Accelerator Tests of Large Area Silicon Detectors for the Advanced Composition Explorer (ACE) Mission
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cosmic rays solar isotope spectrometer SIS cosmic ↗
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Apparatus for Hot Impact Testing of Material Specimens
An apparatus for positioning and holding material specimens is a major subsystem of a system for impact testing of the specimens at temperatures up to 1,500 C. This apparatus and the rest of the system are designed especially for hot impact testing of advanced ceramics, composites, and coating materials. The apparatus includes a retaining fixture on a rotating stage on a vertically movable cross support driven by a linear actuator. These components are located below a furnace wherein the hot impact tests are performed (see Figure 1). In preparation for a test, a specimen is mounted on the retaining fixture, then the cross support is moved upward to raise the specimen, through an opening in the bottom of the furnace, to the test position inside the furnace. On one side of the furnace there is another, relatively small opening on a direct line to the specimen. Once the specimen has become heated to the test temperature, the test is performed by using an instrumented external pressurized-gas-driven gun to shoot a projectile through the side opening at the specimen.
Pawlik, Ralph J.↗
Shearography NDE of NASA COPV
1. 21 Composite Over-wrapped Pressure Vessels (COPV) consisting of Kevlar Space Shuttle Fleet Leaders and Graphite COPV were inspected at NASA WSTF, NM from Sept. 12 through Sept 16. 2. The inspection technique was Pressurization Shearography, tests designed to image composite material damage, degradation or design flaws leading to stress concentrations in the axial or hoop strain load path. 3. The defect types detected consisted of the following: a) Intentional impact damage with known energy. b) Un-intentional impact damage. c) Manufacturing defects. 4. COPV design features leading to strain concentrations detected include: a) Strain concentrations at bosses due to fiber closure pattern. b) Strain concentrations in body of COPV due to fiber wrap pattern. c) Strain concentrations at equator due to liner weld/fiber lay-up.
Newman, John W.↗
Processing and Characterization of Basalt Fiber Reinforced Ceramic Composites for High Temperature Applications Using Polymer Precursors
The development of high temperature structural composite materials has been very limited due to the high cost of the materials and the processing needed. Ceramics can take much higher temperatures, but they are difficult to produce and form in bulk volumes. Polymer Derived Ceramics (PDCs) begin as a polymer matrix, allowing a shape to be formed and cured and then to be pyrolized in order to obtain a ceramic with the associated thermal and mechanical properties. The two PDCs used in this development are polysiloxane and polycarbosilane. Polysiloxanes contain a silicon oxycarbide backbone when pyrolized up to 1000 deg C. Polycarbosilane, an organosilicon polymer, contain a silicon-carbon backbone; around 1200 deg C, Beta-SiC begins to crystallize. The use of basalt in structural and high temperature applications has been under development for over 50 years, yet there has been little published research on the incorporation of basalt fibers as a reinforcement in composites. Basalt is a naturally occurring material found in volcanic rock. Continuous basalt fiber reinforced PDCs have been fabricated and tested for the applicability of this composite system as a high temperature structural composite material. Thermal and mechanical testing includes oxyacetylene torch testing and three point bend testing.
Polymer Derived Ceramics↗
Oxidation Resitant HfC-TaC Rocket Thruster for High Performance Propellants
The purpose of this reasearch effort was to develop high temperature, oxidation resistant thrusters which would lessen the thruster cooling requirements, resulting in increased performance and longer life for onboard propulsion systems for spacecraft. This research effort focussed on developing ceramic matrix composites (CMCs) for this application, and specifically investigated the use of HfC stabilized with TaC. This material composition can potentially operate in a stoichiometric oxygen to hydrogen ratio at a temperature of 5000 deg F (2760 deg C) in a radiatively cooled mode. Various compositions of Hafnium Carbide (HfC) and Tantalum Carbide (TaC) were deposited by chemical vapor deposition (CVD) and tested, in an attempt to identify the composition which offered the best oxidation resistance. Although it was identified that small amounts of TaC appeared to offer improved oxidation resistance over HfC alone, an optimal composition was not identified. A 251bf thruster was fabricated from a novel CMC sandwich construction with a HfC-TaC matrix, and survived two test firings, each of 5 seconds before a failure in the injector caused the run to be aborted. It was not possible to control the relative stoichiometry of the HfC and TaC composition throughout the reactor due to the large difference in the thermodynamics of the HfC and TaC formation from their respective chlorides. This also resulted in an inability to infiltrate TaC into the preform under the experimental conditions investigated. Other material compositions were fabricated and tested and two material systems; HfC-SiC functionally graded to C(sub f)/C and Re functionally graded to C(sub f)/C were selected for further testing. These functionally graded composites have use in a number of propulsion applications presently of interest to NASA and the defense industry. Their ability to withstand extremely hostile thermal environments and the light-weight and high-strength exhibited from the C(sub f)/C composite make these materials particularly suited for these applications. In the Phase III which is presently underway, Re functionally graded to C(sub f)/C is being further developed and tested for application in the thrust cells for the Linear Aerospike Engine for the X33 and RLV.
