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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records

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NASA NTRS1980

Hybridized polymer matrix composites

The extent to which graphite fibers are released from resin matrix composites that are exposed to fire and impact conditions was determined. Laboratory simulations of those conditions that could exist in the event of an aircraft crash and burn situation were evaluated. The effectiveness of various hybridizing concepts in preventing this release of graphite fibers were also evaluated. The baseline (i.e., unhybridized) laminates examined were prepared from commercially available graphite/epoxy, graphite/polyimide, and graphite/phenolic materials. Hybridizing concepts investigated included resin fillers, laminate coatings, resin blending, and mechanical interlocking of the graphite reinforcement. The baseline and hybridized laminates' mechanical properties, before and after isothermal and humidity aging, were also compared. It was found that a small amount of graphite fiber was released from the graphite/epoxy laminates during the burn and impact conditions used in this program. However, the extent to which the fibers were released is not considered a severe enough problem to preclude the use of graphite reinforced composites in civil aircraft structure. It also was found that several hybrid concepts eliminated this fiber release. Isothermal and humidity aging did not appear to alter the fiber release tendencies.

House, E. E.↗

NASA NTRS1975

Development of lightweight reinforced plastic laminates for spacecraft interior applications

Lightweight, Kevlar - reinforced laminating systems that are non-burning, generate little smoke in the space shuttle environment, and are physically equivalent to the fiberglass/polyimide system used in the Apollo program for non-structural cabin panels, racks, etc. Resin systems representing five generic classes were screened as matrices for Kevlar 49 reinforced laminates. Of the systems evaluated, the polyimides were the most promising with the phenolics a close second. Skybond 703 was selected as the most promising resin candidate. With the exception of compression strength, all program goals of physical and mechanical properties were exceeded. Several prototype space shuttle mobility and translation handrail segments were manufactured using Kevlar/epoxy and Kevlar-graphite/epoxy. This application shows significant weight savings over the baseline aluminum configuration used previous. The hybrid Kevlar-graphite/epoxy is more suitable from a processing standpoint.

Hertz, J.↗

NASA NTRS2004

PS300 Tribomaterials Evaluated at 6500C by Bushing Test Rig

A new facility has been developed to test the tribological behavior (friction and wear) of PS300 solid lubricant bushings at high temperatures. PS300 is a commercially available solid lubricant invented at the NASA Glenn Research Center. It can be prepared as a plasma spray coating or as a free-standing powder metallurgy component, designated PM300. PS300 and PM300 composites are designed to lubricate sliding components at temperatures above the capability of today's best oils, greases, and solid lubricants. One of the primary applications being pursued for PM300 is the development of bushings for use in high-temperature machinery. Examples include inlet guide vane bushings for gas turbines and conveyors, and bearings for industrial furnaces and ovens. Encouraging preliminary field trials indicate that PS300 and PM300 lubricant materials have been commercialized successfully in several industrial applications. However, the lack of laboratory performance data has hindered further commercialization especially for new applications that differ significantly from the established experience base. The purpose of the newly developed bushing test rig will be to determine the performance characteristics of PM300, and other materials, under conditions closely matching intended applications. The data will be used to determine engineering friction and wear rates and to estimate the life expectancy of bushings for new applications. In the new rig, the bushing is loaded against a rotating shaft inside a furnace enclosure (see the preceding photograph). Loads can vary from 5 to 200 N, speeds from 1 to 400 rpm, and temperatures from 25 to 800 C. Furnace temperature, bushing temperature, shaft speed, and torque are monitored during the test, and wear of both the bushing and the shaft is measured after testing is completed. Initially, PM300 bushings will be evaluated and compared with lower temperature, traditional bushing materials like graphite and porous bronze. The baseline PM304 composition is 60 wt% NiCr (a binder), 20 wt% Cr2O3 (a hardener), 10 wt% BaF2/CaF2 (a high-temperature lubricant), and 10 wt% Ag (a low-temperature lubricant). Future research efforts will include determining the effects of load, sliding speed, and temperature on tribological performance and, possibly, tailoring composition for specific applications. We expect that the availability of measured performance data will enhance the market penetration of PM300 technology.

