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All sources NASA NTRS DOE OSTI

NASA NTRS1997

New Electromagnetic Interference Shielding Material Demonstrated

A demonstration electromagnetic interference (EMI) shielding cover that has a potential mass savings in excess of 80 percent over conventional aluminum has been fabricated and tested. It was the culmination of a 3-yr effort involving Hughes Space and Communications (Los Angeles), Applied Sciences, Inc. (Cedarville, Ohio), and the NASA Lewis Research Center. The cover was fabricated from a composite of polycyanate ester resin and graphite fibers that had been chemically modified by intercalation to enhance their electrical conductivity.

Gaier, James R.↗

DOE OSTI2024

Infrared-Transparent Semiconductor Membranes for Electromagnetic Interference Shielding of Millimeter Waves

Here, it is demonstrated that single-crystalline and highly doped GaAs membranes are excellent candidates for realizing infrared-transparent shields of electromagnetic interference at millimeter frequencies. Measured optical transmittance spectra for the semiconductor membranes show resonant features between 750 and 2500 nm, with a 100% maximum transmittance. The shielding effectiveness of the membranes is extracted from measured scattering parameters between 65 and 85 GHz. Selected GaAs membranes and membranes/polyamide films exhibit shielding effectiveness ranging from 22 to 40 dB, which are suitable values to ensure the safe operation of infrared devices for commercial applications. Theoretical calculations based on a plane wave model show that the interplay of primary reflection and multiple internal reflections of the radio-frequency waves results in broadband shielding capabilities of the membrane between 10 and 300 GHz.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2023

Printing of electromagnetic interference shielding materials

Here, the proliferation of electronic devices has made electromagnetic interference (EMI) shielding an exponentially growing business. Regulatory requirements change constantly as new technologies continue to emerge. Innovations in materials and new advances in shielding implementation techniques are needed to pass regulatory compliance tests at an affordable cost. Here, we print various EMI shielding materials such as copper, silver and a composite of copper with Fe 3 O 4 using plasma jet printing. Printing enables shields only a few microns thick capable of high shielding effectiveness. Copper's EMI shielding performance is primarily contributed by reflection mechanism, as expected and this is known to cause secondary pollution. A Green Index for EMI shielding, given by the ratio of absorption and reflection contributions to shielding, indicates values lower than 0.1 for printed copper films.

36 MATERIALS SCIENCE↗

NASA NTRS1996

Radiation Protection of New Lightweight Electromagnetic Interference Shielding Materials Determined

Weight savings as high as 80 percent could be achieved by simply switching from aluminum electromagnetic interference (EMI) shielding covers for spacecraft power systems to EMI covers made from intercalated graphite fiber composites. Because EMI covers typically make up about one-fifth of the power system mass, this change would decrease the mass of a spacecraft power system by more than 15 percent. Intercalated graphite fibers are made by diffusing guest atoms or molecules, such as bromine, between the carbon planes of the graphite fibers. The resulting bromine-intercalated fibers have mechanical and thermal properties nearly identical to pristine graphite fibers, but their resistivity is lower by a factor of 5, giving them better electrical conductivity than stainless steel and making these composites suitable for EMI shielding.

Source record↗

DOE OSTI2024

Printed graphene and its composite with copper for electromagnetic interference shielding applications

Abstract Advances in mobile electronics and telecommunication systems along with 5G technologies have been escalating the electromagnetic interference (EMI) problem in recent years. Graphene-based material systems such as pristine graphene, graphene-polymer composites and other graphene-containing candidates have been shown to provide adequate EMI shielding performance. Besides achieving the needed shielding effectiveness (SE), the method of applying the candidate shielding material onto the object in need of protection is of enormous importance due to considerations of ease of application, reduced logistics and infrastructure, rapid prototyping and throughput, versatility to handle both rigid and flexible substrates and cost. Printing readily meets all these criteria and here we demonstrate plasma jet printing of thin films of graphene and its composite with copper to meet the EMI shielding needs. SE over 30 dB is achieved, which represents blocking over 99.9% of the incoming radiation. Graphene and its composite with copper yield higher green index compared to pure copper shields, implying reduced reflection of incoming electromagnetic waves to help reduce secondary pollution.