Patterson, Mark↗
Effect of rolling on the high temperature tensile and stress-rupture properties of tungsten fiber-superalloy composites
An investigation was conducted to determine the effects of mechanical working on the 1093 C tensile and stress-rupture strength of tungsten alloy/superalloy composites. Hot pressed composites containing either conventional tungsten lamp filament wire or tungsten-1% ThO2 wire and a nickel base alloy matrix were hot rolled at 1093 C. The hot pressed and rolled composite specimens were then tested in tension and stress-rupture at 1093 C. Rolling decreased the degree of fiber-matrix reaction as a function of time of exposure at 1093 C. The stress-rupture properties of the rolled composites were superior to hot pressed composites containing equivalent diameter fibers. Rolling did not appreciably affect the 1093 C ultimate tensile strength of the composites.
Petrasek, D. W.↗
Develop Engineered Forms of MOF with Polymers
At Pacific Northwest National Laboratory, mechanical robust composite materials were developed and tested from a gas mixture relevant to potential future nuclear reprocessing applications. Several composite materials were produced using the wet granulation method, which is very scalable. Metal organic framework (MOFs) composite materials were produced using a well-known polymer as binder (poly methyl methyl acrylate) to convert a fine microcrystalline powder into shaped bodies while preserving the intrinsic properties of MOFs. The resulting MOF composite shows an improved mechanical stability (>100% compare to MOF beads without polymer) in comparison with nuclear-grade activated-carbon pellets and with minimal loss of adsorption capacity (~10% reduction) at room temperature.
36 MATERIALS SCIENCE↗
Sensitivity Effects of Hollow Glass Micro-Balloon Doping on RDX-Based Explosives
Sensitivity to initiation is an important characteristic of high explosives. Many chemical and physical properties are fine-tuned to deliver an energetic material that behaves according to the user’s specifications exactly. In some cases, it is advantageous to study the effects that non energetic additives have on the performance of an explosive material. Following on the promising results obtained in other experiments, a study is conducted on the effects of hollow glass micro-balloons (bubbles, spheres), or HGMB, on a material’s sensitivity. Threshold test data is compared between several formulations of explosives. The control formulation is an RDX-based explosive with a non-energetic binder, and the test formulations are identical in composition, but with the addition of HGMB, up to 6% by volume. Safety testing of the new HGMB-doped explosive formulations is conducted to ensure they can be produced and handled safely prior to intentional detonation. This experiment utilizes an attenuation card of varying thicknesses between the initiator and the test article to attenuate the shock imparted, and a witness plate is analyzed for each test article to determine a GO or NO GO result. The data collected and the conclusions of this study affect how additives like HGMB are utilized in future explosive sensitivity threshold experiments.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Interlaminar fracture of composites
Fracture mechanics has been found to be a useful tool for understanding composite delamination. Analyses for calculating strain energy release rates associated with delamination growth have been developed. These analyses successfully characterized delamination onset and growth for particular sources of delamination. Low velocity impact has been found to be the most severe source of composite delamination. A variety of test methods for measuring interlaminar fracture toughness are being developed to identify new composite materials with enhanced delamination resistance.
Obrien, T. K.↗
Interlaminar fracture of composites
Fracture mechanics has been found to be a useful tool for understanding composite delamination. Analyses for calculating strain energy release rates associated with delamination growth have been developed. These analyses successfully characterized delamination onset and growth for particular sources of delamination. Low velocity impact has been found to be the most severe source of composite delamination. A variety of test methods for measuring interlaminar fracture toughness are being developed to identify new composite materials with enhanced delamination resistance.
Obrien, T. K.↗
Durability of composites
Fiber reinforced materials (composites) are considered very seriously for use in primary loadbearing structures. However, the pace at which they will actually be introduced into the structural designs of the future very much depends on the solution of a critical problem, which is the inability to predict the long term behavior of the material in a given service environment. The research and development of integrity evaluation and lifetime prediction schemes for composite materials is thus a burning issue. The information presented is part of an ongoing program which is directed toward and accelerated determination of the endurance limits of composite materials. Real-time testing is simply not feasible because enough integrity has to be designed into composite structures such that they have a service life which is often as long as twenty or thirty years.
