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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

NASA Glenn/AADC Collaboration Optimized Erosion Coatings for Inlet Guide Vanes

There is a need for lightweight, durable materials and structures to reduce the weight of propulsion systems. Polymer matrix composites (PMC's) are promising materials for aerospace applications because of their high strength-to-weight ratio relative to metals. Unfortunately, they are limited to applications where they are not exposed to hightemperature oxidizing atmospheres and/or particulates from ingested air. This is because oxidation and erosion occur on the surface, leading to weight loss, nodulation, and/or cracking on the surface, and a consequent decline of mechanical properties over time. Although prior research has shown that oxidation can be slowed when metallic or ceramic coatings are applied onto PMC's, there remains a need for erosion-resistant coatings that protect PMC's from high-velocity particulates in the engine flow path. These erosionresistant coatings could extend the life of polymer composites. Polymer composites are heavily damaged without an erosion-resistant coating because they are not as hard as metallic engine structures. The effectiveness and life of the coatings depends on their inherent properties as well as on the interaction between the coating and the PMC. Since polymers, in general, have high thermal expansion coefficients in comparison to metals and ceramics, failure of the coatings often occurs at this interface. The objective of this research is to develop strategies to improve this interface and tailor overlays for erosion resistance. The bondcoat, which was developed at the NASA Glenn Research Center, is composed of zinc blended with polyimides to improve the compatibility between the PMC and the overlay material. Initial coating trials at AADC produced vanes that had poor bonding between the overlay and bondcoats. Subsequently, Glenn successfully demonstrated that high-quality plasma-sprayed erosion coating systems could be applied to these guide vanes. Inlet guide vanes from AE 3007 engines fiber composites were coated using a coating system composed of a bondcoat and a hard topcoat. Optimization of the plasma spray process has led to plans for future erosion testing in gas turbine engine environments.

Sutter, James K.↗
DOE OSTI2024

Tracking copper nanofiller evolution in polysiloxane during processing into SiOC ceramic

Polymer-derived ceramics (PDCs) remain at the forefront of research for a variety of applications including ultra-high-temperature ceramics, energy storage and functional coatings. Despite their wide use, questions remain about the complex structural transition from polymer to ceramic and how local structure influences the final microstructure and resulting properties. This is further complicated when nanofillers are introduced to tailor structural and functional properties, as nanoparticle surfaces can interact with the matrix and influence the resulting structure. The inclusion of crystalline nanofiller produces a mixed crystalline–amorphous composite, which poses characterization challenges. With this study, we aim to address these challenges with a local-scale structural study that probes changes in a polysiloxane matrix with incorporated copper nanofiller. Composites were processed at three unique temperatures to capture mixing, pyrolysis and initial crystallization stages for the pre-ceramic polymer. We observed the evolution of the nanofiller with electron microscopy and applied synchrotron X-ray diffraction with differential pair distribution function (d-PDF) analysis to monitor changes in the matrix's local structure and interactions with the nanofiller. The application of the d-PDF to PDC materials is novel and informs future studies to understand interfacial interactions between nanofiller and matrix throughout PDC processing.

Chemistry↗
NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic composites

Polymer matrix composites (PMCs) offer many benefits for the aerospace industry due to their potential for weight reduction when compared to metal or ceramic based materials. Most PMCs currently in flight use thermoset matrices, however, thermoplastic resins are being explored as alternatives due to their ability to be remelted, which is of particular interest due to the potential for in-situ repair and manufacturing required in space. Most thermoplastic resins are semicrystalline polymers. The properties of semicrystalline thermoplastics are largely influenced by their crystallinity, which can vary due to many factors including thermal treatments, environmental conditions, and mechanical deformation. Monitoring the crystallinity of thermoplastic composites is key to ensuring these materials reliably meet the high demands required by space exploration. This talk discusses the use of multiple techniques such as Polarized Light Optical Microscopy and Fourier-Transform Infrared Spectroscopy to characterize the crystallinity in various thermoplastic composites, including carbon fiber reinforced PMCs and novel bio-based Martian and Lunar regolith composites designed for in-situ manufacturing. This work aims to provide the fundamental data necessary to understand the effects of crystallinity on thermoplastic PMCs, which is key to advancing their use in space applications.