Striebing, Donald R.↗

NASA NTRS1984

Evaluation of long-duration exposure to the natural space environment on graphite-polyimide and graphite-epoxy mechanical properties (A0175)

The primary objective of this experiment is to accumulate the needed operational data associated with the exposure of graphite-polyimide and graphite-epoxy material to the environments of space. The experiment will be mounted in two 3-in.-deep peripheral trays. Graphite-polyimide specimens will occupy 1 1/3 trays and the graphite-epoxy specimens will occupy two-thirds of a tray. The experiment approach requires two matched sets of specimens with traceable records that are maintained for materials processing and specimen quality. After fabrication, one set of each test specimen will be sectioned and structurally tested to serve as a data baseline. After the flight, the other set of specimens will undergo extensive measurements of mechanical properties for comparison with the original data baseline. Structural testing of the graphite-polyimide specimens will provide strength and elastic data in tension, compression, and shear. Transverse tension microcracking and crack propagation will be evaluated by photomicroscopy. Structural testing of the graphite-epoxy specimens will include verification of laminate, core, adhesive, and fatigue properties as applied to the design and analysis of the payload bay door. Microcracking and crack propagation will also be analyzed by photomicroscopy.

Powell, J. H.↗

NASA NTRS1987

Baseline tensile tests of composite materials for LDEF (Long Duration Exposure Facility) exposure

Tensile specimens of five graphite fiber reinforced composite materials were tested at room temperature to provide baseline data for similar specimens exposed to the space environment in low-Earth orbit on the NASA Long Duration Exposure Facility. All specimens were 4-ply (+ or - 45 deg)s layups; at least five replicate specimens were tested for each parameter evaluated. Three epoxy-matrix materials and two polysulfone-matrix materials, several fiber volume fractions, and two sizes of specimen were evaluated. Stress-strain and Poisson's ratio-stress curves, ultimate stress, strain at failure, secant modulus at 0.004 strain, inplane shear stress-strain curves, and unidirectional shear modulus at .004 shear strain are presented.

Witte, William G.↗

NASA NTRS1990

Flammabilities Of Graphite-Reinforced Composites

Report describes tests and comparisons of flammabilities, thermal properties, and selected mechanical properties of composite materials made of epoxy and other matrices reinforced by graphite fibers. Composites also compared with baseline epoxy/fiberglass composite. Considers such properties as limiting oxygen index, smoke evolution, products of thermal degradation, total heat release, heat-release rate, loss of mass, spread of flames, resistance to ignition, and thermal stability.

Kourtides, Demetrius A.↗

NASA NTRS1976

Structural design of space telescope

Problematic areas are discussed relative to the design of the NASA Large Space Telescope with a view toward showing how these areas are currently being treated so that the primary goals of the program can be met. The discussion covers basic mission, design parameters, metering structural material, and measurements of thermal expansion coefficient and scale testing. Since the test program has not been completed, there are so far no data available to show comparison between the baseline metering structure design and test. However, graphite-epoxy appears very favorable for structural uses, where precise alignment is necessary and a high degree of thermal stability is desired. It is anticipated that there will be a convergence on a straightforward method of arranging the basic structure for the ease of manufacturing and cost savings.

Arnts, G. W., Jr.↗

NASA NTRS1981

Fillers for improved graphite fiber retention by polymer matrix composites

The results of a program designed to determine the extent to which elemental boron and boron containing fillers added to the matrix resin of graphite/epoxy composites prevent the release of graphite fibers when the composites are exposed to fire and impact conditions are described. The fillers evaluated were boron, boron carbide and aluminum boride. The conditions evaluated were laboratory simulations of those that could exist in the event of an aircraft crash and burn situation. The baseline (i.e., unfilled) laminates evaluated were prepared from commercially available graphite/epoxy. The baseline and filled laminates' mechanical properties, before and after isothermal and humidity aging, also were compared. It was found that a small amount of graphite fiber was released from the baseline graphite/epoxy laminates during the burn and impact conditions used in this program. However, the extent to which the fibers were released is not considered a severe enough problem to preclude the use of graphite reinforced composites in civil aircraft structure. It also was found that the addition of boron and boron containing fillers to the resin matrix eliminated this fiber release. Mechanical properties of laminates containing the boron and boron containing fillers were lower than those of the baseline laminates. These property degradations for two systems: boron (5 micron) at 2.5 percent filler loading, and boron (5 micron) at 5.0 percent filler loading do not appear severe enough to preclude their use in structural composite applications.

