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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Fabrication of a Silicon Backshort Assembly for Waveguide-Coupled Superconducting Detectors

The Cosmology Large Angular Scale Surveyor (CLASS) is a ground-based instrument that will measure the polarization of the cosmic microwave background to search for evidence for gravitational waves from a posited epoch of inflation early in the Universe s history. This measurement will require integration of superconducting transition-edge sensors with microwave waveguide inputs with excellent control of systematic errors, such as unwanted coupling to stray signals at frequencies outside of a precisely defined microwave band. To address these needs we present work on the fabrication of micromachined silicon, producing conductive quarter-wave backshort assemblies for the CLASS 40 GHz focal plane. Each 40 GHz backshort assembly consists of three degeneratively doped silicon wafers. Two spacer wafers are micromachined with through-wafer vias to provide a 2.04 mm long square waveguide delay section. The third wafer terminates the waveguide delay in a short. The three wafers are bonded at the wafer level by Au-Au thermal compression bonding then aligned and flip chip bonded to the CLASS detector at the chip level. The micromachining techniques used have been optimized to create high aspect ratio waveguides, silicon pillars, and relief trenches with the goal of providing improved out of band signal rejection. We will discuss the fabrication of integrated CLASS superconducting detector chips with the quarter-wave backshort assemblies.

Crowe, Erik J.↗
NASA NTRS2012

Fabrication of Silicon Backshorts with Improved Out-of-Band Rejection for Waveguide-Coupled Superconducting Detectors

The Cosmology Large Angular Scale Surveyor (CLASS) is a ground-based instrument that will measure the polarization of the cosmic microqave background to search for gravitational waves form a posited epoch of inflation early in the universe's history. This measurement will require integration of superconducting transition-edge sensors with microwave waveguide inputs with good conrol of systematic errors, such as unwanted coupling to stray signals at frequencies outside of a precisely defined microwave band. To address these needs we will present work on the fabrication of silicon quarter-wave backshorts for the CLASS 40GHz focal plane. The 40GHz backshort consists of three degeneratively doped silicon wafers. Two spacer wafers are micromachined with through wafer vins to provide a 2.0mm long square waveguide. The third wafer acts as the backshort cap. The three wafers are bonded at the wafer level by Au-Au thermal compression bonding then aligned and flip chip bonded to the CLASS detector at the chip level. The micromachining techniques used have been optimized to create high aspect ratio waveguides, silicon pillars, and relief trenches with the goal of providing improved out of band signal rejection. We will discuss the fabrication of integrated CLASS superconducting detectors with silicon quarter wave backshorts and present current measurement results.

Crowe, Erik J.↗
NASA NTRS2003

Cloverleaf Vibratory Microgyroscope with Integrated Post

A modified design and fabrication sequence has been devised to improve the performance of a cloverleaf vibratory microgyroscope that includes an axial rod or post rigidly attached to the center of the cloverleaf structure. The basic concepts of cloverleaf vibratory microgyroscopes, without and with rods or posts, were described in two prior articles in NASA Tech Briefs, Vol. 21, No. 9 (September 1997): Micromachined Planar Vibratory Microgyroscopes (NPO-19713), page 68 and Planar Vibratory Microgyroscope: Alternative Configuration (NPO-19714), page 70. As described in more detail in the second-mentioned prior article, the cloverleaf-shaped structure and the rod or post are parts of a vibratory element that senses rotation via the effect of the Coriolis force upon its vibrations. Heretofore, the posts for devices of this type have been fabricated separately, then assembled manually onto the cloverleaf structures. The resulting imperfections in the assembled units have given rise to asymmetric stresses in the cloverleaf structures and, consequently, to changes in resonant frequencies of vibration and in shapes of vibration modes. These changes, in turn, have caused variations in performance among nominally identical devices. The modified design provides for the fabrication of the upper half of the post as an integral part of the cloverleaf structure; this is accomplished by reactive-ion etching of a single-piece half-post-and-cloverleaf structure from a wafer of silicon. The lower half of the post and a baseplate are also a single piece made by reactive-ion etching from a wafer of silicon. The two pieces are bonded together (see figure) by a thermal-compression metal-to-metal bonding technique to form a cloverleaf gyroscope with an integrated post structure..