Thermoplastics↗
NASA NTRS2009

Self-Assembling, Flexible, Pre-Ceramic Composite Preforms

In this innovation, light weight, high temperature, compact aerospace structures with increased design options are made possible by using self-assembling, flexible, pre-ceramic composite materials. These materials are comprised of either ceramic or carbon fiber performs, which are infiltrated with polymer precursors that convert to ceramics upon thermal exposure. The preform architecture can vary from chopped fibers formed into blankets or felt, to continuous fibers formed into a variety of 2D or 3D weaves or braids. The matrix material can also vary considerably. For demonstration purposes, a 2D carbon weave was infiltrated with a SiC polymer precursor. The green or unfired material is fabricated into its final shape while it is still pliable. It is then folded or rolled into a much more compact shape, which will occupy a smaller space. With this approach, the part remains as one continuous piece, rather than being fabricated as multiple sections, which would require numerous seals for eventual component use. The infiltrated preform can then be deployed in-situ. The component can be assembled into its final shape by taking advantage of the elasticity of the material, which permits the structure to unfold and spring into its final form under its own stored energy. The pre-ceramic composites are converted to ceramics and rigidized immediately after deployment. The final ceramic composite yields a high-temperature, high-strength material suitable for a variety of aerospace structures. The flexibility of the material, combined with its high-temperature structural capacity after rigidization, leads to a less complex component design with an increased temperature range. The collapsibility of these structures allows for larger components to be designed and used, and also offers the potential for increased vehicle performance. For the case of collapsible nozzle extensions, a larger nozzle, and thus a larger nozzle exit plane, is possible because interference with surrounding structures can be avoided in the collapsed state. The larger exit plane leads to an increase in expansion area ratio, which has the potential to increase thrust and overall rocket performance. In general, the use of advanced ceramic materials can lead to improved engine and vehicle performance. The ceramics can run hotter, so less cooling is required. Fuel to coolant ratios can be balanced more readily to reduce weight. Engine efficiency can also be increased with hotter combustion and exhaust temperatures. In addition, the ceramic composites themselves can reduce the component weight by as much as 50 percent, which can translate into greater payload for the vehicle

Jaskowiak, Martha H.↗
NASA NTRS2000

Safe Life Propulsion Design Technologies (3rd Generation Propulsion Research and Technology)

The tasks outlined in this viewgraph presentation on safe life propulsion design technologies (third generation propulsion research and technology) include the following: (1) Ceramic matrix composite (CMC) life prediction methods; (2) Life prediction methods for ultra high temperature polymer matrix composites for reusable launch vehicle (RLV) airframe and engine application; (3) Enabling design and life prediction technology for cost effective large-scale utilization of MMCs and innovative metallic material concepts; (4) Probabilistic analysis methods for brittle materials and structures; (5) Damage assessment in CMC propulsion components using nondestructive characterization techniques; and (6) High temperature structural seals for RLV applications.

Ellis, Rod↗
NASA NTRS2002

Morphologies, Processing and Properties of Ceramic Foams and Their Potential as TPS Materials

The current research is focused on processing ceramic foams with compositions that have potential as a thermal protection material. The use of pre-ceramic polymers with the addition of sacrificial blowing agents or sacrificial fillers offers a viable approach to form either open or closed cell insulation. Our work demonstrates that this is a feasible method to form refractory ceramic foams at relatively low processing temperatures. It is possible to foam complex shapes then pyrolize the system to form a ceramic while retaining the shape of the unfired foam. Initial work focused on identifying suitable pre-ceramic polymers with desired properties such as ceramic yield and chemical make up of the pyrolysis product after firing. We focused on making foams in the Si system (Sic, Si02, Si-0-C), which is in use in current acreage TPS systems. Ceramic foams with different architectures were formed from the pyrolysis of pre-ceramic polymers at 1200 C in different atmospheres. In some systems a sacrificial polyurethane was used as the blowing agent. We have also processed foams using sacrificial fillers to introduce controlled cell sizes. Each sacrificial filler or blowing agent leads to a unique morphology. The effect of different fillers on foam morphologies and the characterization of these foams in terms of mechanical and thermal properties are presented. We have conducted preliminary arc jet testing on selected foams with the materials being exposed to typical re-entry conditions for acreage TPS and these results will be discussed. Foams processed using these approaches have bulk densities ranging from 0.15 to 0.9 g/cm3 and cell sizes ranging from 5 to 500 pm. Compression strengths ranged from 2 to 7 MPa for these systems. Finally, preliminary oxidation studies have been conducted on selected systems and will be discussed.

Stackpoole, Mairead↗
NASA NTRS1991

Micromechanics for ceramic matrix composites

The fiber substructuring concepts and the micromechanics equations that are embedded in the Ceramic Matrix Composite Analyzer (CEMCAN) computer code are described as well as the code itself, its current features and capabilities, and some examples to demonstrate the code's versatility. The methodology is equally applicable to metal matrix and polymer matrix composites. The prediction of ply mechanical and thermal properties agree very well with the existing models in the Integrated Composite Analyzer and the Ceramic Matrix Composite Analyzer, lending credence to the fiber substructuring approach. Fiber substructuring can capture greater local detail than conventional unit-cell-based micromechanical theories. It offers promise in simulating complex aspects of micromechanics in ceramic matrix composites.

