuring a polymeric liner with composite overwrap incurs hydrogen saturation, which eventually causes failure. To prevent the H 2 dissolution in the liner, we have developed a barrier coating comprised of polyurethane/epoxy semi-interpenetrating network (S-IPN) combined with hyperbranched polyglycerol grafted MXene (h-MXene). The hyperbranched structure facilitated the dispersion of MXene in the coating solution by enhancing the exfoliation and improved the polymer filler interaction by forming covalent and H-bonding through end-terminal hydroxyl groups. Leveraging the dense network of S-IPN combined with the dispersed layer structured h-MXene significantly increased the tortuosity of the spray-coated barrier film applied to the nylon 6 liner. The coating exhibited a 90 % reduction in the H 2 gas permeability at only 2 wt% h-MXene concentration, which further improved to above 98 % at 10 wt% loading. Additionally, the h-MXene considerably improved the adhesion with the liner even in a highly stretched condition, signifying the durability of the coating under cyclic pressurization and depressurization of the storage vessel.

08 HYDROGEN↗

DOE OSTI2024

Electrolyte Assisted Hydrogen Storage Reactions (Final Technical Report)

The goal of this project is to address critical deficiencies of hydrogen storage systems design based on hydride materials, as originally identified by the DOE Hydrogen Storage Engineering Center of Excellence (HSECoE). Baseline hydrogen storage technology presently relies on compressed gas operating at ~700 bar pressure, which imposes huge demands on fuel delivery, fuel storage and system cost. For onboard storage applications, Type IV composite overwrapped pressure vessels and associated balance-of-plant components are necessary to ensure safe and effective fuel delivery. However, such compressed gas technology falls well-short of volumetric targets even at 700 bar, given the density of gaseous molecular hydrogen is only 40 g·H2/l at ambient temperatures. One alternative is to utilize hydride materials which accommodate hydrogen in atomic form. Certain hydrides can attain volumetric densities that exceed the density of liquid H2 (71 g·H2/l) while also offering advantageous thermodynamic properties. However, such material systems presently rely on solid-state diffusion for hydrogen release, which has a very high activation barrier for atom mobility and, thus, requires impractically-high temperatures for operation. The initial focus of our research effort is to employ and demonstrate an electrolyte system to mediate the diffusion of species at lower temperatures relevant to transportation applications, with the goal of establishing the critical factors necessary to obviate the need for high-temperature release of hydrogen. A parallel goal of this exploratory effort is to determine the effectiveness of modest electrochemical potentials in overcoming any endothermic requirements for hydrogen release in a similar electrolyte-promoted scenario.

08 HYDROGEN↗

NASA NTRS2000

Composite Tank Development

This paper presents viewgraphs on composite tank development. There is a need for oxidizer tanks and reliable, lightweight fuel. The need for cost-effective and scalable manufacturing is also evident. In order to achieve these goals, tooling methods for tank development must be applied, methods for producing easily adaptable and scalable vessel liners must be developed, insulation layer or protective barriers for containers must be manufactured, and an appropriate fiber/resin system for composite overwrap structures must be identified.

DeLay, Thomas K.↗

NASA NTRS2000

A Regeneratively Cooled Thrust Chamber For The Fastrac Engine

Abstract This paper presents the development of a low-cost, regeneratively-cooled thrust chamber for the Fastrac engine. The chamber was fabricated using hydraformed copper tubing to form the coolant jacket and wrapped with a fiber reinforced polymer composite Material to form a structural jacket. The thrust chamber design and fabrication approach was based upon Space America. Inc.'s 12,000 lb regeneratively-cooled LOX/kerosene rocket engine. Fabrication of regeneratively cooled thrust chambers by tubewall construction dates back to the early US ballistic missile programs. The most significant innovations in this design was the development of a low-cost process for fabrication from copper tubing (nickel alloy was the usual practice) and use of graphite composite overwrap as the pressure containment, which yields an easily fabricated, lightweight pressure jacket around the copper tubes A regeneratively-cooled reusable thrust chamber can benefit the Fastrac engine program by allowing more efficient (cost and scheduler testing). A proof-of-concept test article has been fabricated and will he tested at Marshall Space Flight Center in the late Summer or Fall of 2000.

