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NASA NTRS2000

Directionally Solidified Ceramics Produced

Produced Multiphase, interpenetrating structures are an alternative route to obtaining structural ceramic materials with adequate strength, toughness, and stability for high-temperature aerospace applications. The eutectic architecture, a continuous-reinforcing phase within a higher volume phase or matrix, can be described as a naturally occurring, in situ composite. The phases of a eutectic are thermodynamically compatible at high homologous temperatures. Strong and stable materials have been produced. Toughness, however, remains a technical obstacle. The potential for producing materials with enhanced toughness along with adequate strength and stability was demonstrated using the laser-heated float zone (LHFZ) growth method at the NASA Glenn Research Center at Lewis Field. LHFZ growth at Glenn provides a means to efficiently produce and record the underlying growth phenomena associated with two-phase structures. To initiate directional solidification, a seed of single-crystal sapphire (<0001> direction) was lowered onto the molten liquid until wetting occurred and then withdrawn at a constant rate. Neither the crystal nor the source rod was rotated. The materials produced were tested mechanically in tension, and the resulting microstructure was examined with a scanning electron microscope. Both the inherent properties of the constituent phases and the properties of the interface between them affect the mechanical behavior and the fracture surfaces. The following scanning electron micrographs show the microstructures of two different materials that were tested to failure in tension. In the left micrograph, the flat fracture surface is typical of a material that is strong but has low toughness. In the right micrograph, the crack is effectively deflected at the interface between the two phases, achieving higher toughness at moderately lower strength levels. Conducting mechanical tests to determine the high temperature properties of these materials is the next step in determining their eventual suitability.

Farmer, Serene C.↗

NASA NTRS2003

Functionally Graded Nanophase Beryllium/Carbon Composites

Beryllium, beryllium alloys, beryllium carbide, and carbon are the ingredients of a class of nanophase Be/Be2C/C composite materials that can be formulated and functionally graded to suit a variety of applications. In a typical case, such a composite consists of a first layer of either pure beryllium or a beryllium alloy, a second layer of B2C, and a third layer of nanophase sintered carbon derived from fullerenes and nanotubes. The three layers are interconnected through interpenetrating spongelike structures. These Be/Be2C/C composite materials are similar to Co/WC/diamond functionally graded composite materials, except that (1) W and Co are replaced by Be and alloys thereof and (2) diamond is replaced by sintered carbon derived from fullerenes and nanotubes. (Optionally, one could form a Be/Be2C/diamond composite.) Because Be is lighter than W and Co, the present Be/Be2C/C composites weigh less than do the corresponding Co/WC/diamond composites. The nanophase carbon is almost as hard as diamond. WC/Co is the toughest material. It is widely used for drilling, digging, and machining. However, the fact that W is a heavy element (that is, has high atomic mass and mass density) makes W unattractive for applications in which weight is a severe disadvantage. Be is the lightest tough element, but its toughness is less than that of WC/Co alloy. Be strengthened by nanophase carbon is much tougher than pure or alloy Be. The nanophase carbon has an unsurpassed strength-to-weight ratio. The Be/Be2C/C composite materials are especially attractive for terrestrial and aerospace applications in which there are requirements for light weight along with the high strength and toughness of the denser Co/WC/diamond materials. These materials could be incorporated into diverse components, including cutting tools, bearings, rocket nozzles, and shields. Moreover, because Be and C are effective as neutron moderators, Be/Be2C/C composites could be attractive for some nuclear applications.

Voronov, Oleg A.↗

NASA NTRS2003

Functionally Graded Nanophase Beryllium/Carbon Composites

Choi, Michael K.↗

NASA NTRS1989

Interpenetrating polymer networks from acetylene terminated materials

As part of a program to develop high temperature/high performance structural resins for aerospace applications, the chemistry and properties of a novel class of interpenetrating polymer networks (IPNs) were investigated. These IPNs consist of a simple diacetylenic compound (aspartimide) blended with an acetylene terminated arylene ether oligomer. Various compositional blends were prepared and thermally cured to evaluate the effect of crosslink density on resin properties. The cured IPNs exhibited glass transition temperatures ranging from 197 to 254 C depending upon the composition and cure temperature. The solvent resistance, fracture toughness and coefficient of thermal expansion of the cured blends were related to the crosslink density. Isothermal aging of neat resin moldings, adhesive and composite specimens showed a postcure effect which resulted in improved elevated temperature properties. The chemistry, physical and mechanical properties of these materials will be discussed.