House, E. E.↗

NASA NTRS1978

Study of advanced composite structural design concepts for an arrow wing supersonic cruise configuration, task 3

A structural design study was conducted to assess the relative merits of structural concepts using advanced composite materials for an advanced supersonic aircraft cruising at Mach 2.7. The configuration and structural arrangement developed during Task I and II of the study, was used as the baseline configuration. Allowable stresses and strains were established for boron and advanced graphite fibers based on projected fiber properties available in the next decade. Structural concepts were designed and analyzed using graphite polyimide and boron polyimide, applied to stiffened panels and conventional sandwich panels. The conventional sandwich panels were selected as the structural concept to be used on the wing structure. The upper and lower surface panels of the Task I arrow wing were redesigned using high-strength graphite polyimide sandwich panels over the titanium spars and ribs. The ATLAS computer system was used as the basis for stress analysis and resizing the surface panels using the loads from the Task II study, without adjustment for change in aeroelastic deformation. The flutter analysis indicated a decrease in the flutter speed compared to the baseline titanium wing design. The flutter analysis indicated a decrease in the flutter speed compared to the baseline titanium wing design. The flutter speed was increased to that of the titanium wing, with a weight penalty less than that of the metallic airplane.

Source record↗

NASA NTRS2013

Conducting Wall Hall Thrusters

A unique configuration of the magnetic field near the wall of Hall thrusters, called Magnetic Shielding, has recently demonstrated the ability to significantly reduce the erosion of the boron nitride (BN) walls and extend the life of Hall thrusters by orders of magnitude. The ability of magnetic shielding to minimize interactions between the plasma and the discharge chamber walls has for the first time enabled the replacement of insulating walls with conducting materials without loss in thruster performance. The boron nitride rings in the 6 kW H6 Hall thruster were replaced with graphite that self-biased to near the anode potential. The thruster efficiency remained over 60% (within two percent of the baseline BN configuration) with a small decrease in thrust and increase in Isp typical of magnetically shielded Hall thrusters. The graphite wall temperatures decreased significantly compared to both shielded and unshielded BN configurations, leading to the potential for higher power operation. Eliminating ceramic walls makes it simpler and less expensive to fabricate a thruster to survive launch loads, and the graphite discharge chamber radiates more efficiently which increases the power capability of the thruster compared to conventional Hall thruster designs.

electric propulsion (EP)↗

NASA NTRS1994

A manufacturing database of advanced materials used in spacecraft structures

Cost savings opportunities over the life cycle of a product are highest in the early exploratory phase when different design alternatives are evaluated not only for their performance characteristics but also their methods of fabrication which really control the ultimate manufacturing costs of the product. In the past, Design-To-Cost methodologies for spacecraft design concentrated on the sizing and weight issues more than anything else at the early so-called 'Vehicle Level' (Ref: DOD/NASA Advanced Composites Design Guide). Given the impact of manufacturing cost, the objective of this study is to identify the principal cost drivers for each materials technology and propose a quantitative approach to incorporating these cost drivers into the family of optimization tools used by the Vehicle Analysis Branch of NASA LaRC to assess various conceptual vehicle designs. The advanced materials being considered include aluminum-lithium alloys, thermoplastic graphite-polyether etherketone composites, graphite-bismaleimide composites, graphite- polyimide composites, and carbon-carbon composites. Two conventional materials are added to the study to serve as baseline materials against which the other materials are compared. These two conventional materials are aircraft aluminum alloys series 2000 and series 7000, and graphite-epoxy composites T-300/934. The following information is available in the database. For each material type, the mechanical, physical, thermal, and environmental properties are first listed. Next the principal manufacturing processes are described. Whenever possible, guidelines for optimum processing conditions for specific applications are provided. Finally, six categories of cost drivers are discussed. They include, design features affecting processing, tooling, materials, fabrication, joining/assembly, and quality assurance issues. It should be emphasized that this database is not an exhaustive database. Its primary use is to make the vehicle designer aware of some of the most important aspects of manufacturing associated with his/her choice of the structural materials. The other objective of this study is to propose a quantitative method to determine a Manufacturing Complexity Factor (MCF) for each material being contemplated. This MCF is derived on the basis of the six cost drivers mentioned above plus a Technology Readiness Factor which is very closely related to the Technology Readiness Level (TRL) as defined in the Access To Space final report. Short of any manufacturing information, our MCF is equivalent to the inverse of TRL. As more manufacturing information is available, our MCF is a better representation (than TRL) of the fabrication processes involved. The most likely application for MCF is in cost modeling for trade studies. On-going work is being pursued to expand the potential applications of MCF.

