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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 145 records · Page 8

Push-out tests on a new silicon carbide/reaction-bonded silicon carbide ceramic matrix composite

Fiber push-out tests have been performed on a ceramic matrix composite consisting of carborundum-sintered SiC fibers, with a BN coating, embedded in a reaction-bonded SiC matrix. Analysis of the push-out data, utilizing the most complete theory presently available, shows that one of the fiber/coating/matrix interfaces has a low fracture energy (one-tenth that of the fiber) and a moderate sliding resistance of about 8 MPa. The debonded sliding interface shows some continuous but minor abrasion, which appears to increase the sliding resistance, but overall the system exhibits very clean smooth sliding. The tensile response of a full-scale composite is then modeled using data obtained here and known fiber strengths to demonstrate the good composite behavior predicted for this material.

Curtin, William A.↗

Superfiber For Strong, Light Fabrics

New ultrahigh-molecular-weight fiber offers major advantages as fabric for space suits, diving suits, sporting goods, sails, and ultralight aircraft. Polyolefin fiber has extremely high modulus of elasticity, low elongation, high specific strength, low specific gravity, resistance to chemicals, low moisture absorption, and high resistance to damage by flexure and abrasion. Consists of elongated, highly aligned, highly crystalline polyethylene molecules. Structure not only results in high strength-to-weight ratio but also gives high resistance to tearing and ripping. Fibers woven in many patterns. Offers combination of desirable properties not found in nylon, polyester, or aramid fabrics.

Dawn, Frederic S.↗

Potential of thin, sputtered films as erosion resistant protective coatings, part 1

The characteristics of thin, pyrolytically deposited films for protection of surfaces from oxidation and abrasion are discussed. The limitations of depositing erosion resistant films are described. Environmental tests of first stage compressor blades in a T-58 engine after coating with a thin film were conducted. Photographic examples of the effectiveness of the thin films in protecting the turbine blades are provided. Methods for operating a sputtering system and the equipment used for film deposition are defined.

Gentner, K.↗

Icing tunnel tests of a composite porous leading edge for use with a liquid anti-ice system

The efficacy of liquid ice protection systems which distribute a glycol-water solution onto leading edge surfaces through a porous skin was demonstrated in tests conducted in the NASA Lewis icing research tunnel using a composite porous leading edge panels. The data obtained were compared with the performance of previously tested stainless steel leading edge with the same geometry. Results show: (1) anti-ice protection of a composite leading edge is possible for all the simulated conditions tested; (2) the glycol flow rates required to achieve anti-ice protection were generally much higher than those required for a stainless steel panel; (3) the low reservoir pressures of the glycol during test runs indicates that more uniform distribution of glycol, and therefore lower glycol flow rates, can probably be achieved by decreasing the porosity of the panel; and (4) significant weight savings can be achieved in fluid ice protection systems with composite porous leading edges. The resistance of composite panels to abrasion and erosion must yet be determined before they can be incorporated in production systems.

Kohlman, D. L.↗

Paper-Thin Coating Offers Maximum Protection

Wessex Incorporated has recently taken a technology that was originally developed for NASA as a protective coating for ceramic materials used in heatshields for space vehicles, and modified it for use in applications such as building materials, machinery, and transportation. The technology, developed at NASA Ames Research Center as a protective coating for flexible ceramic composites (PCC), is environmentally safe, water-based, and contains no solvents. Many other flame-retardant materials contain petroleum-based components, which can produce toxic smoke under flame. Wessex versions of PCC can be used to shield ceramics, wood, plasterboard, steel, plastics, fiberglass, and other materials from catastrophic fires. They are extraordinarily tough and exhibit excellent resistance to thermal shock, vibration, abrasion, and mechanical damage. One thin layer of coating provides necessary protection and allows for flexibility while avoiding excessive weight disadvantages. The coating essentially reduces the likelihood of the underlying material becoming so hot that it combusts and thus inhibits the "flashover" phenomenon from occurring.