Connell, J. W.↗

NASA NTRS1996

Low Crossover Polymer Electrolyte Membranes for Direct Methanol Fuel Cells

Direct Methanol Fuel Cells (DMFC's) using polymer electrolyte membranes are promising power sources for portable and vehicular applications. State of the art technology using Nafion(R) 117 membranes (Dupont) are limited by high methanol permeability and cost, resulting in reduced fuel cell efficiencies and impractical commercialization. Therefore, much research in the fuel cell field is focused on the preparation and testing of low crossover and cost efficient polymer electrolyte membranes. The University of Southern California in cooperation with the Jet Propulsion Laboratory is focused on development of such materials. Interpenetrating polymer networks are an effective method used to blend polymer systems without forming chemical links. They provide the ability to modify physical and chemical properties of polymers by optimizing blend compositions. We have developed a novel interpenetrating polymer network based on poly (vinyl - difluoride)/cross-linked polystyrenesulfonic acid polymer composites (PVDF PSSA). Sulfonation of polystyrene accounts for protonic conductivity while the non-polar, PVDF backbone provides structural integrity in addition to methanol rejection. Precursor materials were prepared and analyzed to characterize membrane crystallinity, stability and degree of interpenetration. USC JPL PVDF-PSSA membranes were also characterized to determine methanol permeability, protonic conductivity and sulfur distribution. Membranes were fabricated into membrane electrode assemblies (MEA) and tested for single cell performance. Tests include cell performance over a wide range of temperatures (20 C - 90 C) and cathode conditions (ambient Air/O2). Methanol crossover values are measured in situ using an in-line CO2 analyzer.

Prakash, G. K. Surya↗

NASA NTRS1990

Plastic deformation mechanisms in polyimide resins and their semi-interpenetrating networks

High-performance thermoset resins and composites are critical to the future growth of space, aircraft, and defense industries in the USA. However, the processing-structure-property relationships in these materials remain poorly understood. In the present ASEE/NASA Summer Research Program, the plastic deformation modes and toughening mechanisms in single-phase and multiphase thermoset resins were investigated. Both thermoplastic and thermoset polyimide resins and their interpenetrating networks (IPNs and semi-IPNs) were included. The fundamental tendency to undergo strain localization (crazing and shear banding) as opposed to a more diffuse (or homogeneous) deformation in these polymers were evaluated. Other possible toughening mechanisms in multiphase thermoset resins were also examined. The topological features of network chain configuration/conformation and the multiplicity of phase morphology in INPs and semi-IPNs provide unprecedented opportunities for studying the toughening mechanisms in multiphase thermoset polymers and their fiber composites.

Jang, Bor Z.↗

NASA NTRS2002

Novel High Efficient Organic Photovoltaic Materials: Appendix for Summary of Research

There are many different kinds of conjugated polymers that may be useful in photovoltaic devices. So far, the most popular and successful conjugated polymers used in photovoltaic devices include poly(1,4-)phenylenevinylenes (PPV), C60 and their derivatives. The discovery of electro-luminescence in PPV has stimulated a great deal of interest in developing "plastic" solid-state semiconductor devices. The overall synthetic methodology for the preparation of PPV can be divided into three main categories: (1) side chain derivatization, (2) precursor approach, and (3) in-situ polymerization. In this project, the first method was adopted. As discussed in project proposal and literatures, the overall efficiency of photovoltaic devices containing conjugated polymers is determined by the materials ability to generate excitons from incoming radiation, and then to separate the charges at donor/acceptor interfaces, and then to transport charges to respective electrodes. Given that effective exciton diffusion range are typical less then 30 nm, unique morphological structures are needed. This need led to several research groups to the idea that interpenetrating or bi-continuous networks of donor (electron donating) and acceptor (electron withdrawing) polymers should give better results. One approach involved the use of functionalized PPV. The attachment of electron withdrawing cyano groups to a PPV forms the CN-PPV, making it a strong electron acceptor. Underivatized PPV is a generally considered a hole-transporting material. Using blends of MEH-PPV, a soluble donor PPV derivative, as a hole transporter and CN-PPV as an electron transporter, a quantum efficiencies of up to 6% was achieved.

Sun, Sam↗

NASA NTRS1986

Epoxy/Fluoroether Composites

Composite materials made from unfilled and glass-fiber-reinforced epoxy toughened by copolymerization with elastomeric prepolymers of perfluoroalkyl ether diacyl fluoride (EDAF). Improved properties due to hydrogen bonding between rubber phase and epoxy matrix, plus formation of rubberlike phase domains that molecularly interpenetrate with epoxy matrix. With optimum rubber content, particle size, and particle shape, entire molecular structure reinforced and toughened. Improved composites also show increased failure strength, stiffness, glass-transition temperature, and resistance to water.

