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At least 19 records

Cryogenic Mixed Mode I – Mode II Fracture Toughness of Various Polymer Composite Materials

The present study investigates the mixed mode interlaminar fracture toughness of six polymer matrix composite materials at both room temperature and cryogenic liquid nitrogen temperature. The single leg bending test employed gives a mix of Mode I (opening) and Mode II (in-plane shearing) cracking. The tested thermoplastic-matrix composites were shown to have total mixed mode toughnesses 3.1–4.3 times higher than those of representative thermoset resin composites.

Carbon fiber↗

Solid Freeform Fabrication of Composite-Material Objects

Composite solid freeform fabrication (C-SFF) or composite layer manufacturing (CLM) is an automated process in which an advanced composite material (a matrix reinforced with continuous fibers) is formed into a freestanding, possibly complex, three-dimensional object. In CLM, there is no need for molds, dies, or other expensive tooling, and there is usually no need for machining to ensure that the object is formed to the desired net size and shape. CLM is a variant of extrusion-type rapid prototyping, in which a model or prototype of a solid object is built up by controlled extrusion of a polymeric or other material through an orifice that is translated to form patterned layers. The second layer is deposited on top of the first layer, the third layer is deposited on top of the second layer, and so forth, until the stack of layers reaches the desired final thickness and shape. The elements of CLM include (1) preparing a matrix resin in a form in which it will solidify subsequently, (2) mixing the fibers and matrix material to form a continuous pre-impregnated tow (also called "towpreg"), and (3) dispensing the pre-impregnated tow from a nozzle onto a base while moving the nozzle to form the dispensed material into a patterned layer of controlled thickness. When the material deposited into a given layer has solidified, the material for the next layer is deposited and patterned similarly, and so forth, until the desired overall object has been built up as a stack of patterned layers. Preferably, the deposition apparatus is controlled by a computer-aided design (CAD) system. The basic CLM concept can be adapted to the fabrication of parts from a variety of matrix materials. It is conceivable that a CLM apparatus could be placed at a remote location on Earth or in outer space where (1) spare parts are expected to be needed but (2) it would be uneconomical or impractical to store a full inventory of spare parts. A wide variety of towpregs could be prepared and stored on spools until needed. Long-shelf-life towpreg materials suitable for such use could include thermoplastic-coated carbon fibers and metal-coated SiC fibers. When a spare part was needed, the part could be fabricated by CLM under control by a CAD data file; thus, the part could be built automatically, at the scene, within hours or minutes.

Wang, C. Jeff↗

Diamondlike flake composites

A carbon coating is vacuum arc deposited on a smooth surface of a target which is simultaneously ion beam sputtered. The bombarding ions have sufficient energy to create diamond bonds. Spalling occurs as the carbon deposit thickens. The resulting diamond-like carbon flakes are mixed with a binder or matrix material to form a composite material having improved thermal, electrical, mechanical, and tribological properties when used in aerospace structures and components.

Banks, B. A.↗

Sudbury project (University of Muenster-Ontario Geological Survey): New investigations on Sudbury breccia

Sudbury breccias occur as discordant dike breccias within the footwall rocks of the Sudbury structure, which is regarded as the possible remnant of a multiring basin. Exposures of Sudbury breccias in the North Range are known up to a radial distance of 60-80 km from the Sudbury Igneous Complex (SIC). The breccias appear more frequent within a zone of 10 km adjacent to the SIC and a further zone located about 20-33 km north of the structure. From differences in the structure of the breccias, as for example the size of the breccia dikes, contact relationships between breccia and country rock as well as between different breccia dikes, fragment content, and fabric of the ground mass, as seen in this section, the Sudbury Breccias have been classified into four different types. (1) Early breccias with a clastic/crystalline matrix comprise small dikes ranging in size from approx. 1 cm to max. 20 cm. (2) Polymict breccias with a clastic matrix represent the most common type of Sudbury breccia. The thickness of the dikes varies from several tens of centimeters to a few meters but can also extend to more than 100 m in the case of the largest known breccia dike. Contacts with country rock are sharp or gradational. Heterogenous matrix consisting of a fine-grained rock flour displays nonoriented textures as well as extreme flow lines. Chemical analysis substantiates at least some mixing with allochthonous material. (3) Breccias with a crystalline matrix are a subordinate type of Sudbury breccia. According to petrographical and chemical differences, three subtypes have been separated. (4) Late breccias with a clastic matrix are believed to represent the latest phase of brecciation. Two subtypes have been distinguished due to differences in the fragment content.