Hiel, Clem C.↗
Mechanical and analytical screening of braided composites for transport fuselage applications
The mechanics of materials progress in support of the goal of understanding the application of braided composites in a transport aircraft fuselage are summarized. Composites consisting of both 2-D and 3-D braid patterns are investigated. Both consolidation of commingled graphite/PEEK and resin transfer molding of graphite-epoxy braided composite processes are studied. Mechanical tests were used to examine unnotched tension, open hole tension, compression, compression after impact, in-plane shear, out-of-plane tension, bearing, and crippling. Analytical methods are also developed and applied to predict the stiffness and strengths of test specimens. A preliminary study using the test data and analytical results is performed to assess the applicability of braided composites to a commercial aircraft fuselage.
Fedro, Mark J.↗
Advanced thermoset resins for fire-resistant composites
The thermal and flammability properties of some thermoset polymers and composites are described. The processing and evaluation of composites fabricated from currently used resins and advanced fire-resistant resins are also described. Laboratory test methodology used to qualify candidate composite materials includes thermochemical characterization of the polymeric compounds and evaluation of the glass reinforced composites for flammability and smoke evolution. The use of these test methods will be discussed in comparing advanced laminating resins and composites consisting of modified epoxies, phenolics and bismaleimide, with conventional baseline materials consisting of epoxy.
Kourtides, D. A.↗
Assessment of Long Term Creep Using Strain Rate Matching From the Stepped Isostress Method
Creep testing is an ongoing need, particularly with the development of new candidate alloy systems for advanced energy systems. The conventional creep test (CT) is regarded as a proven method to gather creep data however, the test is impractical due to being real-time: lasting up to 105 hours to characterize the service of long-lived turbomachinery components. Accelerated methods to gather the long-term creep properties of materials are needed to reduce the time to qualification of new materials. The time-temperature-stress-superposition principle (TTSSP) and the derivative time-temperature superposition principle (TTSP), time-stress superposition principle (TSSP), stepped isothermal method (SIM), and stepped isostress method (SSM) are accelerated creep tests (ACT) commonly used to predict the long-term creep behaviors of polymers and composites. The TTSP and TSSP tests require multiple specimen tested at various temperatures/stresses whereas the SIM and SSM tests employ a single specimen where temperature/stress are periodically step increased until rupture. The stepped creep deformation curve can then be time and strain shifted to produce a master creep curve. While these ACTs are useful tools to predict long-term creep, the drawback is the lack of mathematical laws to determine the virtual start time and time shift factors, especially for different materials. In this paper, a new self-calibration approach is developed and compared to existing SSM data for Kevlar 49. This new approach focuses on matching the creep strain rates between stress steps and fitting the data to a master curve using a modified theta projection model. This is performed using a MATLAB code consisting of five subroutines. The first subroutine takes the stress, time, and creep strain from SSM/SIM tests, and segregates the data intro arrays corresponding to each stress level. The second subroutine finds the constants for the modified theta projection model for each stress level. The third subroutine performs a time shift adjustment using creep strain rate matching. The fourth subroutine calculates the accelerated time of rupture. The last subroutine generates accelerated creep versus time plots. Kevlar 49 SSM data is gathered from literature and run through the MATLAB code. The master curves generated from the MATLAB are compared to the conventional creep curve of Kevlar 49 as well as the master curve gathered from literature in order to validate the feasibility of this new approach. The goal of this project is to vet if the self-calibration approach can produce results similar to the reference calibration approach.
