Engineered Composites for USC Applications
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11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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A theory of electrical conductivity, dielectric constant, and electromagnetic interference shielding for lightweight graphene composite foams
This work was driven by the need to understand the electromagnetic interference (EMI) shielding effectiveness (SE) of light weight, flexible, and high performance graphene composite foams, but as EMI SE of a material depends on its electrical conductivity, dielectric permittivity, and magnetic permeability, the investigation of these three properties also became a priority. In this paper, we first present a continuum theory to determine these three electromagnetic properties, and then use the obtained properties to evaluate the EMI SE of the foam. A two-scale composite model is conceived to evaluate these three properties, with the large one being the skeleton-void composite and the small one being the graphene-polymer composite that serves as the skeleton of the foam. To evaluate the properties of the skeleton, the effective-medium approach is taken as the starting point. Subsequently, the effect of an imperfect interface and the contributions of electron tunneling to the interfacial conductivity and Maxwell-Wagner-Sillars polarization mechanism to the dielectric constant are also implemented. The derived skeleton properties are then utilized on the large scale to determine the three properties of the composite foam at a given porosity. Then a uniform plane electromagnetic wave is considered to evaluate the EMI SE of the foam. It is demonstrated that the electrical conductivity, dielectric constant, and EMI SE of the foam calculated from the developed theory are in general agreement with the reported experimental data of graphene/PDMS composite foams. The theory is further proven to be valid for the EMI SE of solid graphene/epoxy and solid carbon nanotube/epoxy nanocomposites. It is also shown that, among the three electromagnetic properties, electrical conductivity has the strongest influence on the EMI shielding effectiveness.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Thermal Cycling of Thermal Control Paints on Carbon-Carbon and Carbon-Polyimide Composites
Carbon-carbon composites and carbon-polyimide composites are being considered for space radiator applications owing to their light weight and high thermal conductivity. For those radiator applications where sunlight will impinge on the surface, it will be necessary to apply a white thermal control paint to minimize solar absorptance and enhance infrared emittance. Several currently available white thermal control paints were applied to candidate carbon-carbon and carbon-polyimide composites and were subjected to vacuum thermal cycling in the range of -100 C to +277 C. The optical properties of solar absorptance and infrared emittance were evaluated before and after thermal cycling. In addition, adhesion of the paints was evaluated utilizing a tape test. The test matrix included three composites: resin-derived carbon-carbon and vapor infiltrated carbon-carbon, both reinforced with pitch-based P-120 graphite fibers, and a polyimide composite reinforced with T-650 carbon fibers, and three commercially available white thermal control paints: AZ-93, Z-93-C55, and YB-71P.
Jaworske, Donald A.↗
Structural, Thermal, and Mechanical Characterization of a Thermally Conductive Polymer Composite for Heat Exchanger Applications
Polymer composites are being considered for numerous thermal applications because of their inherent benefits, such as light weight, corrosion resistance, and reduced cost. In this work, the microstructural, thermal, and mechanical properties of a 3D printed polymer composite with high thermal conductivity are examined using multiple characterization techniques. Infrared spectroscopy and X-ray diffraction reveal that the composite contains a polyphenylene sulfide matrix with graphitic fillers, which is responsible for the high thermal conductivity. Furthermore, differential scanning calorimetry determines that the glass transition and melting point of the composite are 87.6 °C and 285.6 °C, respectively. Thermogravimetric analysis reveals that the composite is thermally stable up to ~400 °C. Creep tests are performed at different isotherms to evaluate the long-term performance of the composite. The creep result indicates that the composite can maintain mechanical integrity when used below its glass transition temperature. Nanoindentation tests reveal that modulus and hardness of the composite is not significantly influenced by heating or creep conditions. These findings indicate that the composite is potentially suitable for heat exchanger applications.
36 MATERIALS SCIENCE↗
Hybrid Heat Exchangers
A hybrid light-weight heat exchanger concept has been developed that uses high-conductivity carbon-carbon (C-C) composites as the heat-transfer fins and uses conventional high-temperature metals, such as Inconel, nickel, and titanium as the parting sheets to meet leakage and structural requirements. In order to maximize thermal conductivity, the majority of carbon fiber is aligned in the fin direction resulting in 300 W/m.K or higher conductivity in the fin directions. As a result of this fiber orientation, the coefficient of thermal expansion (CTE) of the C-C composite in both non-fiber directions matches well with the CTE of various high-temperature metal alloys. This allows the joining of fins and parting sheets by using high-temperature braze alloys.