Mueller-Mohr, V.↗

Modified Epoxy Matrix Resins for Reduced Dependence on Redundant Fasteners in Secondary-Bonded Composite Structures

In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination that can lead to weak bonds. No methods currently exist to measure the strength of an adhesive bond nondestructively. For these reasons, regulating organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to achieve certification for civil transport aircraft. To meet this requirement, manufacturers commonly install redundant fasteners (~105 fasteners in a twin-aisle airframe with composite fuselage and wings), which add tremendous complexity, time and cost, and significantly reduce performance of the airframe. Under NASA’s Convergent Aeronautics Solutions (CAS) Program, the Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy matrix resins to enable reflow and diffusion of the resin at the interface during a secondary bonding/cure process. The mixing process eliminates the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion across a nearly two-dimensional boundary. The AERoBOND interface is similar to the interlaminar region formed during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin, which can be measured, inspected non-destructively, and certified for flight with fewer redundant fasteners. This presentation describes the ongoing development of stoichiometrically-offset epoxy resins to control the degree of cure in composite joints and enable interfacial mixing during secondary bonding/curing. Details on the resin formulation, laminate fabrication, and mechanical testing will also be presented. The precracked mode-II fracture toughness measured from preliminary AERoBOND joints was similar for joints fabricated with conventional epoxy matrix materials.

thermoset, hardener, prepreg, assembly↗

Ordered mixed-layer structures in the Mighei carbonaceous chondrite matrix

High resolution transmission electron microscopy of the Mighei carbonaceous chondrite matrix has revealed the presence of a new mixed layer structure material. This mixed-layer material consists of an ordered arrangement of serpentine-type (S) and brucite-type (B) layers in the sequence SBBSBB. Electron diffraction and imaging techniques show that the basal periodicity is approximately 17 A. Discrete crystals of SBB-type material are typically curved, of small size (less than 1 micron) and show structural variations similar to the serpentine group minerals. Mixed-layer material also occurs in association with planar serpentine. Characteristics of SBB-type material are not consistent with known terrestrial mixed-layer clay minerals. Evidence for formation by a condensation event or by subsequent alteration of pre-existing material is not yet apparent.

Mackinnon, I. D. R.↗

Tailorable Dielectric Material with Complex Permittivity Characteristics

A dielectric material includes a network of nanosubstrates, such as but not limited to nanotubes, nanosheets, or other nanomaterials or nanostructures, a polymer base material or matrix, and nanoparticles constructed at least partially of an elemental metal. The network has a predetermined nanosubstrate loading percentage by weight with respect to a total weight of the dielectric material, and a preferential or predetermined longitudinal alignment with respect to an orientation of an incident electrical field. A method of forming the dielectric material includes depositing the metal-based nanoparticles onto the nanosubstrates and subsequently mixing these with a polymer matrix. Once mixed, alignment can be achieved by melt extrusion or a similar mechanical shearing process. Alignment of the nanosubstrate may be in horizontal or vertical direction with respect to the orientation of an incident electrical field.