Bao, Han P.↗

NASA NTRS1985

Antenna Technology for QUASAT application

A hybrid growth version of the advanced Sunflower, or precision deployable, antenna was adopted as the configuration proposed for the QUASAT very long baseline interferometry mission. The antenna consists of rigid panels of graphite-epoxy facesheets covering aluminum honeycomb sandwich. The six main folding panels are hinged to a cantilevered support ring attached to the periphery of the center section. Six pairs of intermediate panels are located between these panels and are hinged to each other and to the main panels. The flight configuration, antenna weight, a mass properties, frequency, and contour tolerance are discussed. The advantages of the solid antenna surface cover an all-mesh contour are examined.

Archer, J. S.↗

NASA NTRS1972

Development and fabrication of a graphite polyimide box beam

The state-of-the-art of graphite/polyimide structures was evaluated and key design and fabrication issues to be considered in future hardware programs are defined. The fabrication and testing at 500 F of a graphite/polyimide center wing box beam using OV-10A aircraft criteria was accomplished. The baseline design of this box was developed in a series of studies of other advanced composite materials: glass/epoxy, boron/epoxy, and boron/polyimide. The use of this basic design permits ready comparison of the performance of graphite/polyimide with these materials. Modifications to the baseline composite design were made only in those areas effected by the change of materials. Processing studies of graphite fiber polyimide resins systems resulted in the selection of a Modmor II/Gemon L material.

Nadler, M. A.↗

NASA NTRS1981

Preliminary design of tetrahedral truss reflector structure

A baseline structure proposed for the microwave radiometer spacecraft (MRS) reflector is a large graphite-epoxy truss. The truss structure was selected to provide adequate stiffness to minimize control problems and to provide a low-expansion 'strong back' on which to mount and control reflector mesh panels. Details of the structural members, joints and assembly concepts are presented, a concept for the reflector mesh surface is discussed, and preliminary estimates of the mass and structural natural frequencies of the reflector system are presented.

Card, M. F.↗

NASA NTRS1980

Performance Properties of Graphite Reinforced Composites with Advanced Resin Matrices

This article looks at the effect of different resin matrices on thermal and mechanical properties of graphite composites, and relates the thermal and flammability properties to the anaerobic char yield of the resins. The processing parameters of graphite composites utilizing graphite fabric and epoxy or other advanced resins as matrices are presented. Thermoset resin matrices studied were: aminecured polyfunctional glycidyl aminetype epoxy (baseline), phenolicnovolac resin based on condensation of dihydroxymethyl-xylene and phenol cured with hexamine, two types of polydismaleimide resins, phenolic resin, and benzyl resin. The thermoplastic matrices studied were polyethersulfone and polyphenylenesulfone. Properties evaluated in the study included anaerobic char yield, limiting oxygen index, smoke evolution, moisture absorption, and mechanical properties at elevated temperatures including tensile, compressive, and short-beam shear strengths. Generally, it was determined that graphite composites with the highest char yield exhibited optimum fire-resistant properties.