Tu, Jianping Gene↗
Electrospun Synthesis of Reduced Graphene Oxide (RGO)/NiZn Ferrite Nanocomposites for Excellent Microwave Absorption Properties
In this work, NiZn ferrite nanofibers were fabricated via electrospinning technique, followed by physical conversion into reduced graphene oxide (RGO)/NiZn ferrite nanocomposites. The whole graphene nanosheets were uniformly decorated with these magnetic nanocrystals without aggregation. The obtained ternary composite was characterized by various instruments for the chemical composition and microstructure. The results show that RGO/NiZn ferrite nanocomposites have remarkable improvements in both permittivity and permeability, which can be attributed to the combination of the good conductivity of light-weight graphene and high magnetocrystalline anisotropy of NiZn ferrites, thus significantly improving microwave absorption properties. With a matching thickness of only 2.0 mm, the reflection loss of superior sample of RGO/Ni{sub 0.7}Zn{sub 0.3}Fe{sub 2}O{sub 4} hybrid can reach − 37.71 dB at 12.5 GHz, and a reflection loss exceeding 10 dB absorption bandwidth can achieve 3.68 GHz. This indicates that the RGO/NiZn ferrite composite is an excellent and promising microwave absorbent with good absorption property, thin thickness, and wide absorption bandwidth.
77 NANOSCIENCE AND NANOTECHNOLOGY↗
High temperature insulation barrier composite
A composite material suitable for providing insulation for the nozzle structure of the Space Shuttle and other similar surfaces is disclosed. The composite layer is comprised of an outer skin layer of nickel chromium and an interleaved inner region comprising a top layer of nickel chromium foil which acts as a primary convective shield. There are at least two layers of alumina batting adjacent to the layers of silicon carbide fabric. An additional layer of nickel chromium foil is used as a secondary convective shield. The composite is particularly advantageous for use as nozzle insulation because of its ability to withstand high reentry temperatures, its flexibility, oxidation resistance, low conductivity, and light weight.
Onstott, Joseph W.↗
Ceramic Aerogel Composite Materials and Characterization
Aerogels a.k.a "Solid Smoke" are gels with the liquid phase replaced by gas, leaving behind a highly porous material with a nanoscale framework. Due to the porous, nanoscale structure, aerogels have the lowest known density and conductivity of solids. Aerogels have the potential for being a breakthrough material because of their extremely light weight and unique properties. In this paper, we address overcoming their most profound weaknesses: mechanical fragility and very high surface activity, which leads to a lowered sintering temperature. A matrix of ceramic aerogel composite materials was produced to investigate their properties and functionality. Mechanical property measurements and Scanning Electron Micrographs are used to identify trends and structure of these ceramic composite materials. Thermal cycling was used to identify the sintering points of the materials.
White, Susan↗
NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)
The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program was initiated in 1986 and continues with a high level of activity. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. We generally aim to produce relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies. Three research areas are being actively investigated, including: (1) Mechanical and environmental degradation mechanisms in advanced light metals, (2) Aerospace materials science, and (3) Mechanics of materials for light aerospace structures.
Scully, John R.↗
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)↗
SPINEL-BASED REFRACTORIES FOR IMPROVED PERFORMANCE IN COAL GASIFICATION ENVIRONMENTS
Oak Ridge National Laboratory, in collaboration with refractory manufacturer Minteq International, Inc., academic partner Missouri University of Science and Technology and refractory end users have developed novel refractory systems and techniques to reduce energy consumption of refractory lined vessels. The objective of this U.S. DOE funded project was to address the need for innovative refractory compositions by developing MgO-Al 2O3 spinel gunnable refractory compositions utilizing new aggregate materials, bond systems, protective coatings, and phase formation techniques. Materials have been developed specifically for coal gasification environments and work has been performed to develop and apply low cost coatings using a colloidal approach for protection against attack of the refractory brick by the service environment and to develop a light-weight back-up refractory system to help offset the high thermal conductivity inherent in spinel materials. This paper discusses the systematic development of these materials, laboratory testing and evaluation of these materials, and relevant results achieved toward the reduction of chemical reactions and mechanical degradation by the service environment though compositional and processing modifications.
Hemrick, James Gordon↗
High Conductivity Carbon-Carbon Heat Pipes for Light Weight Space Power System Radiators
Based on prior successful fabrication and demonstration testing of a carbon-carbon heat pipe radiator element with integral fins this paper examines the hypothetical extension of the technology via substitution of high thermal conductivity composites which would permit increasing fin length while still maintaining high fin effectiveness. As a result the specific radiator mass could approach an ultimate asymptotic minimum value near 1.0 kg/m2, which is less than one fourth the value of present day satellite radiators. The implied mass savings would be even greater for high capacity space and planetary surface power systems, which may require radiator areas ranging from hundreds to thousands of square meters, depending on system power level.
Juhasz, Albert J.↗
Effect of formation temperature on properties of graphite/stannum composite for bipolar plate
Bipolar plates are key components in Proton Exchange Membrane (PEM) fuel cells. They carry current away from the cell and withstand the clamping force of the stack assembly. Therefore, PEM fuel cell bipolar plates must have high electrical conductivity and adequate mechanical strength, in addition to being light weight and low cost in terms of both applicable materials and production methods. In this research, the raw materials used to fabricate the high performance bipolar plate are Graphite (Gr), Stannum (Sn) and Polypropylene (PP). All materials used was in powder form and Gr and Sn act as fillers and the PP acts as binder. The ratio of fillers (Gr/Sn) and binder (PP) was fixed at 80:20. For the multi-conductive filler, small amount of Sn, which is 10 up to 20wt% (from the total weight of fillers 80%) have been added into Gr/Sn/PP composite. The fillers were mixed by using the ball mill machine. The second stage of mixing process between the mixer of fillers and binder is also carried out by using ball mill machine before the compaction process by the hot press machine. The effect of formation temperatures (160°C-170°C) on the properties of Gr/Sn/PP composite had been studied in detail, especially the electrical conductivity, bulk density, hardness and microstructure analysis of Gr/Sn/PP composite. The result shows that there are significant improvement in the electrical conductivity and bulk density, which are exceeding the US-DoE target with the maximum value of 265.35 S/cm and 1.682g/cm{sup 3} respectively.