Murthy, P. L. N.↗
NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic Composites for Aerospace Applications

Polymer matrix composites (PMCs) offer many benefits for the aerospace industry due to their potential for weight reduction when compared to metal or ceramic based materials. Most PMCs currently in flight use thermoset matrices, however, thermoplastic resins are being explored as alternatives due to their ability to be remelted, which is of particular interest due to the potential for in-situ repair and faster production. Most thermoplastic resins are semicrystalline polymers. The properties of semicrystalline thermoplastics are directly influenced by their crystallinity, which can vary due to many factors including thermal treatments, environmental conditions, and mechanical deformation. Within thermoplastic PMC parts, crystallinity gradients can arise due to variations in part geometry, across part thicknesses, and along bonded joints. Monitoring the crystallinity of thermoplastic composites is key to ensuring these materials meet the high demands required for aerospace. Several different analytical techniques exist that can be used to characterize the bulk crystallinity of thermoplastic materials. However, many existing methods lack the specificity required to identify the subtle variations in crystallinity that may play a significant role in the performance and durability of PMC parts. Because of this, a significant amount of work is still required to fully characterize and understand the crystallinity profiles of thermoplastic PMCs and the resulting impact to material properties. This talk discusses the use of multiple techniques such as Differential Scanning Calorimetry, Polarized Light Optical Microscopy, and Fourier-Transform Infrared Spectroscopy to characterize the crystallinity in carbon fiber/thermoplastic composites. Samples of different crystallinity profiles were manufactured using various cooling procedures. This work aims to provide the fundamental data necessary to understand the effects of crystallinity on thermoplastic PMCs, which is key to advancing their use in aerospace applications.

Thermoplastics↗
NASA NTRS1992

Progress report

The NASA funding allowed Clark Atlanta University (CAU) to establish a High Performance Polymers And Ceramics (HiPPAC) Research Center. The HiPPAC Center is consolidating and expanding the existing polymer and ceramic research capabilities at CAU through the development of interdepartmental and interinstitutional research in: (1) polymer synthesis; (2) polymer characterization and properties; (3) polymer processing; (4) polymer-based ceramic synthesis; and (5) ceramic characterization and properties. This Center has developed strong interactions between scientists and materials scientists of CAU and their counterparts from sister institutions in the Atlanta University Center (AUC) and the Georgia Institute of Technology. As a component of the center, we have started to develop strong collaborations with scientists from other universities and the HBCU's, national and federal agency laboratories, and the private sector during this first year. During this first year we have refined the focus of the research in the HiPPAC Center to three areas with seven working groups that will start programmatic activities on January 1, 1993, as follows: (1) nonlinear optical properties of chitosan derivatives; (2) polymeric electronic materials; (3) nondestructive characterization and prediction of polyimide performance; (4) solution processing of high-performance materials; (5) processable polyimides for composite applications; (6) sol-gel based ceramic materials processing; and (7) synthetic based processing of pre-ceramic polymers.

Abhiraman, A.↗
NASA NTRS1997

Metal oxide-polymer composites

A method of making metal oxide clusters in a single stage by reacting a metal oxide with a substoichiometric amount of an acid in the presence of an oxide particle growth terminator and solubilizer. A method of making a ceramer is also disclosed in which the metal oxide clusters are reacted with a functionalized polymer. The resultant metal oxide clusters and ceramers are also disclosed.

Wellinghoff, Stephen T.↗
NASA NTRS1994

Metal oxide-polymer composites

A method of making metal oxide clusters in a single stage by reacting a metal oxide with a substoichiometric amount of an acid in the presence of an oxide particle growth terminator and solubilizer. A method of making a ceramer is also disclosed in which the metal oxide clusters are reacted with a functionalized polymer. The resultant metal oxide clusters and ceramers are also disclosed.

Wellinghoff, Stephen T.↗
NASA NTRS1982

Advanced Materials Technology

Composites, polymer science, metallic materials (aluminum, titanium, and superalloys), materials processing technology, materials durability in the aerospace environment, ceramics, fatigue and fracture mechanics, tribology, and nondestructive evaluation (NDE) are discussed. Research and development activities are introduced to the nonaerospace industry. In order to provide a convenient means to help transfer aerospace technology to the commercial mainstream in a systematic manner.