Source record↗

Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering↗

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

Lunar dust has posed a major challenge to exploration efforts due to abrasion and impact. This work focuses on fundamental studies on ceramic coatings as candidates for enhanced resistance to impact and wear. As a first step, standard and modified approaches to the method of abrasion testing were explored for options to incorporate lunar regolith as wear media, the effects of which were presented for AL6061-T6 control samples. Following this, wear results for air plasma-sprayed (APS) alumina coatings were investigated due to their superior strength and surface hardness. In addition, APS 8 wt % yttria-stabilized zirconia (8YSZ) coatings were studied for their strength and martensitic transformation toughness. Measurements were made by assessing the mass loss, with a standard scale at various intervals. In addition, surface roughness was measured with a profilometer and features identified with a high-resolution microscope. The findings demonstrated that wear media has a distinct effect on the abrasion. The alumina coatings demonstrated improved wear over 8YSZ. However, the tailorability of 8YSZ makes it an attractive option to continue to modify as a wear-resistant coating to protect against lunar dust abrasion. The results of these measurements provide insight into the wear behavior of future directions in candidate ceramic coatings for the harsh lunar environment.

ceramic coatings↗

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

Lunar dust has posed a major challenge to exploration efforts due to abrasion and impact. This work focuses on fundamental studies on ceramic coatings as candidates for enhanced resistance to impact and wear. As a first step, standard and modified approaches to the method of abrasion testing were explored for options to incorporate lunar regolith as wear media, the effects of which were presented for AL6061-T6 control samples. Following this, wear results for air plasma-sprayed (APS) alumina coatings were investigated due to their superior strength and surface hardness. In addition, APS 8 wt % yttria-stabilized zirconia (8YSZ) coatings were studied for their strength and martensitic transformation toughness. Measurements were made by assessing the mass loss, with a standard scale at various intervals. In addition, surface roughness was measured with a profilometer and features identified with a high-resolution microscope. The findings demonstrated that wear media has a distinct effect on the abrasion. The alumina coatings demonstrated improved wear over 8YSZ. However, the tailorability of 8YSZ makes it an attractive option to continue to modify as a wear-resistant coating to protect against lunar dust abrasion. The results of these measurements provide insight into the wear behavior of future directions in candidate ceramic coatings for the harsh lunar environment.

ceramic coatings↗

Microstructural effects on fracture toughness of polycrystalline ceramics in combined mode I and mode II loading

Fracture toughness of polycrystalline alumina and ceria partially-stabilized tetragonal zirconia (CeO2-TZP) ceramics were assessed in combined mode I and mode II loading using precracked disk specimens in diametral compression. Stress states ranging from pure mode I, combined mode I and mode II, and pure mode II were obtained by aligning the center crack at specific angles relative to the loading diameter. The resulting mixed-mode fracture toughness envelope showed significant deviation to higher fracture toughness in mode II relative to the predictions of the linear elastic fracture mechanics theory. Critical comparison with corresponding results on soda-lime glass and fracture surface observations showed that crack surface resistance arising from grain interlocking and abrasion was the main source of the increased fracture toughness in mode II loading of the polycrystalline ceramics. The normalized fracture toughness for pure mode II loading, (KII/KIc), increased with increasing grain size for the CeO2-TZP ceramics. Quantitative fractography confirmed an increased percentage of transgranular fracture of the grains in mode II loading.

Singh, D.↗

Diamondlike Protective Coats For Infrared Windows

Report describes experiments in which four infrared-transparent window materials were coated with diamondlike carbon films. Purpose to investigate ability of films to protect infrared windows against erosion by rain and wind-blown hard particles. Diamondlike films chosen as protective coats because they are transparent over broad spectral range and resist attack by chemicals, moisture, and abrasion. Experiments yield mixed results.