Materials Science↗

NASA NTRS2015

Hexavalent Chrome Free Coatings for Electronics Electromagnetic Interference (EMI) Shielding Effectiveness (SE) Interim Test Report

Test specimen configuration was provided by Parker Chomerics. The EMI gasket used in this project was Cho-Seal 6503E. Black oxide alloy steel socket head bolts were used to hold the plates together. Non-conductive spacers were used to control the amount of compression on the gaskets. The following test fixture specifications were provided by Parker Chomerics. The CHO‐TP09 test plate sets selected for this project consist of two aluminum plates manufactured to the specifications detailed in CHO‐TP09. The first plate, referred to as the test frame, is illustrated in Figure 1. The test frame is designed with a cutout in the center and two alternating bolt patterns. One pattern is used to bolt the test frame to the corresponding test cover plate (Figure 2), forming a test plate set. The second pattern accepts the hardware used to mount the fully assembled test plate set to the main adapter plate (Figure 3).

trivalent chromium↗

NASA NTRS2016

Hexavalent Chrome Free Coatings for Electronics: Electromagnetic Interference (EMI) Shielding Effectiveness (SE)

Determine the suitability of trivalent chromium conversion coatings that meet the requirements of MIL-DTL-5541, Type II, for use in applications where high-frequency electrical performance is important. Evaluate the ability of hexavalent chrome free pretreated aluminum to form adequate EMI seals, and maintain that seal while being subjected to harsh environmental conditions. Assess the performance of trivalent chromium pretreatments against a known control hexavalent chrome pretreatment before and after they have been exposed to a set of environmental conditions. It is known that environmental testing causes a decrease in shielding effectiveness when hexavalent chrome pretreatments are used (Alodine 1200s). Need to determine how shielding effectiveness will be affected with the use of hexavalent chrome free pretreatments. Performance will be assessed by evaluating shielding effectiveness (SE) test data from a variety of test samples comprised of different aluminum types and/or conversion coatings. The formation of corrosion will be evaluated between the mating surfaces and gasket to assess the corrosion resistant properties of the pretreatments, comparing the hexavalent control to the hexavalent chrome free pretreatments.

hexavalent chrome free↗

NASA NTRS2014

Hexavalent Chrome Free Coatings for Electronics; Electromagnetic Interference (EMI) Shielding Effectiveness (SE)

The purpose of this testing is to determine the suitability of trivalent chromium conversion coatings that meet the requirements of MIL-DTL-5541, Type II, for use in applications where high-frequency electrical performance is important. This project will evaluate the ability of coated aluminum to form adequate EMI seals. Testing will assess performance of the trivalent chromium coatings against the known control hexavalent chromium MIL-DTL-5541 Type I Class 3 before and after they have been exposed to a set of environmental conditions. Performance will be assessed by evaluating shielding effectiveness (SE) test data from a variety of test samples comprised of different aluminum types and/or conversion coatings.

hexavalent chrome↗

NASA NTRS2016

Final Test Report: Hexavalent Chrome Free Coatings for Electronics Electromagnetic Interference (EMI) Shielding Effectiveness (SE)

The test results for Salt Spray Resistance, Static Heat and Humidity and Marine Environment can be found in Sections 3.1.3.3, 3.1.4.3 and 3.1.5.3 respectively. In summary, both the Metalast TCP and SurTec 650 Type 2 conversion coatings perform very similar to the incumbent Type 1 conversion coating against both 6061 and 5052 aluminum under all three test conditions. Significant prior work was performed to select the aluminum and conversion coating included within this test cycle; Reference - NASA GSDO Program Hexavalent Chrome Alternatives Final Pretreatments Test Report Task Order: NNH12AA45D September 01, 2013. As illustrated in the data, the 6061 aluminum panels SLIGHTLY out-performed the 5052 aluminum panels. Individual shielding effectiveness graphs for each panel are included within Appendix C and D. One other notable effect found during review of the data is that the Test Panels exposed to B117 Salt Fog reduced in shielding effectiveness significantly more than the Marine Environment Test Panels. The shielding effectiveness of the Marine Test Panels was approximately 20dB higher than the Test Panels that underwent B117 Salt Fog Exposure. The intent of this evaluation was not to maximize shielding effectiveness values. The same Parker Chomerics Cho-Seal 6503 gasket material was used for all panels with aluminum and conversion coating variants. A typical EMI gasket design for corrosive environments would be done quite differently. The intent was to execute a test that would provide the best possible evaluation of different aluminum materials and conversion coatings in corrosive environments. The test program achieved this intent. The fact that the two aluminums and two Type II conversion coatings performed similar to the incumbent Type 1 conversion coating is a positive outcome. It was desired to have an outcome that further differentiation the performance of two aluminum types and two conversion coating types but this could not be extracted by the test results. Further analysis of the test plates may be done by X-Ray Photoelectron Spectroscopy (XPS) or Electrochemical Impedance Spectroscopy (EIS). Feasibility of this is under review.