36 MATERIALS SCIENCE↗
Refractory Materials based on Magnesia-Alumina Spinel for Improved Performance in Coal Gasification Environments
As part of a larger project to develop novel refractory systems and techniques to reduce energy consumption of refractory lined vessels, a team composed of Oak Ridge National Laboratory, refractory manufacturer Minteq International, Inc., and academic partner Missouri University of Science and Technology have developed new refractory materials and coating systems specifically for application in coal gasification environments. Materials were developed under this U.S. DOE funded project to address the need for innovative refractory compositions by developing MgO-Al2O3 spinel gunnable refractory compositions utilizing new aggregate materials, bond systems, protective coatings, and phase formation techniques. Work was conducted to develop and deploy these new materials and to develop and apply low cost coatings using a colloidal approach for protection against attack of the refractory brick by the serviced environment. Additionally, a light-weight back-up refractory system was developed to help offset the high thermal conductivity inherent in spinel materials. This paper discusses the efforts involved in the development of these materials, along with the laboratory testing and evaluation of these materials leading to relevant results achieved toward the reduction of chemical reactions and mechanical degradation by the service environment though compositional and processing modifications.
Hemrick, James Gordon↗
NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)
The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program continues a high level of activity. Progress achieved between 1 Jan. and 30 Jun. 1993 is reported. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light weight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. The following projects are addressed: environmental fatigue of Al-Li-Cu alloys; mechanisms of localized corrosion and environmental fracture in Al-Cu-Li-Mg-Ag alloy X2095 and compositional variations; the effect of zinc additions on the precipitation and stress corrosion cracking behavior of alloy 8090; hydrogen interactions with Al-Li-Cu alloy 2090 and model alloys; metastable pitting of aluminum alloys; cryogenic fracture toughness of Al-Cu-Li + In alloys; the fracture toughness of Weldalite (TM); elevated temperature cracking of advanced I/M aluminum alloys; response of Ti-1100/SCS-6 composites to thermal exposure; superplastic forming of Weldalite (TM); research to incorporate environmental effects into fracture mechanics fatigue life prediction codes such as NASA FLAGRO; and thermoviscoplastic behavior.
Gangloff, Richard P.↗
Plasma-Sprayed Refractory Oxide Coatings on Silicon-Base Ceramics
Silicon-base ceramics are promising candidate materials for high temperature structural applications such as heat exchangers, gas turbines and advanced internal combustion engines. Composites based on these materials are leading candidates for combustor materials for HSCT gas turbine engines. These materials possess a combination of excellent physical and mechanical properties at high temperatures, for example, high strength, high toughness, high thermal shock resistance, high thermal conductivity, light weight and excellent oxidation resistance. However, environmental durability can be significantly reduced in certain conditions such as when molten salts, H2 or water vapor are present. The oxidation resistance of silicon-base materials is provided by SiO2 protective layer. Molten salt reacts with SiO2 and forms a mixture of SiO2 and liquid silicate at temperatures above 800C. Oxygen diffuses more easily through the chemically altered layer, resulting in a catastrophic degradation of the substrate. SiC and Si3N4 are not stable in pure H2 and decompose to silicon and gaseous species such as CH4, SiH, SiH4, N2, and NH3. Water vapor is known to slightly increase the oxidation rate of SiC and Si3N4. Refractory oxides such as alumina, yttria-stabilized zirconia, yttria and mullite (3Al2O3.2SiO2) possess excellent environmental durability in harsh conditions mentioned above. Therefore, refractory oxide coatings on silicon-base ceramics can substantially improve the environmental durability of these materials by acting as a chemical reaction barrier. These oxide coatings can also serve as a thermal barrier. The purpose of this research program has been to develop refractory oxide chemical/thermal barrier coatings on silicon-base ceramics to provide extended temperature range and lifetime to these materials in harsh environments.
Tewari, Surendra↗
NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)
The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program was initiated in 1986 and continues with a high level of activity. Here, we report on progress achieved between July I and December 31, 1996. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. We generally aim to produce relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies. The accomplishments presented in this report are summarized as follows. Three research areas are being actively investigated, including: (1) Mechanical and Environmental Degradation Mechanisms in Advanced Light Metals, (2) Aerospace Materials Science, and (3) Mechanics of Materials for Light Aerospace Structures.
Gangloff, Richard P.↗