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Grinding tool installed on conventional milling machine cuts precise cavities in foam blocks. Method is well suited for prototype or midsize production runs and can be adapted to computer control for mass production. Method saves time and materials compared to bonding or hot wire techniques.
Smart adaptive materials are an important class of materials which can be used in space deployable structures, morphing wings, and structural air vehicle components where remote actuation can improve fuel efficiency. Adaptive materials can undergo deformation when exposed to external stimuli such as electric fields, thermal gradients, radiation (IR, UV, etc.), chemical and electrochemical actuation, and magnetic field. Large strain, controlled and repetitive actuation are important characteristics of smart adaptive materials. Polymer nanocomposites can be tailored as shape memory polymers and actuators. Magnetic actuation of polymer nanocomposites using a range of iron, iron cobalt, and iron manganese nanoparticles is presented. The iron-based nanoparticles were synthesized using the soft template (1) and Sun's (2) methods. The nanoparticles shape and size were examined using TEM. The crystalline structure and domain size were evaluated using WAXS. Surface modifications of the nanoparticles were performed to improve dispersion, and were characterized with IR and TGA. TPU nanocomposites exhibited actuation for approximately 2wt% nanoparticle loading in an applied magnetic field. Large deformation and fast recovery were observed. These nanocomposites represent a promising potential for new generation of smart materials.
Shape-memory poly(isocyanurate-urethane) (PIR-PUR) aerogels are low-density monolithic nanoporous solids that remember and return to their permanent shape through a heating actuation step. Herein, through structural design at the macro scale, the shape-memory response is augmented with an auxetic effect manifested by a negative Poisson’s ratio of approximately -0.8 at 15% compressive strain. Thus, auxetic shape-memory PIR-PUR monoliths experience volume contraction upon compression at a temperature above the glass transition temperature of the base polymer (Tg ~ 30 °C), and they can be stowed indefinitely in that temporary shape by cooling below Tg. By heating back above Tg, the compressed/shrunk form expands back to their original shape/size. This technology is relevant to a broad range of industries spanning the commercial, aeronautical, and aerospace sectors. The materials are referred to as meta-aerogels and their potential applications include minimally invasive medical devices, soft robotics, and in situations where volume is at a premium, as for example for storage of deployable space structures and planetary habitats during transport to the point of service.
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Rankings of relative toxicity can be markedly affected by changes in test variables. Revision of the USF/NASA toxicity screening test procedure to eliminate the connecting tube and supporting floor and incorporate a 1.0 g sample weight, 200 C starting temperature, and 800 C upper limit temperature for pyrolysis, reversed the rankings of flexible polyurethane and polychloroprene foams, not only in relation to each other, but also in relation to cotton and red oak. Much of the change is attributed to reduction of the distance between the sample and the test animals, and reduction of the sample weight charged. Elimination of the connecting tube increased the relative toxicity of the polyurethane foams. The materials tested were flexible polyurethane foam, without and with fire retardant; rigid polyurethane foam with fire retardant; flexible polychloroprene foam; cotton, Douglas fir, red oak, hemlock, hardboard, particle board, polystyrene, and polymethyl methacrylate.
A hybrid lightweight composite tank has been created using specially designed materials and manufacturing processes. The tank is produced by using a hybrid structure consisting of at least two reinforced composite material systems. The inner composite layer comprises a distinct fiber and resin matrix suitable for cryogenic use that is a braided-sleeve (and/or a filamentwound layer) aramid fiber preform that is placed on a removable mandrel (outfitted with metallic end fittings) and is infused (vacuum-assisted resin transfer molded) with a polyurethane resin matrix with a high ductility at low temperatures. This inner layer is allowed to cure and is encapsulated with a filamentwound outer composite layer of a distinct fiber resin system. Both inner and outer layer are in intimate contact, and can also be cured at the same time. The outer layer is a material that performs well for low temperature pressure vessels, and it can rely on the inner layer to act as a liner to contain the fluids. The outer layer can be a variety of materials, but the best embodiment may be the use of a continuous tow of carbon fiber (T-1000 carbon, or others), or other high-strength fibers combined with a high ductility epoxy resin matrix, or a polyurethane matrix, which performs well at low temperatures. After curing, the mandrel can be removed from the outer layer. While the hybrid structure is not limited to two particular materials, a preferred version of the tank has been demonstrated on an actual test tank article cycled at high pressures with liquid nitrogen and liquid hydrogen, and the best version is an inner layer of PBO (poly-pphenylenebenzobisoxazole) fibers with a polyurethane matrix and an outer layer of T-1000 carbon with a high elongation epoxy matrix suitable for cryogenic temperatures. A polyurethane matrix has also been used for the outer layer. The construction method is ideal because the fiber and resin of the inner layer has a high strain to failure at cryogenic temperatures, and will not crack or produce leaks. The outer layer serves as more of a high-performance structural unit for the inner layer, and can handle external environments.