Kessel, Kurt R.↗

NASA NTRSDate not supplied

Feasibility of Micro-Multilayer Multifunctional Electrical Insulation (MMEI) System for High Voltage Applications

The newly patented micro-multilayer multifunctional electrical insulation (MMEI) system was developed for future electric aircraft applications which critically require lightweight but high voltage (HV), high temperature, and corona or partial discharge (PD) resistant insulation. During the initial development stages, the concept and practicability of the MMEI system were successfully validated with its exceptionally high dielectric breakdown voltages. The multilayer structures were optimized in terms of material type, individual layer thickness, and overall layer configuration along with potential mechanisms identified for its superior performance. Subsequently, scalability, manufacturability, and commercial applicability of the MMEI system were demonstrated with the 1 meter long, 3-phase HV, high power (HP) bus bar prototypes. Two prototypes, one with the conventional SOA insulation system including Mica sheet and the other with an optimized MMEI, were designed, fabricated, and tested successfully. Both prototypes passed both HiPot and PD tests up to the highest test voltage available, 15 kVAC, although the latter showed a slight increase in PD activities at 12.5 kV. However, the prototype with MMEI was 15% lighter or 12% thinner than the other one. Current efforts to significantly enhance the PD resistance of the MMEI system by employing semiconductive shielding layers, which can be also multifunctional, e.g., electromagnetic interference shielding, moisture blocking, heat dissipation, for various HV applications are also discussed in this paper.

Novel Electrical Insulation↗

NASA NTRSDate not supplied

Feasibility of Micro-Multilayer Multifunctional Electrical Insulation (MMEI) System for High Voltage Applications

Novel Electrical Insulation↗

DOE OSTI2026

Development of in-situ polymerized intrinsically conductive resin and low-cost carbon pigments offering high conductivity for sensing, EMI shielding and lighting protection

Electrically conductive composites are emerging across diverse industries such as electronic, automotive, aerospace, advanced air mobility, biomedical, infrastructure, defense and security offering static charge dissipation, electromagnetic interference shielding, lighting protection, sensing, dicing, corrosion monitoring, etc. Conductivity enhanced composites provide several advantages compared to conventional metals including weight reduction, corrosion resistance, energy efficient processability, tunable properties and multifunctionality. Polymers are typically insulating in nature and require conducting filler for electron transport. However, dispersion and polymer-filler interphases are critical and often disrupt conducting pathways. Besides, conductive fillers such as graphene, carbon nanotube, MXene, silver nanowire, etc. are expensive, limiting their wide adoption in composite industry. On the other hand, a limited number of intrinsically conductive polymers are available among which polyaniline (PANI) has been widely studied due to its high conductivity, thermal and chemical stability. However, PANI is difficult to process and exhibits weak mechanical properties. In brief, there is a significant demand for electrically conductive polymer formulation with cost-effective conducting fillers that offer processability in scale to expand the market of conductivity enhanced materials.