Swec, Diane M.↗

Applications of fibrous substrates containing insolubilized phase change polymers

Incorporation of polyethylene glycols into fibrous substrates produces several improved functional properties when they are insolubilized by crosslinking with a methylolamide resin or by polyacetal formation by their reaction with glyoxal. The range of molecular weights of polyols that may be insolubilized is broad as are the curing conditions (0.25-10 min at 80-200C). Most representative fiber types and blends (natural and synthetic) and all types of fabric constructions (woven, nonwoven and knit) have been modified by incorporation of the bound polyols. The most novel property is the thermal adaptability of the modified substrates to many climatic conditions. This adaptability is due to the high latent heat of the crosslinked polyols that function as phase change materials, the hydrophilic nature of the crosslinked polymer and its enhanced thermal conductivity. Other enhanced properties imparted to fabrics include flex and flat abrasion, antimicrobial activity, reduced static charge, resistance to oily soils, resiliency, wind resistance and reduced lint loss. Applications commercialized in the U.S. and Japan include sportswear and skiwear. Several examples of electric sets of properties useful for specific end uses are given. In addition, other uses are biomedical horticultural, aerospace, indoor insulation, automotive interiors and components and packaging material.

Vigo, Tyrone L.↗

Effect of 3D-printed surface textures on wear mechanism in 3-body abrasion of soil

This study systematically investigates the enhancement of wear resistance in 3D printed surface textures through both experimental and theoretical approaches. Three distinct surface morphologies (Smooth Surface, Surface with uniformly distributed Pits, and Surface with uniformly distributed Bumps) were fabricated using High-Impact Polystyrene, where the meso-scale textures were precisely controlled through the 3D printing process. Wear behavior was evaluated using a 3-body wear tester in an abrasive particle environment, analyzing the influence of surface textures under various operating conditions. Systematic wear tests revealed that optimally designed surface textures achieved a remarkable 77 % reduction in wear compared to the worst-performing sample. The wear mechanisms were comprehensively characterized through weight loss measurements, Scanning Electron Microscopy (SEM), and Energy Dispersive Spectroscopy (EDS) analyses, elucidating the surface morphology changes and their interaction with wear particles. Notably, the study identified how the geometric characteristics of surface textures influence the movement of wear particles and the distribution of contact stresses. Discrete element method simulations corroborated the experimental findings, providing theoretical validation for the enhanced wear resistance of the optimal structure. The high correlation between simulated wear patterns and experimental results validates the reliability of the proposed design methodology. In conclusion, these results demonstrate that 3D printed surface texturing offers a cost-effective and scalable approach to significantly improve wear resistance in engineering applications, presenting a practical alternative to conventional, high-cost surface engineering methods.

3-body abrasion↗

Wheel Abrasion Experiment Metals Selection for Mars Pathfinder Mission

A series of metals was examined for suitability for the Wheel Abrasion Experiment, one of ten microrover experiments of the Mars Pathfinder Mission. The seven candidate metals were: Ag, Al, Au, Cu, Ni, Pt, and W. Thin films of candidate metals from 0.1 to 1.0 micrometer thick were deposited on black anodized aluminum coupons by e-beam and resistive evaporation and chemical vapor deposition. Optical, corrosion, abrasion, and adhesion criteria were used to select Al, Ni, and Pt. A description is given of the deposition and testing of thin films, followed by a presentation of experimental data and a brief discussion of follow-on testing and flight qualification.

Hepp, Aloysius F.↗

Protective coatings for composite tubes in space applications

Protective coatings for graphite/epoxy (Gr/Ep) tubular structures for a Manned Space Station truss structure were evaluated. The success of the composite tube truss structure depends on its stability to long-term exposure to the Low Earth Orbit (LEO) environment with particular emphasis placed on atomic oxygen. Concepts for protectively coating Gr/Ep tubes include use of inorganic coated metal foils and electroplating. These coatings were applied to Gr/Ep tubes and then subjected to simulated LEO environmnet to evaluate survivability of coatings and coated tubes. Evaluation included: atomic oxygen resistance, changes in optical properties and adhesion, abrasion resistancem surface preparation required, coating uniformity, and formation of microcracks in the Gr/Ep tubes caused by thermal cycling. Program results demonstrated that both phosphoric and chromic acid anodized Al foil provided excellent adhesion to Gr/Ep tubes and exhibited stable optical properties when subjected to simulated LEO environment. The SiO2/Al coatings speuttered onto Al foils also resulted in an excellent protective coating. Electroplated Ni exhibited unaccepatble adhesion loss to Gr/Ep tubes during atomic oxygen exposure.