Tang, Tony K.↗
NASA NTRS2009

Advanced Embedded Active Assemblies for Extreme Space Applications

This work describes the development and evaluation of advanced technologies for the integration of electronic die within membrane polymers. Specifically, investigators thinned silicon die, electrically connecting them with circuits on flexible liquid crystal polymer (LCP), using gold thermo-compression flip chip bonding, and embedding them within the material. Daisy chain LCP assemblies were thermal cycled from -135 to +85degC (Mars surface conditions for motor control electronics). The LCP assembly method was further utilized to embed an operational amplifier designed for operation within the Mars surface ambient. The embedded op-amp assembly was evaluated with respect to the influence of temperature on the operational characteristics of the device. Applications for this technology range from multifunctional, large area, flexible membrane structures to small-scale, flexible circuits that can be fit into tight spaces for flex to fit applications.

lead bonding↗
NASA NTRS1981

Design, Fabrication and Test of Graphite/Polyimide Composite Joints and Attachments for Advanced Aerospace Vehicles

Standard and advanced bonded joint concepts were evaluated to develop a data base for the design and analysis of advanced composite joints for use at elevated temperatures (561K (550F)). Design concepts for specific joint applications and the fundamental parameters controlling the static strength characteristics of such joints were identified. Test results are presented for rail shear and sandwich beam compression tests and tension tests of moisture conditioned specimens and bonded on "T" sections. Coefficients of thermal expansion data are presented for A7F (LARC 13 Amide-imide modified) adhesion. Static discriminator test results for type 1 and type 2 bonded and bolted preliminary attachment concepts are presented and discussed.

Cushman, J. B.↗
NASA NTRS2009

Durable Suit Bladder with Improved Water Permeability for Pressure and Environment Suits

Water vapor permeability is shown to be useful in rejecting heat and managing moisture accumulation in launch-and-entry pressure suits. Currently this is accomplished through a porous Gortex layer in the Advanced Crew and Escape Suit (ACES) and in the baseline design of the Constellation Suit System Element (CSSE) Suit 1. Non-porous dense monolithic membranes (DMM) that are available offer potential improvements for water vapor permeability with reduced gas leak. Accordingly, three different pressure bladder materials were investigated for water vapor permeability and oxygen leak: ElasthaneTM 80A (thermoplastic polyether urethane) provided from stock polymer material and two custom thermoplastic polyether urethanes. Water vapor, carbon dioxide and oxygen permeability of the DMM's was measured in a 0.13 mm thick stand-alone layer, a 0.08 mm and 0.05 mm thick layer each bonded to two different nylon and polyester woven reinforcing materials. Additional water vapor permeability and mechanical compression measurements were made with the reinforced 0.05 mm thick layers, further bonded with a polyester wicking and overlaid with moistened polyester fleece thermal underwear .This simulated the pressure from a supine crew person. The 0.05 mm thick nylon reinforced sample with polyester wicking layer was further mechanically tested for wear and abrasion. Concepts for incorporating these materials in launch/entry and Extravehicular Activity pressure suits are presented.

Bue, Grant C.↗
NASA NTRS1980

Effect of thermal cycling on ZrO2-Y2O3 thermal barrier coatings

A study was made of the comparative life of plasma sprayed ZrO2-Y2O3 thermal barrier coatings on NiCrAlY bond coats on Rene 41 in short (4 min) and long (57 min) thermal cycles to 1040 C in a 0.3 Mach flame. Short cycles greatly reduced the life of the ceramic coating in terms of time at temperature as compared to longer cycles. Appearance of the failed coating indicated compressive failure. Failure occurred at the bond coat-ceramic coat junction. At heating rates greater than 550 kw/sq m, the calculated coating detachment stress was in the range of literature values of coating adhesive/cohesive strength. Methods are discussed for decreasing the effect of high heating rate by avoiding compressive stress.

Mcdonald, G.↗
NASA NTRS1972

Metal aircraft structural elements reinforced with graphite filamentary composites

Strain compatibility equations are used to evaluate the thermal stresses existing when unidirectional graphite composites are bonded to aluminum structures. Based on thermal stresses and optimum placement of the composite, skin-stringer aluminum panels are optimized for minimum weight compression panels with selective composite reinforcement. Composite reinforced skin-stringer panels are thermal cycled to determine the effect of thermal fatigue on structural integrity. Both cycled and uncycled panels are tested in compression and tension. Test results are correlated with predicted loads. Use of filamentary graphite composites is an efficient method of reinforcing metal structures, but care must be taken to minimize thermal stresses.