Dudley, Kenneth L.↗

Overview of C/C-SiC Composite Development for the Orion Launch Abort System

Past and present efforts by the authors to further understanding of the ceramic matrix composite (CMC) material used in the valve components of the Orion Launch Abort System (LAS) Attitude Control Motor (ACM) will be presented. The LAS is designed to quickly lift the Orion Crew Exploration Vehicle (CEV) away from its launch vehicle in emergency abort scenarios. The ACM is a solid rocket motor which utilizes eight throttleable nozzles to maintain proper orientation of the CEV during abort operations. Launch abort systems have not been available for use by NASA on manned launches since the last Apollo ]Saturn launch in 1975. The CMC material, carbon-carbon/silicon-carbide (C/C-SiC), is manufactured by Fiber Materials, Inc. and consists of a rigid 4-directional carbon-fiber tow weave reinforced with a mixed carbon plus SiC matrix. Several valve and full system (8-valve) static motor tests have been conducted by the motor vendor. The culmination of these tests was the successful flight test of the Orion LAS Pad Abort One (PA ]1) vehicle on May 6, 2010. Due to the fast pace of the LAS development program, NASA Marshall Space Flight Center assisted the LAS community by performing a series of material and component evaluations using fired hardware from valve and full ]system development motor tests, and from the PA-1 flight ACM motor. Information will be presented on the structure of the C/C-SiC material, as well as the efficacy of various non ]destructive evaluation (NDE) techniques, including but not limited to: radiography, computed tomography, nanofocus computed tomography, and X-ray transmission microscopy. Examinations of the microstructure of the material via scanning electron microscopy and energy dispersive spectroscopy will also be discussed. The findings resulting from the subject effort are assisting the LAS Project in risk assessments and in possible modifications to the final ACM operational design.

Allen, Lee R.↗

Materials development for precision segmented reflector applications

The requirements developed to guide the selection of current and future materials for precision segmented reflectors are presented along with a list of desirable properties. Some potential candidate materials including modified fiber reinforced organic matrix composites as well as carbon/carbon composites, graphite/glass composites, and metal matrix composites are identified. It is noted that in the near term, it is likely that modified fiber reinforced organic matrix composites have good applicability. In the longer term, materials such as carbon/carbon composites, graphite/glass composites and metal matrix composites may provide the best mix of properties.

Coulter, Daniel R.↗

Latent Cure Epoxy Resins for Reliable Joints in Secondary-Bonded Composite Structures

In high-performance polymer matrix composite assemblies, adhesive bonding is generally superior to mechanical fastening in structural performance and manufacturing efficiency. However, adhesive bonds are susceptible to minute levels of contamination accumulated during assembly that can lead to unpredictable, weak bonds. Current methods of measuring bond strength are all destructive mechanical tests. To overcome these challenges, redundant load paths (e.g., mechanical fasteners) are often implemented in secondary-bonded, primary-structures, which can greatly reduce structural performance. This study investigated reformulated aerospace epoxy matrix resins with stoichiometric offset to inhibit cure of the matrix resin prior to assembly. Inhibited resins can reflow and mix across the joint interface, which eliminates the material discontinuity and forms a homogenous joint with reliable fracture properties. The goal of this study was to develop and demonstrate secondary composite assemblies that are mechanically and microscopically indistinguishable from a co-cured composite joint. This article describes the development of latent epoxy resins, the fabrication of test articles, and the mechanical properties measured from experimental joints compared with conventional, co-cured laminates. Methods of in-line quality control using and infrared spectroscopy and post-assembly forensics are also described. The final mode-II fracture toughness measured from precracked AERoBOND specimens was similar to that measured from co-cured laminates indicating that later cure epoxy materials could be a suitable replacement for secondary bonding.

Polymer-matrix composites (PMCs)↗

Thermal properties of heterogeneous grains

Cometary dust is not spherical nor homogeneous, yet these are the assumptions used to model its thermal, optical, and dynamical properties. To better understand the effects of heterogeneity on the thermal and optical properties of dust grains, the effective dielectric constant for an admixture of magnetite and a silicate were calculated using two different effective medium theories: the Maxwell-Garnett theory and the Bruggeman theory. In concept, the MG theory describes the effective dielectric constant of a matrix material into which is embedded a large number of very small inclusions of a second material. The Bruggeman theory describes the dielectric constant of a well mixed aggregate of two or more types of materials. Both theories assume that the individual particles are much smaller than the wavelength of the incident radiation. The refractivity for a heterogeneous grain using the MG theory is very similar to the refractivity of the matrix material, even for large volume fractions of the inclusion. The equilibrium grain temperature for spherical particles sized from .001 to 100 microns in radius at 1 astronomical unit from the sun was calculated. Further explanation is given.