Charles P. Blankenship↗
NASA NTRS2006

The Cutting Edge of High-Temperature Composites

NASA s Ultra-Efficient Engine Technology (UEET) program was formed in 1999 at Glenn Research Center to manage an important national propulsion program for the Space Agency. The UEET program s focus is on developing innovative technologies to enable intelligent, environmentally friendly, and clean-burning turbine engines capable of reducing harmful emissions while maintaining high performance and increasing reliability. Seven technology projects exist under the program, with each project working towards specific goals to provide new technology for propulsion. One of these projects, Materials and Structures for High Performance, is concentrating on developing and demonstrating advanced high-temperature materials to enable high-performance, high-efficiency, and environmentally compatible propulsion systems. Materials include ceramic matrix composite (CMC) combustor liners and turbine vanes, disk alloys, turbine airfoil material systems, high-temperature polymer matrix composites, and lightweight materials for static engine structures.

Source record↗
NASA NTRS2021

Microstructural, Strength, and Creep Characterization of Sylramic™, Sylramic™-iBN and Super Sylramic™-iBN SiC Fibers

The chemical composition, microstructure, strength, and thermal stability of polymer-derived Sylramic™ SiC fibers fabricated by Dow Corning and COI Ceramics, Inc., and nitrogen-treated Sylramic™ SiC fibers, referred to as Sylramic™-iBN and Super Sylramic™-iBN SiC fibers, were investigated and compared. The baseline Sylramic™ SiC fibers fabricated by both vendors as well as the nitrogen-treated Sylramic™ SiC fibers are composed mostly of β-SiC (~97 wt%) with small amounts of TiB2 (~2 wt%), amorphous carbon (~1 wt%) and trace amounts of B4C. Most of the amorphous carbon is segregated at the core/interior of the fibers. Both baseline and nitrogen-treated Sylramic™ SiC fibers have similar grain size and pore size distribution, except for a thin layer of in-situ grown crystalline BN (30 to 70 nm) on the surface of Sylramic™-iBN and Super Sylramic™-iBN fibers. Wide variation in strength within a batch as well as between batches is observed in both baseline and nitrogen-treated Sylramic™ SiC fibers but both types of fibers are microstructurally stable at temperatures to 1800°C in argon and nitrogen environments compared to Nicalon™-S and Tyranno®-SA SiC fibers. Under the same creep condition, Super Sylramic™-iBN fibers show better creep resistance compared to Sylramic™, Sylramic™-iBN, Hi-Nicalon™-S, and Tyranno®-SA fibers. Possible reasons for strength variability and the mechanism of in-situ BN formation on Sylramic™ SiC fibers are discussed.

SiC fibers↗
NASA NTRS1990

Development of polysilsesquioxane composites

Polymer composites are increasingly being required to operate for prolonged durations at higher temperatures than in the past. Hence there have been increased efforts devoted to synthesizing and characterizing polymers capable of withstanding temperatures greater than 300 C for long periods. Several such organic polymers have been investigated in recent times. This research effort seeks to enquire if inorganic polymers can be utilized to provide the same result. Ceramics have long been recognized as providing superior thermal properties for demanding applications. However, the extremely high softening temperatures preclude their being shaped into complex shapes through melt processing techniques common to organic polymers. One approach towards solving this problem has been through the development of preceramic polymers. These are capable of being processed in the polymeric state with ease, and subsequently being pyrolyzed to ceramic structures. This experimental study is aimed at studying the feasibility of using preceramic polymers (that have not been subject to the pyrolysis step) as high performance composite matrices for high temperature applications. A preliminary study of this nature is not geared towards optimizing mechanical properties suitable for such composites. Rather, this study attempts to process such resins in composite form and suitably characterize their properties.

Srinivasan, K.↗
NASA NTRS1987

Heat's on to develop high-temperature materials

An evaluation is made of the state-of-the-art and foreseeable development prospects in high temperature engineering materials applicable to advanced heat engines and other aerothermodynamically affected structures. Attention is given to monocrystal- and microcrystal-producing metal solidification processes, soft oxide and chemically stable fluoride high temperature solid lubricants, polyimide and other high temperature polymers for propulsion system applications, high strength/toughness ceramics for heat engine structural components, thermal barrier coatings, and metal-matrix composites employing refractory matrices as well as reinforcing fibers.

Gray, Hugh R.↗
NASA NTRS2001

Polymer/Silicate Nanocomposites Developed for Improved Thermal Stability and Barrier Properties

The nanoscale reinforcement of polymers is becoming an attractive means of improving the properties and stability of polymers. Polymer-silicate nanocomposites are a relatively new class of materials with phase dimensions typically on the order of a few nanometers. Because of their nanometer-size features, nanocomposites possess unique properties typically not shared by more conventional composites. Polymer-layered silicate nanocomposites can attain a certain degree of stiffness, strength, and barrier properties with far less ceramic content than comparable glass- or mineral-reinforced polymers. Reinforcement of existing and new polyimides by this method offers an opportunity to greatly improve existing polymer properties without altering current synthetic or processing procedures.

Campbell, Sandi G.↗