Brown, Kendall K.↗

NASA NTRS1999

Mars Observer Propulsion and Pyrotechnics Corrective Actions Test Program Status-1999

An extensive propulsion and pyrotechnic test program has been in progress at the NASA White Sands Test Facility since 1995. This program created the capabilities to: accurately measure and characterize pyrovalve combustion product blow-by into propellant systems; characterize valve operation using a Velocity Interferometer System for Any Reflector (VISAR); and evaluate hydrazine and monomethylhydrazine thermal decomposition initiated by blow-by. These capabilities were further utilized and refined this year. Low blow-by pyrovalves manufactured by Conax Florida Corporation continued to be evaluated as a potential corrective measure for blow-by induced propellant explosions. Development and testing of various advanced pyrovalves and investigation of explosion mechanisms also continued. Current and near-term testing includes: evaluation of 3/8 in. Conax pyrovalves and other commercially available valves; development and testing of advanced pyrovalve subcomponent technologies including a zero blow-by pyrovalve ram, composite overwrapped ram cylinder, and a zero particulate generating poppet; investigation of non-destructive evaluation techniques to evaluate pyrovalve ram seals; and testing and modeling of pyrotechnically induced explosive hydrazine decomposition. Evaluation of 3/8 in. Conax valves will include operational margin testing to be accomplished at NASA Langley Research Center. The test program also seeks to compile and format significant amounts of data from this and other pyrovalve test programs to generate a pyrovalve applications handbook. The handbook will facilitate formation of standards that ensure safe spacecraft applications. Current data and future plans are discussed, and community interaction is encouraged.

Saulsberry, Regor↗

NASA NTRS2003

A Titan Explorer Mission Utilizing Solar Electric Propulsion and Chemical Propulsion Systems

Mission and Systems analyses were performed for a Titan Explorer Mission scenario utilizing medium class launch vehicles, solar electric propulsion system (SEPS) for primary interplanetary propulsion, and chemical propulsion for capture at Titan. An examination of a range of system factors was performed to determine their affect on the payload delivery capability to Titan. The effect of varying the launch vehicle, solar array power, associated number of SEPS thrusters, chemical propellant combinations, tank liner thickness, and tank composite overwrap stress factor was investigated. This paper provides a parametric survey of the aforementioned set of system factors, delineating their affect on Titan payload delivery, as well as discussing aspects of planetary capture methodology.

Cupples, Michael↗

NASA NTRS2005

Pressure Vessel with Impact and Fire Resistant Coating and Method of Making Same

An impact and fire resistant coating laminate is provided which serves as an outer protective coating for a pressure vessel such as a composite overwrapped vessel with a metal lining. The laminate comprises a plurality of fibers (e.g., jute twine or other, stronger fibers) which are wound around the pressure vessel and an epoxy matrix resin for the fibers. The epoxy matrix resin including a plurality of microspheres containing a temperature responsive phase change material which changes phase in response to exposure thereof to a predetermined temperature increase so as to afford increased insulation and hear absorption.

Thomas K DeLay↗

NASA NTRS2007

A Process for Producing Highly Wettable Aluminum 6061 Surfaces Compatible with Hydrazine

NASA's Global Precipitation Measurement (GPM) mission is an ongoing Goddard Space Flight Center (GSFC) project whose basic objective is to improve global precipitation measurements. The space-based portion of the mission architecture consists of a primary or core spacecraft and a constellation of NASA and contributed spacecrafts. The efforts described in this paper refer to the core spacecraft (hereafter referred to as simply GPM) which is to be fabricated at GSFC. It has been decided that the GPM spacecraft is to be a "design-for-demise-spacecraft." This requirement resulted in the need for a propellant tank that would also demise or ablate to an appropriate degree upon re-entry. Composite overwrapped aluminum lined propellant tanks with aluminum propellant management devices (PMD) were shown by analyses to demise and thus became the baseline configuration for GPM. As part of the GPM tank development effort, long term compatibility and wettability testing with hydrazine was performed on Al6061 and 2219 coupons fabricated and cleaned by conventional processes. Long term compatibility was confirmed. However, the wettability of the aluminum as measured by contact angle produced higher than desired angles (greater than 30 deg.) with excessive scatter. The availability of PMD materials exhibiting consistently low contact angles aids in the design of simple PMDs. Two efforts performed by Angeles Crest Engineering and funded by GSFC were undertaken to reduce the risk of using aluminum for the GPM PMD. The goal of the first effort was to develop a cleaning or treatment process to produce consistently low contact angles. The goal of the second effort was to prove via testing that the processed aluminum would retain compatibility with hydrazine and retain low contact angle after long term exposure to hydrazine. Both goals were achieved. This paper describes both efforts and the results achieved.