Wave Energy Converters (WECs) rely on hydraulic Power Take-Off (PTO) systems to transform the kinetic energy of ocean waves into electricity, where hydraulic seals play a critical role in preventing fluid leakage and ensuring watertight operation under harsh marine conditions. However, seal degradation due to wear, fatigue, and corrosion remains a key challenge limiting system reliability and increasing maintenance costs. In this study, the tribological performance of elastomeric materials for hydraulic sealing applications that are based on commercial polyurethane and custom-compounded Ethylene Propylene Diene Monomer (EPDM) is investigated. Using a CSM tribometer, reciprocating wear tests were conducted in accordance with ASTM G133 under dry sliding conditions, with normal loads ranging from 3 to 10 N, and sliding speeds of 10 to 30 mm/s. Coefficient of friction (COF), specific wear rate, and worn surface morphology are evaluated to understand how load, velocity, and material composition affect seal durability. Improved wear stability and high Shore A hardness (93–94) were demonstrated by the commercial thermoplastic polyurethane (Duralast 4203 and 4758). EPDM-based compounds showed different filler-dependent behaviors, formulations filled with carbon black (E3) had the lowest wear rate (1.45 × 10?4 mm³ N?¹ m?¹) and increased load-bearing capacity, while samples modified with silica and plasticizer (E4, E5) had better conformability and damping but less hardness. Compounded EPDMs showed wider deformation zones because of their lower modulus and filler-matrix interfacial fluctuations, while commercial grades exhibited shallower wear scars (= 380 µm), according to optical profilometry. The Archard model-based lifetime estimation showed that, under 10 N and 30 mm/s, operational endurance ranged from 3.1 to 6.2 years. Because of its low wear rate and steady interfacial behavior, E3 had the longest anticipated life. For medium-load hydraulic sealing applications, these results demonstrate the possibility of customized EPDM formulations as affordable substitutes for commercial polyurethanes. They also offer a quantitative foundation for material selection and lifespan prediction.
The effects of novel aromatic diamine structures on the adhesive properties of epoxy and polyurethane adhesives were studied. Aromatic diamines based on benzophenone and diphenyl-methane isomers were evaluated as curing agents for epoxy resins and benzophenone and diphenyl-methane based diamine isomers were evaluated as curing agents for polyurethane adhesives. Polyurethane adhesives were prepared based on m, m prime-diisocyanato-diphenyl-methane and m, m prime-diisocyanato-benzophenone. The m, m prime-diisocayanato-diphenyl-methane based adhesive had properties comparable to state-of-the-art adhesives. The m, m prime-diisocyanato-benzophenone based adhesive was extremely reactive.
Five component level flammability tests were conducted in a 400 cubic foot chamber to determine the products of combustion and relative destruction of coated (with fire-retardants) and uncoated polyurethane foams during exposure of the foams to a large flaming ignition source for five minutes. The test results indicate that the improved state-of-the-art polyurethane foams without the added fire retardant and coating treatments were not significantly better than untreated older less fire-resistant polyurethane foams. however, by treating and coating the state-of-the-art foams, the production of toxic gases was delayed and the destruction of the foam limited.
One sample each of commercial polyurethane and polychloroprene flexible foams were evaluated using the USF/NASA toxicity screening test method. Air flow rates of 0, 0.16, 16, and 48 ml/sec were used to determine the effect of air flow on relative toxicity. Time to first sign of incapacitation and time to death were substantially reduced with both polyurethane and polychloroprene flexible foams by the introduction of 16 to 48 ml/sec air flow. The relative toxicity rankings of these materials were not altered by changes in air flow. Under these test conditions, the polyurethane foam consistently appeared more toxic than the polychloroprene foam. Samples of six different colors from the same fabric were evaluated separately, using the USF/NASA toxicity screening test method, to determine the effect of fabric dye, if any. The material was an upholstery fabric, consisting of 46 percent cotton, 33 percent wool, and 21 percent nylon. There appeared to be no significant effect of fabric dye on relative toxicity, for this material under these test conditions.
An electron-bombardment ion-thruster was used as a neutralized-ion-beam sputtering source to texture the surfaces of biological implant materials. The materials investigated included 316 stainless steel; titanium-6% aluminum, 4% vanadium; cobalt-20% chromium, 15% tungsten; cobalt-35% nickel, 20% chromium, 10% molybdenum; polytetrafluoroethylene; polyoxymethylene; silicone and polyurethane copolymer; 32%-carbon-impregnated polyolefin; segmented polyurethane; silicone rubber; and alumina. Scanning electron microscopy was used to determine surface morphology changes of all materials after ion-texturing. Electron spectroscopy for chemical analysis was used to determine the effects of ion-texturing on the surface chemical composition of some polymers. Liquid contact angle data were obtained for ion-textured and untextured polymer samples. Results of tensile and fatigue tests of ion-textured metal alloys are presented. Preliminary data of tissue response to ion-textured surfaces of some metals, polytetrafluoroethylene, alumina, and segmented polyurethane have been obtained.