Kourtides, Demetrius A.↗

NASA NTRS1994

Sub-ply level scaling approach investigated for graphite-epoxy composite beam columns

Scale model graphite-epoxy composite specimens were fabricated using the 'sub-ply level' approach and tested as beam-columns under an eccentric axial load to determine the effect of specimen size on flexural response and failure. In the current research project, although the fiber diameters are not scaled, the thickness of the pre-preg material itself has been scaled by adjusting the number of fibers through the thickness of a single ply. Three different grades of graphite-epoxy composite material (AS4/3502) were obtained from Hercules, Inc., in which the number of fibers through the thickness of a single ply was reduced (Grade 190 with 12 to 16 fibers, Grade 95 with 6 to 8 fibers, and Grade 48 with 3 to 4 fibers). Thus, using the sub-ply level approach, a baseline eight ply quasi-isotropic laminate could be fabricated using either the Grade 48 or Grade 95 material and the corresponding full-scale laminate would be constructed from Grade 95 or standard Grade 190 material, respectively. Note that in the sub-ply level approach, the number of ply interfaces is constant for the baseline and full-scale laminates. This is not true for the ply level and sublaminate level scaled specimens. The three grades of graphite-epoxy composite material were used to fabricate scale model beam-column specimens with in-plane dimensions of 0.5*n x 5.75*n, where n=1,2,4 corresponsing to 1/4, 1/2, and full-scale factors. Angle ply, cross ply, and quasi-isotropic laminate stacking sequences were chosen for the investigation and the test matrices for each laminate type are given. Specimens in each laminate family with the same in-plane dimensions but different thicknesses were tested to isolate the influence of the thickness dimension on the flexural response and failure. Also, specific lay-ups were chosen with blocked plies and dispersed plies for each laminate type. Specimens were subjected to an eccentric axial load until failure. The load offset was introduced through a set of hinges which were attached to the platens of a standard load test machine. Three sets of geometrically scaled hinges were used to ensure that scaled loading conditions were applied. This loading condition was chosen because it promotes large flexural deformations and specimens fail at the center of the beam, away from the grip supports. Five channels of data including applied vertical load, end shortening displacement, strain from gages applied back-to-back at the midspan of the beam, and rotation of the hinge from a bubble inclinometer were recorded for each specimen. The beam-column test configuration was used previously to study size effects in ply level scaled composite specimens of the same material system, sizes, and stacking sequences. Thus, a direct comparison between the two scaling approaches is possible. Ply level scaled beam-columns with angle ply, cross ply, and quasi-isotropic lay-ups exhibited no size dependencies in the flexural response, but significant size effects in strength. The reduction in strength with increasing specimen size was not predicted successfully by analysis techniques. It is anticipated that results from this investigation will lead to a better understanding of the strength scale effect in composite structures.

Jackson, Karen E.↗

NASA NTRS1980

Integrated application of active controls (IAAC) technology to an advanced subsonic transport project. Conventional baseline configuration study

Characteristics of the U.S. domestic fleet were evaluated to determine the mission characteristics that would have the most impact on U. S. transport fuel use in the future. This resulted in selection of a 197-passenger (plus cargo), about 3710-km (2000 nmi) mission. The existing data base was reviewed and additional analysis was conducted as necessary to complete the technical descriptions. The resulting baseline configuration utilizes a double-lobe, but nearly circular, body with seven-abreast seating. External characteristics feature an 8.71 aspect ratio, 31.5-degree sweep wing, a T-tail empennage, and a dual CF6-6D2, wing-mounted engine arrangement. It provides for 22 LD-2 or 11 LD-3 containers plus bulk cargo in the lower lobe. Passenger/cargo loading, servicing provisions, taxi/takeoff speeds, and field length characteristics are all compatible with accepted airline operations and regulatory provisions. The baseline configuration construction uses conventional aluminum structure except for advanced aluminum alloys and a limited amount of graphite epoxy secondary structure. Modern systems are used, including advanced guidance, navigation, and controls which emphasize application of digital electronics and advanced displays.

Source record↗

NASA NTRS1991

Effects of processing induced defects on laminate response - Interlaminar tensile strength

Four different layup methods were used in the present study of the interlaminar tensile strength of AS4/3501-6 graphite-reinforced epoxy as a function of defects from manufacturing-induced porosity. The methods were: (1) baseline hand layup, (2) solvent wipe of prepreg for resin removal, (3) moisture-introduction between plies, and (4) a low-pressure cure cycle. Pore characterization was conducted according to ASTM D-2734. A significant reduction is noted in the out-of-plane tensile strength as a function of increasing void content; the porosity data were used in an empirical model to predict out-of-plane strength as a function of porosity.

Gurdal, Zafer↗