Moore, N. R.↗

NASA NTRS1994

Waste gas storage

Method for storing a waste gas mixture comprised of nitrogen, oxygen, carbon dioxide, and inert gases, the gas mixture containing corrosive contaminants including inorganic acids and bases and organic solvents, and derived from space station operations. The gas mixture is stored under pressure in a vessel formed of a filament wound composite overwrap on a metal liner, the metal liner being pre-stressed in compression by the overwrap, thereby avoiding any tensile stress in the liner, and preventing stress corrosion cracking of the liner during gas mixture storage.

Vickers, Brian D.↗

NASA NTRS2005

Pressure vessel with impact and fire resistant coating and method of making same

DeLay, Thomas K.↗

NASA NTRS2008

Development of COPVS for High pressure, In-Space, Cryogenic Fuel Storage

Polymeric composite overwrapped pressure vessels (COPVs) provide an attractive material system to support developing commercial launch business and alternate fuel ventures. However to be able to design with these materials, the mechanical behavior of the materials must be understood with regards to processing, performance, damage tolerance, and environment. For the storage of cryogenic propellants, it is important to evaluate the materials performance and impact damage resistance at cryogenic temperatures in order to minimize weight and to ensure safety and reliability. To evaluate the ultimate performance, various polymeric COPV's have been statically burst tested at cryogenic conditions before and after exposure to irradiation. Materials selected for these COPVs were based on the measured mechanical properties of candidate resin systems and fibers that were also tested at cryogenic conditions before and after exposure to irradiation. The correlation of COPV burst pressures with the constituent material properties has proven to be a valuable screening method for selection of suitable candidate materials with resistance to material degradation due to exposure to temperature and radiation.

DeLay, Tom↗

NASA NTRS2008

High Performance COPVs for In-Space Storage of High Pressure Cryogenic Fuels

Polymeric composite overwrapped pressure vessels (COPVs) provide an attractive material system to support developing commercial launch business and alternate fuel ventures. However to be able to design with these materials, the mechanical behavior of the materials must be understood with regards to processing, performance, damage tolerance, and environment. For the storage of cryogenic propellants, it is important to evaluate the materials performance and impact damage resistance at cryogenic temperatures in order to minimize weight and to ensure safety and reliability. As part of this study, material tests of candidate fiber and resin systems were used as the basis for the selection of the material combinations for evaluation in a COPV at cryogenic conditions. This comprehensive approach has also been expanded to address issues with impact damage tolerance and material degradation due to environmental factors. KEY WORDS: Cryogenic testing, evaluation and applications for pressure vessels, COPVs, tanks, or storage vessels.

Schneider, Judy↗

NASA NTRS2009

Bayes Analysis and Reliability Implications of Stress-Rupture Testing a Kevlar/Epoxy COPV using Temperature and Pressure Acceleration

Composite Overwrapped Pressure Vessel (COPVs) that have survived a long service time under pressure generally must be recertified before service is extended. Sometimes lifetime testing is performed on an actual COPV in service in an effort to validate the reliability model that is the basis for certifying the continued flight worthiness of its sisters. Currently, testing of such a Kevlar49(registered TradeMark)/epoxy COPV is nearing completion. The present paper focuses on a Bayesian statistical approach to analyze the possible failure time results of this test and to assess the implications in choosing between possible model parameter values that in the past have had significant uncertainty. The key uncertain parameters in this case are the actual fiber stress ratio at operating pressure, and the Weibull shape parameter for lifetime; the former has been uncertain due to ambiguities in interpreting the original and a duplicate burst test. The latter has been uncertain due to major differences between COPVs in the data base and the actual COPVs in service. Any information obtained that clarifies and eliminates uncertainty in these parameters will have a major effect on the predicted reliability of the service COPVs going forward. The key result is that the longer the vessel survives, the more likely the more optimistic stress ratio is correct. At the time of writing, the resulting effect on predicted future reliability is dramatic, increasing it by about one nine , that is, reducing the probability of failure by an order of magnitude. However, testing one vessel does not change the uncertainty on the Weibull shape parameter for lifetime since testing several would be necessary.