Ablative materials are used to provide thermal protection for heat sensitive substrates against large jet fuel fires. The present investigation is concerned with the possibility to increase the available egress time for passengers, from a transport aircraft, in which the flexible polyurethane seating is exposed to the action of a large pool fire. Suitable approaches for providing sufficient ablative protection for polyurethane cushioning are considered. The efficiency of any fire blocking layer is defined as the ratio of the incident radiant heating rate, to the rate of production of combustible gas produced per unit area per second, generated by the pyrolysis of the substrate polyurethane foam. It is found that adequate fire blocking protection can be achieved through replacement of cotton batting slip covers with a wide variety of fire blocking layers. Metallized high temperature resistant char forming ablatives appear to provide optimum protection.
Polymer coatings are finding increasing applications in aerospace industry. The effectiveness of coatings depends strongly on their microstructure and adhesion to the substrates. Currently, there is no technique for adequately monitoring the quality of the coatings. We adapted positron lifetime spectroscopy for the investigation of thin coatings. Results of measurements on 0.001-in-thick polyurethane coatings on aluminum and steel substrates and thicker (0.080-in.) self-standing polyurethane discs were compared. In all cases, we find positron lifetime groups centered around 560 ps, corresponding to the presence of 0.9 A exp 3 free volume cells. However, the number of free volume cells in thin coatings is larger, suggesting that the morphology of thin coatings is different from that of bulk polyurethane. These results and their structural implications are discussed.
Thermal Protection Systems (TPS) of NASA's Space Shuttle External Tank include polyurethane and polyisocyanurate modified polyurethane foam insulations. These insulations, currently foamed with CFC 11 blowing agent, serve to maintain cryogenic propellant quality, maintain the external tank structural temperature limits, and minimize the formation of ice and frost that could potentially damage the ceramic insulation on the space shuttle orbiter. During flight the external tank insulations are exposed to mechanical, thermal and acoustical stresses. TPS must pass cryogenic flexure and substrate adhesion tests at -253 C, aerothermal and radiant heating tests at fluxes up to approximately 14 kilowatts per square meter, and thermal conductivity tests at cryogenic and elevated temperatures. Due to environmental concerns, the polyurethane insulation industry and the External Tank Project are tasked with replacing CFC 11. The flight qualification of foam insulations employing HCFC 141b as a foaming agent is currently in progress; HCFC 141b blown insulations are scheduled for production implementation in 1995. Realizing that the second generation HCFC blowing agents are an interim solution, the evaluation of third generation blowing agents with zero ozone depletion potential is underway. NASA's TPS Materials Research Laboratory is evaluating third generation blowing agents in cryogenic insulations for the External Tank; one option being investigated is the use of water as a foaming agent. A dimensionally stable insulation with low friability, good adhesion to cryogenic substrates, and acceptable thermal conductivity has been developed with low viscosity materials that are easily processed in molding applications. The development criteria, statistical experimental approach, and resulting foam properties will be presented.
Military and aerospace industries use Mil-Spec type electrical connections on bulkhead panels that require inline access for mate and demate operations. These connectors are usually in tight proximity to other connectors, or recessed within panels. The pliers described here have been designed to work in such tight spaces, and consist of a mirrored set of parallel handles, two cross links, two return springs, and replaceable polyurethane-coated end effectors. The polyurethane eliminates metal-to-metal contact and provides a high-friction surface between the jaw and the connector. Operationally, the user would slide the pliers over the connector shell until the molded polyurethane lip makes contact with the connector shell edge. Then, by squeezing the handles, the end effector jaws grip the connector shell, allowing the connector to be easily disconnected by rotating the pliers. Mating the connector occurs by reversing the prescribed procedure, except the connector shell is placed into the jaws by hand. The molded lip within the jaw allows the user to apply additional force for difficult-to-mate connectors. Handle design has been carefully examined to maximize comfort, limit weight, incorporate tether locations, and improve ergonomics. They have been designed with an off-axis offset for wiring harness clearance, while placing the connector axis of rotation close to the user s axis of wrist rotation. This was done to eliminate fatigue during multiple connector panel servicing. To limit handle opening width, with user ergonomics in mind, the pliers were designed using a parallel jaw mechanism. A cross-link mechanism was used to complete this task, while ensuring smooth operation.