Berg, K. R.↗
NASA NTRS2007

Strain Gauges Indicate Differential-CTE-Induced Failures

A method of detecting mechanical failure induced by variation in temperature at an adhesive bond between two materials that have different coefficients of thermal expansion (CTEs) involves monitoring of strain-gauge readings. This method can be regarded as an exploitation of the prior observation that the readings of strain gauges commonly used in tensile and compressive testing of material specimens include features indicative of incremental failures in the specimens. In this method, one or more strain gauges are bonded to either or both of the two materials near the bond between the materials. (The adhesive used to bond the strain gauges would not ordinarily be the same as the one used to bond the two materials). Then strain-gauge readings are recorded as the temperature of the materials is varied through a range of interest. Any significant discontinuity in the slope of the resulting strain-versus-temperature curve(s) is taken to be a qualitative indication of a failure of the bond between the two materials and/or a failure within one of the materials in the vicinity of the bond. The method has been demonstrated in experiments on specimens consisting of polyacrylonitrile-fiber/epoxy-matrix laminated composite plates bonded by epoxy to smaller plates made, variously, of aluminum, titanium, and a low-CTE nickel/iron alloy. In preparation for each experiment, strain gauges were bonded, by use of cryogenic-rated adhesives, to the composite plate near the corners of the metal plate (see Figure 1). In each experiment, strain-gauge and temperature readings were taken as the specimen was cooled from room temperature to 20 K. The specimens were then returned to room temperature and ultrasonically inspected for damage in the bond region. No failure events were detectable in the strain-gauge readings from the composite/ titanium and composite/low-thermalexpansion- alloy specimens, and ultrasonic inspection of these specimens revealed no damage. However, failure events were seen in the strain-gauge readings from the composite/aluminum specimens (see Figure 2), and ultrasonic inspection confirmed that there was damage in the bond regions of these specimens.

Harris, Brian↗
NASA NTRS1990

Mechanical strength and thermophysical properties of PM212: A high temperature self-lubricating powder metallurgy composite

A powder metallurgy composite, PM212, composed of metal bonded chromium carbide and solid lubricants is shown to be self-lubricating to a maximum application temperature of 900 C. The high temperature compressive strength, tensile strength, thermal expansion and thermal conductivity data needed to design PM212 sliding contact bearings and seals are reported for sintered and isostatically pressed (HIPed) versions of PM212. Other properties presented are room temperature density, hardness, and elastic modulus. In general, both versions appear to have adequate strength to be considered as sliding contact bearing materials, but the HIPed version, which is fully dense, is much stronger than the sintered version which contains about 20 percent pore volume. The sintered material is less costly to make, but the HIPed version is better where high compressive strength is important.

Edwards, Phillip M.↗
NASA NTRS2017

Quantitative Characterization of Structural and Mechanical Properties of Boron Nitride Nanotubes in High Temperature Environments

The structural stability and mechanical integrity of boron nitride nanotubes (BNNTs) in high temperature environments are of importance in pursuit of their applications that are involved with extreme thermal processing and/or working conditions, but remain not well understood. In this paper, we perform an extensive study of the impacts of high temperature exposure on the structural and mechanical properties of BNNTs with a full structural size spectrum from nano- to micro- to macro-scale by using a variety of in situ and ex situ material characterization techniques. Atomic force microscopy (AFM) and high resolution transmission electron microscopy measurements reveal that the structures of individual BNNTs can survive at up to 850 °C in air and capture the signs of their structural degradation at 900 °C or above. In situ Raman spectroscopy measurements reveal that the BN bonds in BNNT micro-fibrils undergo substantial softening at elevated temperatures of up to 900 °C. The AFM-based nanomechanical compression measurements demonstrate that the mechanical integrity of individual BNNTs remain intact after being thermally baked at up to 850 °C in air. The studies reveal that BNNTs are structurally and mechanically stable materials in high temperature environments, which enables their usages in high temperature applications.