Rosser, R. W.↗

NASA NTRS1990

Film properties of high performance semi-interpenetrating polyimide networks

Consideration is given to an approach to provide a semi-IPN in which two constituent materials have nearly the same chemical structure and polymer chain length. A reactive endcapped LARC-TPI polyamic acid having a formulated molecular weight of 20,000 is prepared and then combined with various quantities of a commercial LARC-TPI polyamic acid solution. The polyimide films of semi-IPNs are tested along with two constituent materials. The physical and mechanical properties of the polyimide films are presented. The applicability of using this approach to minimize phase separation and to maximize long-term phase stability is discussed. The concept of controlling morphology by chemistry is proven for providing LARC-TPI based semi-2-IPNs. A very long chain LARC-TPI endcapped with a nadic group exhibits physical properties almost identical to unendcapped LARC-TPI.

Gerber, M. K.↗

NASA NTRS1996

Far-Infrared Water Emissions from Magnetohydrodynamic Shock Waves

Nondissociative, magnetohydrodynamic, C-type shock waves are expected to be a prodigious source of far-infrared water emissions in dense interstellar regions. We have constructed a model to calculate the farinfrared H20 line spectra that emerge from such shocks. Using the best estimates currently available for the radiative cooling rate and the degree of ion-neutral coupling within the shocked gas, we modeled the temperature structure of MHD shocks using standard methods in which the charged and neutral particles are treated separately as two weakly coupled, interpenetrating fluids. Then we solved the equations of statistical equilibrium to find the populations of the lowest 179 and 170 rotational states of ortho- and para-H2O We have completed an extensive parameter study to determine the emergent H2O line luminosities as a function of preshock density in the range n(H2) equals 10(exp 4) - 10(sup 6.5)/cc and shock velocity in the range upsilon(sub s) = 5 - 40 km/ s. We find that numerous rotational transitions of water are potentially observable using the Infrared Space Observatory and the Submillimeter Wave Astronomy Satellite and may be used as diagnostics of the shocked gas. We have also computed the rotational and ro-vibrational emissions expected from H2, CO, and OH, and we discuss how complementary observations of such emissions may be used to further constrain the shock conditions. In common with previous studies, we come close to matching the observed H2, and high-J CO emissions from the Orion-KL star-forming region on the basis of a single shock model. We present our predictions for the strengths of H2O line emission from the Orion shock, and we show how our results may be scaled to other regions where molecular shocks are likely to be present.

Kaufman, Michael J.↗

NASA NTRS2000

Solid Freeform Fabrication of Continuous Fiber Reinforced Composites for Propulsion Applications

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500'C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible- manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. This is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths With carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites-, they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP process.

Vaidyanathan, R.↗

NASA NTRS2001

Solid Free-Form Fabrication of Continuous Fiber Reinforced Composites for Propulsion Application

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500 C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible-manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. M is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths with carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites; they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP processes.

Vaidyanathan, R.↗

NASA NTRS1991

Nonlinear optical properties of organic materials: A theoretical study

Replacement of electronic switching circuits in computing and telecommunication systems with purely optical devices offers the potential for extremely high throughput and compact information processing systems. The potential application of organic materials containing molecules with large nonresonant nonlinear effects in this area have triggered intensive research during the last decade. Interest on this area was due to two facts: (1) that many organic materials show nonlinearities that are orders of magnitude larger than those of conventional inorganic materials such as lithium niobate and potassium dihydrogen phosphate; and (2) that organic materials show much flexibility in terms of molecular designs. Some of the desirable characteristics that these materials should have are that they be transparent to the frequency of the incident laser and its second or third harmonic, that they have a high damage threshold, and, in the case of second-order effects, that their crystal structure or molecular orientation be accentric. Since polymeric assemblages can enhance the nonlinear response of organic molecules severalfold, efforts have been directed toward the synthesis of thin films with interpenetrating lattices of electroactive molecules. The goal of this theoretical investigation is to predict the magnitude of the molecular polarizabilities of organic molecules that could be incorporated into films. These calculations are intended to become a powerful tool to assist material scientists in screening for the best candidates for optical applications. The procedure that was developed for the present calculations is based on the static-field approach, and is a modification to the method developed by Dewar and Stewart, 1984 for calculating molecular linear polarizabilities.

Cardelino, Beatriz H.↗

NASA NTRS2004

Thermally Stable Heterocyclic Imines as New Potential Nonlinear Optical Materials

In the course of a search for new thermostable acentric nonlinear optical crystalline materials, several heterocyclic imine derivatives were designed, with the general structure D-pi-A(D'). Introduction of a donor amino group (D') into the acceptor moiety was expected to bring H-bonds into their crystal structures, and so to elevate their melting points and assist in an acentric molecular packing. Six heterocycle-containing compounds of this type were prepared, single crystals were grown for five of them, and these crystals were characterized by X-ray analysis. A significant melting temperature elevation was found for all of the synthesized compounds. Three of the compounds were also found to crystallize in acentric space groups. One of the acentric compounds is built as a three-dimensional H-bonded molecular network. In the other two compounds, with very similar molecular structure, the molecules form one-dimensional H-bonded head-to-head associates (chains). These chains are parallel in two different crystallographic directions and form very unusual interpenetrating chain patterns in an acentric crystal. Two of the compounds crystallized with centrosymmetric molecular packing.