Kumar, Vipin [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2025

In Situ MOF Pyrolysis Construction of Hierarchical Porous Co‐Nanoparticles/Carbon Cloth Composites for Enhanced Electromagnetic Wave Shielding and Absorption

The development of high-performance electromagnetic protection materials integrating broadband absorption and effective shielding capabilities is hindered by challenges in simultaneously optimizing multiple electromagnetic properties through conventional material designs. This study pioneers a hierarchical porous Co nanoparticle/carbon cloth (Co/CC) composite via controlled annealing of a Co-MOF precursor on carbon cloth. The Co-MOF served a dual role as both magnetic source and pore-forming agent, enabling in situ generation of uniformly dispersed Co nanoparticles and creation of abundant pores/interfaces on the CC fibers during pyrolysis. This unique architecture synergistically enhanced dielectric loss (via interfacial/dipolar polarization) and magnetic loss (via natural resonance, exchange interactions, and eddy currents), significantly improving impedance matching. The hierarchical pores further functioned as integrated “absorption–reflection” units for efficient electromagnetic energy attenuation. Consequently, the Co/CC composite annealed at 800°C (Co/CC-800) achieves minimum reflection loss (−40.69 dB) and 120% effective absorption bandwidth extension (6.16 GHz) as a filler, and exhibits superior electromagnetic interference shielding effectiveness (46.66 dB) as an integrated component. Significantly, Co/CC-800 demonstrated robust photothermal and electrothermal conversion capabilities, ensuring operational stability in ice-covered and humid harsh environments. This work pioneers a pore-structure-mediated strategy to harmonize dielectric–magnetic synergy, providing a new paradigm for designing advanced multifunctional electromagnetic protection materials.

dielectric‐magnetic synergy↗

DOE OSTI2024

A magnetic diagnostic suite for the Pegasus-III experiment

Pegasus-III is an ultralow aspect ratio spherical tokamak providing a dedicated US experiment for comparative solenoid-free startup studies. A new magnetic diagnostic suite for equilibrium and low frequency (<200 kHz) magnetohydrodynamic mode analysis has been installed. These new diagnostics address the significant challenges of measuring magnetic field in a high noise environment with the majority constrained to fit in an 8 mm diagnostic gap on the high field side. Electrostatic switching noise generated by the 16 independent current feedback-controlled power supplies produces dV cm /dt ~ 1 kV/μs and volt level common mode noise on the magnetics. Immunity to this switching noise is accomplished through differential signal runs and signal processing, along with end-to-end electromagnetic interference shielding. The magnetic measurements are simultaneously digitized at 1 MHz and conditioned by precision 8 pole Butterworth filters with a corner frequency of 200 kHz to prevent aliasing down to the 16-bit level over the full passband. Ex-vessel calibrations of the B p coils were completed with a typical uncertainty of <0.5%. Stray toroidal field pickup from coil misalignment or positioning errors is corrected using a physics-based model. Comparisons of the corrected measurements to modeling agree to within 1.3% on average. This is within the 1.5% measurement uncertainty that a sensitivity analysis determined is needed for accurate fast boundary and equilibrium reconstruction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1986

Properties and potential applications of brominated P-100 carbon fibers

A review of the properties and potential applications of bromine-intercalated pitch-based carbon fibers is presented. The dynamics of the intercalation reaction are summarized, and characteristics, such as resistivity, density, and stability, are discussed. In addition, the mechanical and electrical properties of bromine-intercalated fiber-epoxy conposites will be addressed. With conductivities comparable to stainless steel, these brominated carbon fibers may be used in a number of composite applications, such as electromagnetic interference shielding containers, large conductive space structures, lightning strike-tolerant aircraft surfaces, and aircraft deicing applications.

Jaworske, D. A.↗

NASA NTRS1998

Fabrication and Resistivity of IBr Intercalated Vapor-Grown Carbon Fiber Composites