Lien, David J.↗

Optimal Composite Material for Low Cost Fabrication of Large Composite Aerospace Structures using NASA Resins or POSS Nanoparticle Modifications

Thermoplastic laminates in situ consolidated via tape or tow placement require full mechanical properties. Realizing full properties requires resin crystallinity to be controlled - partial crystallinity leads to unacceptably low laminate compression properties. There are two approaches: utilize an amorphous matrix resin; or place material made from a semi-crystalline resin featuring kinetics faster than the process. In this paper, a matrix resin evaluation and trade study was completed with commercial and NASA amorphous polyimides on the one hand, and with PEKK mixed with POSS nanoparticles for accelerated crystallinity growth on the other. A new thermoplastic impregnated material, 6 mm wide (0.25-in) AS-4 carbon/LaRC(TradeMark)8515 dry polyimide tow, was fabricated. Since LaRC(TradeMark)8515 is fully amorphous, it attains full properties following in situ consolidation, with no post processing required to build crystallinity. The tow in situ processing was demonstrated via in situ thermoplastic filament winding it into rings.

Lamontia, Mark A.↗

Structures and textures of the Murchison and Mighei carbonaceous chondrite matrices

High-resolution transmission electron microscopy has confirmed earlier observations that the character of the Murchison and Mighei fine-grained matrices is complex in mineralogy and texture. Layer structure minerals occur as planar laths, rounded grains or subhedral grains, and range in size from less than 100 A to about 1 micrometer. Serpentine-type and brucite-type structures predominate in the CM matrices. The occurrence of Povlen chrysolite and a vein of disordered mixed-layer and brucite-type material cutting a large lizardite-type grain suggests that at least some of the matrix materials were formed by alteration of preexisting material.

Mackinnon, I. D. R.↗

Lunar soil evolution processes and Apollo 16 core 60013/60014

Soils of the 62-cm deep Apollo 16 double drive tube 60013/14 are mature at the top and submature at the bottom. Modal analyses of 5529 grains from the 90-150 micrometers and the 500-1000 micrometers fractions from 12 levels of the core show that, in general, agglutinate abundance increases somewhat monotonically to the top and mimics the Is/FeO profile. There is a general decrease in the modal abundance of monomineralic fragments towards the top, suggesting that agglutinates were formed in part at the expense of monomineralic grains, especially feldspars, which are by far the most abundant mineral in these soils. In detail, the top 27 cm of the core differs from the bottom 21 cm, and the middle 14 cm is intermediate in its properties. In the upper segment, variations in the abundances of feldspars correspond with those of feldspathic fragmental breccias and cataclastic anorthosites; in the bottom segment, a similar but weak correspondence between feldspars and crystalline matrix breccias is observed. Mixing of the comminuted products of these three rock types likely produced the bulk of the core material. Many single feldspars in all size fractions are remarkably fresh, show no damage from shock, and are similar in appearance to the large feldspars in anorthosites and feldspathic fragmental breccias, which we consider to be the primary sources of single feldspars in this core. Major (Na, Al, Si, K, Ca) and minor (Fe, Ba) element analyses of 198 single feldspar grains indicate the presence of only one population of feldspars, which is consistent with our interpretation of feldspar provenance. Classification of 890 monomineralic feldspar, olivine, pyroxene, and glass spherules on the basis of the presence or absence of thin brownish coating--related to reworking at the surface--shows that coated grains are much more abundant in the top segment than in the bottom segment. A comparison with the mixing and maturation model (McKay et al., 1977) of soils in the core 60009/10, some 60 m away from 60013/14, shows that mixtures of an immature, nearly pure plagioclase soil (dominant in 60009/10) and another immature, crystalline breccia-rich soil (dominant in 60013/14) may have matured through in situ reworking to produce the soils under investigation. We conclude that the soils in this core are products of mixing along soil evolution Path 2 of McKay et al. (1974). Superimposed on that soil column is the reworking of the upper part, which has evolved more recently along Path 1. This core thus represents a consanguineous column of the lunar regolith with an upper reworked segment.