Phoenix, S. Leigh↗

NASA NTRS2009

Fracture Test Methods for Plastically Responding COPV Liners

An experimental procedure for evaluating the validity of using uniaxial tests to provide a conservative bound on the fatigue crack growth rate behavior small cracks in bi-axially loaded Composite Overwrapped Pressure Vessel (COPV) liners is described. The experimental procedure included the use of a laser notch to quickly generate small surface fatigue cracks with the desired size and aspect ratios. An out-of-plane constraint system was designed to allow fully reversed, fully plastic testing of thin sheet uniaxial coupons. Finally, a method was developed to determine to initiate small cracks in the liner of COPVs.

Dawicke, David S.↗

NASA NTRS2009

Bayes Analysis and Reliability Implications of Stress-Rupture Testing a Kevlar/Epoxy COPV Using Temperature and Pressure Acceleration

Composite Overwrapped Pressure Vessels (COPVs) that have survived a long service time under pressure generally must be recertified before service is extended. Flight certification is dependent on the reliability analysis to quantify the risk of stress rupture failure in existing flight vessels. Full certification of this reliability model would require a statistically significant number of lifetime tests to be performed and is impractical given the cost and limited flight hardware for certification testing purposes. One approach to confirm the reliability model is to perform a stress rupture test on a flight COPV. Currently, testing of such a Kevlar49 (Dupont)/epoxy COPV is nearing completion. The present paper focuses on a Bayesian statistical approach to analyze the possible failure time results of this test and to assess the implications in choosing between possible model parameter values that in the past have had significant uncertainty. The key uncertain parameters in this case are the actual fiber stress ratio at operating pressure, and the Weibull shape parameter for lifetime; the former has been uncertain due to ambiguities in interpreting the original and a duplicate burst test. The latter has been uncertain due to major differences between COPVs in the database and the actual COPVs in service. Any information obtained that clarifies and eliminates uncertainty in these parameters will have a major effect on the predicted reliability of the service COPVs going forward. The key result is that the longer the vessel survives, the more likely the more optimistic stress ratio model is correct. At the time of writing, the resulting effect on predicted future reliability is dramatic, increasing it by about one "nine," that is, reducing the predicted probability of failure by an order of magnitude. However, testing one vessel does not change the uncertainty on the Weibull shape parameter for lifetime since testing several vessels would be necessary.

Phoenix, S. Leigh↗

NASA NTRS2010

Fiber Breakage Model for Carbon Composite Stress Rupture Phenomenon: Theoretical Development and Applications

Stress rupture failure of Carbon Composite Overwrapped Pressure Vessels (COPVs) is of serious concern to Science Mission and Constellation programs since there are a number of COPVs on board space vehicles with stored gases under high pressure for long durations of time. It has become customary to establish the reliability of these vessels using the so called classic models. The classical models are based on Weibull statistics fitted to observed stress rupture data. These stochastic models cannot account for any additional damage due to the complex pressure-time histories characteristic of COPVs being supplied for NASA missions. In particular, it is suspected that the effects of proof test could significantly reduce the stress rupture lifetime of COPVs. The focus of this paper is to present an analytical appraisal of a model that incorporates damage due to proof test. The model examined in the current paper is based on physical mechanisms such as micromechanics based load sharing concepts coupled with creep rupture and Weibull statistics. For example, the classic model cannot accommodate for damage due to proof testing which every flight vessel undergoes. The paper compares current model to the classic model with a number of examples. In addition, several applications of the model to current ISS and Constellation program issues are also examined.

Murthy, Pappu L. N.↗