Composites using vapor-crown carbon fibers (VGCF), the most conductive of the carbon fiber types, are attractive for applications where low density, high strength, and at least moderate conductivity are required, such as electromagnetic interference shielding covers for spacecraft. The conductivity can be enhanced another order of magnitude by intercalation of the VGCF. If a high Z intercalate is used, the protection of components from ionizing radiation can be enhanced also. Thus, the intercalation of VGCF with IBr is reported. Since composite testing is required to verify properties, the intercalation reaction optimization, stability of the intercalation compound, scale-up of the intercalation reaction, composite fabrication, and resistivity of the resulting composites is also reported. The optimum conditions for low resistivity and uniformity for the scaled up reaction (20-30 g of product) were 114 C for at least 72 hr, yielding a fiber with a resistivity of 8.7+/-2 micro-Omega-cm. The thermal stability of these fibers was poor, with degradation occurring at temperatures as low as 40 C in air, though they were insensitive to water vapor. Composite resistivity was 20-30 micro-Omega-cm, as measured by contactless conductivity measurements, about a factor of five higher than would be expected from a simple rule of mixtures. The addition of 1.0 percent Br2, intercalated microfibers increased the resistivity of the composites by more than 20 percent.

Gaier, James R.↗

NASA NTRS1999

Highly Conducting Graphite Epoxy Composite Demonstrated

Weight savings as high as 80 percent could be achieved if graphite polymer composites could replace aluminum in structures such as electromagnetic interference shielding covers and grounding planes. This could result in significant cost savings, especially for the mobile electronics found in spacecraft, aircraft, automobiles, and hand-held consumer electronics. However, such composites had not yet been fabricated with conductivity sufficient to enable these applications. To address this lack, a partnership of the NASA Lewis Research Center, Manchester College, and Applied Sciences, Inc., fabricated nonmetallic composites with unprecedented electrical conductivity. For these composites, heat-treated, vapor-grown graphite fibers were selected which have a resistivity of about 80 mW-cm, more than 20 times more conductive than typical carbon fibers. These fibers were then intercalated with iodine bromide (IBr). Intercalation is the insertion of guest atoms or molecules between the carbon planes of the graphite fibers. Since the carbon planes are not highly distorted in the process, intercalation has little effect on mechanical and thermal properties. Intercalation does, however, lower the carbon fiber resistivity to less than 10 mW-cm, which is comparable to that of metal fibers. Scaleup of the reaction was required since the initial intercalation experiments would be carried out on 20-mg quantities of fibers, and tens of grams of intercalated fibers would be needed to fabricate even small demonstration composites. The reaction was first optimized through a time and temperature study that yielded fibers with a resistivity of 8.7 2 mW-cm when exposed to IBr vapor at 114 C for 24 hours. Stability studies indicated that the intercalated fibers rapidly lost their conductivity when exposed to temperatures as low as 40 C in air. They were not, however, susceptible to degradation by water vapor in the manner of most graphite intercalation compounds. The 1000-fold scaleup experiments concluded that 114 C was near the optimum temperature, but that the intercalation time needed to be lengthened by a factor of 3.

Gaier, James R.↗

NASA NTRS2001

Specimens Prepared for Materials International Space Station Experiment

The Materials International Space Station Experiment (MISSE) is a materials flight experiment sponsored by the Materials and Manufacturing Directorate of the Air Force Research Laboratory at Wright-Patterson Air Force Base and the NASA Space Environmental Effects Program at the NASA Marshall Space Flight Center. MISSE is a cooperative effort among the Air Force, several NASA field centers, and industry. The experiment package will be placed on the exterior of the International Space Station in the summer of 2001. Approximately half of the specimens will be exposed to the space environment for 1 year, and the other half will be exposed for 3 years. The Electro-Physics Branch at the NASA Glenn Research Center has prepared and delivered over 150 specimens to be included in MISSE. Specimens include: 1) Double-coated polyimide Kapton to compare mass loss from in-space atomic oxygen undercutting erosion to ground-laboratory atomic oxygen undercutting erosion for predicting in-space durability; 2) Silicones to study changes in surface hardness and optical properties after combined atomic oxygen--ultraviolet radiation exposure for predicting in-space durability; 3) Forty-one different polymers to accurately measure their atomic oxygen erosion yields; 4) Scattering chambers to study atomic oxygen scattering characteristics that are relevant to the degradation found in spacecraft with exterior openings; 5) Thin polymer film disks and tensile specimens to study the effects of radiation on their optical properties and mechanical properties; 6) Lightweight intercalated graphite epoxy composites to study electromagnetic interference shielding performance; and 7) Polymer-based materials utilizing new atomic oxygen protection concepts to study their durability.

Banks, Bruce A.↗