Dursch, Harry W.↗

Erosion-Resistant Water-And-Grit-Blasting Assembly

Nozzle assembly adds abrasive particles to high-pressure water jet. Abrasive nozzle combined with high-pressure tapered stripping nozzle and standard connector. Partial vacuum in relatively large chamber of abrasive-injector housing entrains grit particles from abrasive supply.

Roberts, Marion L.↗

Developing Materials and Coating Technologies for Mitigation of Lunar Dust Adhesion and Abrasion

In order to support long duration missions on the Moon’s surface, materials resistant to the harsh lunar environment are critically needed. Lunar dust poses a major threat to the durability of components and vehicles due to its fine, jagged morphology and highly abrasive nature, enabling the particles to adhere and embed onto surfaces of components and devices and potentially leading to premature failure. There is significant effort within NASA to develop novel materials and coating technologies to mitigate lunar dust adhesion and abrasion. This effort has been exploring a variety of production routes and examining properties of candidate material systems, including ceramic, metallic and polymeric. Manufacturing methods investigated include ceramic powder processing, additive manufacturing and surface modification via laser ablation patterning of bulk materials and coatings. An overview of ongoing NASA materials and coating research and development efforts to enable lunar surface exploration will be presented.

Materials, Coatings, lunar dust mitigation↗

Developing Materials and Coating Technologies for Mitigation of Lunar Dust Adhesion and Abrasion

In order to support long duration missions on the Moon’s surface, materials resistant to the harsh lunar environment are critically needed. Lunar dust poses a major threat to the durability of components and vehicles due to its fine, jagged morphology and highly abrasive nature, which enables the particles to adhere and embed into surfaces of components and devices potentially leading to premature failure. Consequently, significant effort within NASA aims to develop novel materials and coating technologies to limit lunar dust adhesion and abrasion by exploring a variety of production routes and examining properties of candidate material systems, including ceramic, metallic and polymeric. Manufacturing methods investigated include traditional powder processing, additive manufacturing and surface modification via laser ablation patterning of bulk materials and coatings. An overview of ongoing NASA materials and coating research and development to enable lunar exploration will be presented.

Materials↗

Performance improvement of proton exchange membrane water electrolysis by surface modification of porous transport layers

Proton exchange membrane water electrolysis (PEMWE) is a promising option for hydrogen production from a variety of energy sources. Cost-effective production of hydrogen with PEMWE requires reduction of costly precious metals as well as optimization of the components and interfaces in the cell. The interface between the platinum-coated titanium porous transport layer (PTL) and catalyst layer (CL) significantly impacts the performance of the electrolyzer cell. Here, we report on two PTL modification methods, mechanical abrasion and chemical etching, which we find improve PEMWE performance by lowering the resistance of the PTL/CL interface. The PTL surface modifications enabled performance improvements up to 77 mV at 4 A cm −2 and reduction of the high frequency resistance, demonstrating that the resistance of the PTL/CL interface is a significant factor in the cell performance. The PTL surface roughness was varied using abrasive materials ranging from 0.1 to 140 μm in grain sizes and chemical etching was found to also increase the surface roughness. The surface roughness was quantified using confocal laser microscopy and the surface oxidation was measured using X-ray photoemission spectroscopy. These results demonstrate that both increasing surface roughness and oxide removal contribute to lowering the PTL/CL interfacial resistance and increasing cell performance.

08 HYDROGEN↗