Chen, Xiaoming↗
NASA NTRS2013

Nickel-Graphite Composite Compliant Interface and/or Hot Shoe Material

Next-generation high-temperature thermoelectric-power-generating devices will employ segmented architectures and will have to reliably withstand thermally induced mechanical stresses produced during component fabrication, device assembly, and operation. Thermoelectric materials have typically poor mechanical strength, exhibit brittle behavior, and possess a wide range of coefficient of thermal expansion (CTE) values. As a result, the direct bonding at elevated temperatures of these materials to each other to produce segmented leg components is difficult, and often results in localized microcracking at interfaces and mec hanical failure due to the stresses that arise from the CTE mismatch between the various materials. Even in the absence of full mechanical failure, degraded interfaces can lead to increased electrical and thermal resistances, which adversely impact conversion efficiency and power output. The proposed solution is the insertion of a mechanically compliant layer, with high electrical and thermal conductivity, between the low- and high-temperature segments to relieve thermomechanical stresses during device fabrication and operation. This composite material can be used as a stress-relieving layer between the thermoelectric segments and/or between a thermoelectric segment and a hot- or cold-side interconnect material. The material also can be used as a compliant hot shoe. Nickel-coated graphite powders were hot-pressed to form a nickel-graphite composite material. A freestanding thermoelectric segmented leg was fabricated by brazing the compliant pad layer between the high-temperature p- Zintl and low-temperature p-SKD TE segments using Cu-Ag braze foils. The segmented leg stack was heated in vacuum under a compressive load to achieve bonding. The novelty of the innovation is the use of composite material that re duces the thermomechanical stresses en - countered in the construction of high-efficiency, high-temperature therm - o-electric devices. The compliant pad enables the bonding of dissimilar thermoelectric materials while maintaining the desired electrical and thermal properties essential for efficient device operation. The modulus, CTE, electrical, and thermal conductances of the composite can be controlled by varying the ratio of nickel to graphite.

Firdosy, Samad A.↗
NASA NTRS1984

Failure analysis for composite laminates

A discussion of the tensor polynomial failure criterion is presented together with a description of a biaxial compression test procedure used in the evaluation of the interaction strength parameters. In addition, a formulation for predicting the fatigue life of laminates is given based on the experimental evaluation of fatigue functions which are also utilized in a form of the tensor polynomial failure criterion as well. Experimental results are provided to compare with the fatigue life predictions and to demonstrate the effect of flaws and environment. Both bond-line defects in sandwich beam construction and inter-laminar disbond flaws are studied. Up to present, compressive strength test data have been obtained for ambient and elevated temperature, moisture-saturated conditions, including results from thermal-spike cycling simulating supersonic flight.

Tennyson, R. C.↗
NASA NTRS1982

Graphite/polyimide technology overview and Space Shuttle Orbiter applications

The materials, production processes, testing procedures, and repair techniques for composite structures on the Orbiter are reviewed. The Orbiter currently features graphite/epoxy payload bay doors, as well as graphite/polyimide elevons, vertical tail, and aft body flap, which can withstand up to 600 F temperatures. Graphite/polyimide is also being considered for areas of the baseline aluminum structure and the thermal protection system in order to achieve a 20-30% weight reduction, i.e., over 7.5 tons. An analysis of the allowable stresses on FRC imide thermal protection system tiles bonded directly to the structure has shown satisfactory performances in high temperature and cryogenic conditions, although failure modes are yet to be determined. Ultrasonic emissions have been used for defect detection in nondestructive evaluations, together with tension, notch, shear, and compression tests. Field repairs have not been perfected, and require the evolution of high temperature adhesives that are curable under vacuum pressure and heat blankets.

Morita, W. H.↗
NASA NTRS1993

Effect of thermal cycling on interface bonding requirements in Al2O3 fiber-reinforced superalloy composites

CTE (coefficient of thermal expansion) mismatch-induced stresses as they affect the fiber-matrix bond integrity of Al2O3 fiber-reinforced superalloy composites are examined. Of the three individual stress components, only the radial stress directly affects the integrity of the fiber-matrix interface. It is noted that a compressive radial stress leads to a clamping action on the fiber and is therefore beneficial to the integrity of the fiber-matrix bond. A radial tensile stress, on the other hand, can cause debonding of the fiber from the matrix for a weak fiber-matrix bond.