short duration↗

Genetic Relationships Between Chondrules, Rims and Matrix

The most primitive chondrites are composed of chondrules and chondrule fragments, various types of inclusions, discrete mineral grains, metal, sulfides, and fine-grained materials that occur as interchondrule matrix and as chondrule/inclusion rims. Understanding how these components are related is essential for understanding how chondrites and their constituents formed and were processed in the solar nebula. For example, were the first generations of chondrules formed by melting of matrix or matrix precursors? Did chondrule formation result in appreciable transfer of chondrule material into the matrix? Here, we consider three types of data: 1) compositional data for bulk chondrites and matrix, 2) mineralogical and textural information, and 3) the abundances and characteristics of presolar materials that reside in the matrix and rims. We use these data to evaluate the roles of evaporation and condensation, chondrule formation, mixing of different nebular components, and secondary processing both in the nebula and on the parent bodies. Our goal is to identify the things that are reasonably well established and to point out the areas that need additional work.

Huss, G. R.↗

Thermal shock and erosion resistant tantalum carbide ceramic material

Ceramic tantalum carbide artifacts with high thermal shock and mechanical erosion resistance are provided by incorporating tungsten-rhenium and carbon particles in a tantalum carbide matrix. The mix is sintered by hot pressing to form the ceramic article which has a high fracture strength relative to its elastic modulus and thus has an improved thermal shock and mechanical erosion resistance. The tantalum carbide is preferable less than minus 100 mesh, the carbon particles are preferable less than minus 100 mesh, and the tungsten-rhenium particles are preferable elongate, having a length to thickness ratio of at least 2/1. Tungsten-rhenium wire pieces are suitable as well as graphite particles.

Honeycutt, L., III↗

Polyphase alloys as rechargeable electrodes in advanced battery systems

The rechargeability of electrochemical cells is often limited by negative electrode problems. These may include loss of capacity, increased impedance, macroscopic shape change, dendrite growth, or a tendency for filamentary or whisker growth. In principle, these problems can be reduced or eliminated by the use of alloys that undergo either displacement or insertion reactions at reactant species activities less than unity, rather than pure elements. The fundamental reasons for some of these problems with elemental electrodes, as well as the basic principles involved in the different behavior of alloys, are briefly discussed. More information is now available concerning the thermodynamic and kinetic properties of a number of alloys of potential interest for use as electrodes in elevated temperature lithium battery systems. Recent results have extended these results down to ambient temperatures, indicating that some such materials may be of interest for use with new low temperature molten salt electrolytes, or with organic solvent electrolytes. The all solid mixed conductor matrix concept is also reviewed.

Huggins, Robert A.↗

The effects of radiation on the interlaminar fracture toughness of a graphite/epoxy composite

An experimental study is made of the effect of electron irradiation (10 to the 10th rad), simulating a 30-year geosynchronous orbit exposure, on the fracture toughness of a graphite/epoxy composite, T300/934. The double cantilever beam (DBC) test is used to determine Mode I (peel) critical strain energy release rate and the edge delamination tension (EDT) test is used to determine mixed Mode I and II (peel and shear) critical strain energy release rate. It is found that the electron interaction of the epoxy matrix material enhances the fracture toughness properties of the composite and that the test temperature has a significant effect on the fracture toughness of both baseline and irradiated material.

Funk, J. G.↗