36 MATERIALS SCIENCE↗
Damage Simulation in Composite Materials: Why It Matters and What Is Happening Currently at NASA in This Area
Use of lightweight composite materials in space and aircraft structure designs is often challenging due to high costs associated with structural certification. Of primary concern in the use of composite structures is durability and damage tolerance. This concern is due to the inherent susceptibility of composite materials to both fabrication and service induced flaws. Due to a lack of general industry accepted analysis tools applicable to composites damage simulation, a certification procedure relies almost entirely on testing. It is this reliance on testing, especially compared to structures comprised of legacy metallic materials where damage simulation tools are available, that can drive costs for using composite materials in aerospace structures. The observation that use of composites can be expensive due to testing requirements is not new and as such, research on analysis tools for simulating damage in composite structures has been occurring for several decades. A convenient approach many researchers/model-developers in this area have taken is to select a specific problem relevant to aerospace structural certification and develop a model that is accurate within that scope. Some examples are open hole tension tests, compression after impact tests, low-velocity impact, damage tolerance of an embedded flaw, and fatigue crack growth to name a few. Based on the premise that running analyses is cheaper than running tests, one motivation that many researchers in this area have is that if generally applicable and reliable damage simulation tools were available the dependence on certification testing could be lessened thereby reducing overall design cost. It is generally accepted that simulation tools if applied in this manner would still need to be thoroughly validated and that composite testing will never be completely replaced by analysis. Research and development is currently occurring at NASA to create numerical damage simulation tools applicable to damage in composites. The Advanced Composites Project (ACP) at NASA Langley has supported the development of composites damage simulation tools in a consortium of aerospace companies with a goal of reducing the certification time of a commercial aircraft by 30%. And while the scope of ACP does not include spacecraft, much of the methodology and simulation capabilities can apply to spacecraft certification in the Space Launch System and Orion programs as well. Some specific applications of composite damage simulation models in a certification program are (1) evaluation of damage during service when maintenance may be difficult or impossible, (2) a tool for early design iterations, (3) gaining insight into a particular damage process and applying this insight towards a test coupon or structural design, and (4) analysis of damage scenarios that are difficult or impossible to recreate in a test. As analysis capabilities improve, these applications and more will become realized resulting in a reduction in cost for use of composites in aerospace vehicles. NASA is engaged in this process from both research and application perspectives. In addition to the background information discussed previously, this presentation covers a look at recent research at NASA in this area and some current/potential applications in the Orion program.
McElroy, Mack↗
Constraints on the Origin of Mercury’s Large Core from Core-Mantle Differentiation Models
Mercury’s core is notoriously large when compared to other planets of our solar system. The origin of this large core is still uncertain. Available data on the surface composition and internal structure of Mercury from the past MESSENGER mission and future data collected by BepiColombo will continue to provide clues to Mercury’s formation. Here, we present results combining experimental data on elemental distribution between core and mantle with spacecraft data, to estimate bulk Mercury composition. We applied this strategy to major elements (Fe, Si, Mg, Al and O), as well as minor elements (Cr and Ti), and compared derived compositions to chondritic data and the chemical compositions of the other terrestrial planets. Our results show that Mercury has a chemical composition significantly different from all known materials of the solar system. In addition, numerous scenarios were proposed to explain Mercury’s structure, including “chaotic models” such as giant impacts and “orderly models” such as aerodynamic sorting. Here, we tested whether Mercury’s composition can be explained by mantle stripping by impacts. We will show how such a scenario reconciles several features of Mercury’s geochemistry with chondritic data. We will also discuss the outlook of additional constraints from supplementary data potentially collected by BepiColombo.
Mercury↗
Measurements of extinct fission products in nuclear bomb debris: Determination of the yield of the Trinity nuclear test 70 y later
This study describes an approach to measuring extinct fission products that would allow for the characterization of a nuclear test at any time. The isotopic composition of molybdenum in five samples of glassy debris from the 1945 Trinity nuclear test has been measured. Nonnatural molybdenum isotopic compositions were observed, reflecting an input from the decay of the short-lived fission products 95 Zr and 97 Zr. By measuring both the perturbation of the 95 Mo/ 96 Mo and 97 Mo/ 96 Mo isotopic ratios and the total amount of molybdenum in the Trinity nuclear debris samples, it is possible to calculate the original concentrations of the 95 Zr and 97 Zr isotopes formed in the nuclear detonation. Together with a determination of the amount of plutonium in the debris, these measurements of extinct fission products allow for new estimates of the efficiency and yield of the historic Trinity test.
73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
Tensile strength of composite sheets with unidirectional stringers and crack-like damage
The damage tolerance characteristics of metal tension panels with riveted and bonded stringers are well known. The stringers arrest unstable cracks and retard propagation of fatigue cracks. Residual strengths and fatigue lives are considerably greater than those of unstiffened or integrally stiffened sheets. The damage tolerance of composite sheets with bonded composite stringers loaded in tension was determined. Cracks in composites do not readily propagate in fatigue, at least not through fibers. Moreover, the residual strength of notched composites is sometimes even increased by fatigue loading. Therefore, the residual strength aspect of damage tolerance, and not fatigue crack propagation, was investigated. About 50 graphite/epoxy composite panels were made with two sheet layups and several stringer configurations. Crack-like slots were cut in the middle of the panels to simulate damage. The panels were instrumented and monotonically loaded in tension to failure. The tests indicate that the composite panels have considerable damage tolerance, much like metal panels. The stringers arrested cracks that ran from the crack-like slots, and the residual strengths were considerably greater than those of unstiffened composite sheets. A stress intensity factor analysis was developed to predict the failing strains of the stiffened panels. Using the analysis, a single design curve was produced for composite sheets with bonded stringers of any configuration.
Poe, C. C., Jr.↗