Nesterov, Volodymyr V.↗

NASA NTRS1980

Finite elements for contact problems in two-dimensional elastodynamics

A finite element approach for contact problems in two dimensional elastodynamics was proposed. Sticking, sliding, and frictional contact were taken into account. The method consisted of a modification of the shape functions, in the contact region, in order to involve the nodes of the contacting body. The formulation was symmetric (both bodies were contactors and targets), in order to avoid interpenetration. Compatibility over the interfaces was satisfied. The method was applied to the impact of a block on a rigid target. It is shown that the formulation can be applied to fluid structure interaction, and to problems involving material nonlinearity.

Zimmermann, T. K.↗

NASA NTRS2012

Evidence for Two Separate but Interlaced Components of the Chromospheric Magnetic Field

Chromospheric fibrils are generally thought to trace out horizontal magnetic fields that fan out from flux concentrations in the photosphere. A high-resolution (0.2") image taken in the core of the Ca IJ854.2 nm line shows the dark fibrils within an active region remnant as fine, loop-like features that are aligned parallel to each other and have lengths on the order of a supergranular diameter (approx.30 Mm). Comparison with a line-of-sight magnetogram confirms that the fibrils are centered above intranetwork areas, with one end rooted just inside the neighboring plage or strong unipolar network but the other endpoint less clearly defined. Focusing on a particular arcade-like structure lying entirely on one side of a filament channel (large-scale polarity inversion), we find that the total amount of positive-polarity flux underlying this "fibril arcade' is 50 times greater than the total amount of negative-polarity flux. Thus, if the fibrils represent closed loops, they must consist of very weak fields (in terms of flux density), which are interpenetrated by a more vertical field that contains most of the flux. This surprising result suggests that the fibrils in unipolar regions connect the network to the nearby intranetwork flux, while the bulk of the network flux is diverted upward into the corona and connects to remote regions of the opposite polarity. We conclude that the chromospheric field near the edge of the network has an interlaced structure resembling that in sunspot penumbrae, with the fibrils representing the low-lying horizontal flux that remains trapped within the highly nonpotential chromospheric layer.

Muglach, K.↗

NASA NTRS2011

Evidence for Two Separate but Interlaced Components of the Chromospheric Magnetic Field

Chromospheric fibrils are generally thought to trace out low-lying, mainly horizontal magnetic elds that fan out from flux concentrations in the photosphere. A high-resolution (approximately 0.1" per pixel) image, taken in the core of the Ca II 854.2 nm line and covering an unusually large area, shows the dark brils within an active region remnant as fine, looplike features that are aligned parallel to each other and have lengths comparable to a supergranular diameter. Comparison with simultaneous line-of-sight magnetograms confirms that the fibrils are centered above intranetwork areas (supergranular cell interiors), with one end rooted just inside the neighboring plage or strong unipolar network but the other endpoint less clearly defined. Focusing on a particular arcade-like structure lying entirely on one side of a lament channel (large-scale polarity inversion), we find that the total amount of positive-polarity flux underlying this "fibril arcade" is approximately 50 times greater than the total amount of negative-polarity flux. Thus, if the brils represent closed loops, they must consist of very weak fields (in terms of total magnetic flux), which are interpenetrated by a more vertical field that contains most of the flux. This surprising result suggests that the fibrils in unipolar regions connect the network to the nearby intranetwork flux, while the bulk of the network flux links to remote regions of the opposite polarity, forming a second, higher canopy above the fibril canopy. The chromospheric field near the edge of the network thus has an interlaced structure resembling that in sunspot penumbrae.

Reardom, K. P.↗

NASA NTRS2015

A Numerical Study on the Effect of Facesheet-Core Disbonds on the Buckling Load of Curved Honeycomb Sandwich Panels

A numerical study on the effect of facesheet-core disbonds on the post-buckling response of curved honeycomb sandwich panels is presented herein. This work was conducted as part of the development of a damage tolerance approach for the next-generation Space Launch System heavy lift vehicle payload fairing. As such, the study utilized full-scale fairing barrel segments as the structure of interest. The panels were composed of carbon fiber reinforced polymer facesheets and aluminum honeycomb core. The panels were analyzed numerically using the finite element method. Facesheet and core nodes in a predetermined circular region were detached to simulate a disbond induced via low-speed impact between the outer mold line facesheet and honeycomb core. Surface-to-surface contact in the disbonded region was invoked to prevent interpenetration of the facesheet and core elements. The diameter of this disbonded region was varied and the effect of the size of the disbond on the post-buckling response was observed. A significant change in the slope of the edge load-deflection response was used to determine the onset of global buckling and corresponding buckling load.

structural failure↗