Misra, Ajay K.↗
NASA NTRS2010

Silica/Polymer and Silica/Polymer/Fiber Composite Aerogels

Aerogels that consist, variously, of neat silica/polymer alloys and silica/polymer alloy matrices reinforced with fibers have been developed as materials for flexible thermal-insulation blankets. In comparison with prior aerogel blankets, these aerogel blankets are more durable and less dusty. These blankets are also better able to resist and recover from compression . an important advantage in that maintenance of thickness is essential to maintenance of high thermal-insulation performance. These blankets are especially suitable as core materials for vacuum- insulated panels and vacuum-insulated boxes of advanced, nearly seamless design. (Inasmuch as heat leakage at seams is much greater than heat leakage elsewhere through such structures, advanced designs for high insulation performance should provide for minimization of the sizes and numbers of seams.) A silica/polymer aerogel of the present type could be characterized, somewhat more precisely, as consisting of multiply bonded, linear polymer reinforcements within a silica aerogel matrix. Thus far, several different polymethacrylates (PMAs) have been incorporated into aerogel networks to increase resistance to crushing and to improve other mechanical properties while minimally affecting thermal conductivity and density. The polymethacrylate phases are strongly linked into the silica aerogel networks in these materials. Unlike in other organic/inorganic blended aerogels, the inorganic and organic phases are chemically bonded to each other, by both covalent and hydrogen bonds. In the process for making a silica/polymer alloy aerogel, the covalent bonds are introduced by prepolymerization of the methacrylate monomer with trimethoxysilylpropylmethacrylate, which serves as a phase cross-linker in that it contains both organic and inorganic monomer functional groups and hence acts as a connector between the organic and inorganic phases. Hydrogen bonds are formed between the silanol groups of the inorganic phase and the carboxyl groups of the organic phase. The polymerization process has been adapted to create interpenetrating PMA and silica-gel networks from monomers and prevent any phase separations that could otherwise be caused by an overgrowth of either phase. Typically, the resulting PMA/silica aerogel, without or with fiber reinforcement, has a density and a thermal conductivity similar to those of pure silica aerogels. However, the PMA enhances mechanical properties. Specifically, flexural strength at rupture is increased to 102 psi (=0.7 MPa), about 50 times the flexural strength of typical pure silica aerogels. Resistance to compression is also increased: Applied pressure of 17.5 psi (=0.12 MPa) was found to reduce the thicknesses of several composite PMA/silica aerogels by only about 10 percent.

Ou, Danny↗
NASA NTRSDate not supplied

Numerical Prediction of Heat Transfer Coefficients during Xenon Tank Fill in Microgravity

NASA’s Gateway will serve as an orbital outpost to enable sustained human lunar exploration and facilitate access to destinations beyond the Moon. To maintain sustainable deep space missions, on-orbit propellant transfer and refueling must be realized. One of Gateway’s critical components, the Power and Propulsion Element (PPE), will use solar electric propulsion to perform attitude control maneuvers and orbit transfers. Xenon will be used as the propellant for the PPE and stored in a composite overwrapped pressure vessel (COPV). During the propellant refueling process, xenon will compress causing the fluid and tank walls to warm. There is concern that the bond between the tank liner and composite may degrade at elevated temperatures, along with the possibility of the tank exceeding design pressure. While on-orbit testing is being proposed, numerical models are being used to predict the thermal response and reduce risk during a refueling operation in microgravity where natural convection is diminished. Accurate numerical models may be used to inform decisions for follow-on testing, or design and operation of refueling architectures. Challenges of modeling xenon tank fill in microgravity include non-ideal gas behavior, operating near the fluid’s critical point, and lack of experimental flight data. This study presents a computational fluid dynamics (CFD) model with conjugate heat transfer that is used to predict averaged heat transfer coefficients during tank filling. At the anticipated injection flow rates, the CFD results showed that forced convection dominates in microgravity. Initial results from a multi-node Thermal Desktop model that assumed a purely conducting fluid (Nu=1) over-predicted the CFD fluid temperature and pressure, while a similar model allowing for natural convection under-predicted. The heat transfer coefficients predicted by CFD were implemented into the multi-node model, and the COPV thermal response from the two computational approaches were compared with good agreement.

Heat Transfer↗