Hybrid deployable radio antennas and reflectors of a proposed type would feature rigid narrower apertures plus wider adjoining apertures comprising reflective surfaces supported by open-cell polymeric foam structures (see figure). The open-cell foam structure of such an antenna would be compressed for compact stowage during transport. To initiate deployment of the antenna, the foam structure would simply be released from its stowage mechanical restraint. The elasticity of the foam would drive the expansion of the foam structure to its full size and shape. There are several alternatives for fabricating a reflective surface supported by a polymeric foam structure. One approach would be to coat the foam with a metal. Another approach would be to attach a metal film or a metal-coated polymeric membrane to the foam. Yet another approach would be to attach a metal mesh to the foam. The hybrid antenna design and deployment concept as proposed offers significant advantages over other concepts for deployable antennas: 1) In the unlikely event of failure to deploy, the rigid narrow portion of the antenna would still function, providing a minimum level of assured performance. In contrast, most other concepts for deploying a large antenna from compact stowage are of an "all or nothing" nature: the antenna is not useful at all until and unless it is fully deployed. 2) Stowage and deployment would not depend on complex mechanisms or actuators, nor would it involve the use of inflatable structures. Therefore, relative to antennas deployed by use of mechanisms, actuators, or inflation systems, this antenna could be lighter, cheaper, amenable to stowage in a smaller volume, and more reliable. An open-cell polymeric (e.g., polyurethane) foam offers several advantages for use as a compressible/expandable structural material to support a large antenna or reflector aperture. A few of these advantages are the following: 3) The open cellular structure is amenable to compression to a very small volume - typically to 1/20 of its full size in one dimension. 4) At a temperature above its glass-transition temperature (T(sub g)), the foam strongly damps vibrations. Even at a temperature below T(sub g), the damping should exceed that of other materials. 5) In its macroscopic mechanical properties, an open-cell foam is isotropic. This isotropy facilitates computational modeling of antenna structures. 6) Through chemical formulation, the T(sub g) of an open-cell polyurethane foam can be set at a desired value between about - 100 and about 0 C. Depending on the application, it may or may not be necessary to rigidify a foam structure after deployment. If rigidification is necessary, then the T(sub g) of the foam can be tailored to exceed the temperature of the deployment environment, in conjunction with providing a heater to elasticize the foam for deployment. Once deployed, the foam would become rigidified by cooling to below T(sub g). 7) Techniques for molding or machining polymeric foams (especially including open-cell polyurethane foams) to desired sizes and shapes are well developed.
An apparatus characterized as both a membrane probe and a bone ultrafiltration probe has been developed to enable in vivo sampling of interstitial fluid in bone. The probe makes it possible to measure the concentration of calcium and other constituents of the fluid that may be relevant to bone physiology. The probe could be especially helpful in experimental studies of microgravitational bone loss and of terrestrial bone-loss disease states, including osteoporosis. The probe can be implanted in the bone tissue of a living animal and can be used to extract samples of the interstitial bone fluid from time to time during a long-term study. The probe includes three 12-cm-long polyacrylonitrile fibers configured in a loop form and attached to polyurethane tubing [inside diameter 0.025 in. (0.64 mm), outside diameter 0.040 in. (1 mm)]; the attachment is made by use of a 1-cm-long connecting piece of polyurethane tubing [inside diameter 0.035 0.003 in. (0.89 0.08 mm), outside diameter 0.060 0.003 in. (1.52 0.08 mm)]. At the distal end, a 2-cm-long piece of polyurethane tubing of the same inner and outer diameters serves as a connector to a hub. A 1-cm long piece of expanded poly (tetrafluoroethylene) tubing over the joint between the fibers and the connecting tubing serves as a tissue-in-growth site.
The primary application for cryogenic insulating foams will be fuel tank applications for fueling systems. It is crucial for this insulation to be incorporated into systems that survive vacuum and terrestrial environments. It is hypothesized that by forming an open-cell silica-reinforced polymer structure, the foam structures will exhibit the necessary strength to maintain shape. This will, in turn, maintain the insulating capabilities of the foam insulation. Besides mechanical stability in the form of crush resistance, it is important for these insulating materials to exhibit water penetration resistance. Hydrocarbon-terminated foam surfaces were implemented to impart hydrophobic functionality that apparently limits moisture penetration through the foam. During the freezing process, water accumulates on the surfaces of the foams. However, when hydrocarbon-terminated surfaces are present, water apparently beads and forms crystals, leading to less apparent accumulation. The object of this work is to develop inexpensive structural cryogenic insulation foam that has increased impact resistance for launch and ground-based cryogenic systems. Two parallel approaches will be pursued: a silica-polymer co-foaming technique and a post foam coating technique. Insulation characteristics, flexibility, and water uptake can be fine-tuned through the manipulation of the polyurethane foam scaffold. Silicate coatings for polyurethane foams and aerogel-impregnated polyurethane foams have been developed and tested. A highly porous aerogel-like material may be fabricated using a co-foam and coated foam techniques, and can insulate at liquid temperatures using the composite foam