ALBERT

Description: HAN-TEAN (hydroxylammonium nitrate - triethanolammonium nitrate - in water) is being considered for various propellant applications. This propellant has advantages in terms of insensitivity to impact and fire, low vapor pressure and environmentally benign reaction products. One office concerns with HAN-TEAN is its stability and shelf-life, especially when contaminated with trace metals. Stabilizer systems, consisting of anti-oxidants and/or chealating agents were investigated for their ability to control the decomposition of HAN-TEAN. Isothermal microcalorimetry, an ultrasensitive heat measurement technique, was used to monitor the decomposition of HANTEAN at near ambient temperatures. Isothermal microcalorimetry measures the heat flow from a reaction vessel into a surrounding heat sink. Microcalorimetry is approximately 1,000 times more sensitive than accelerating rate calorimetry (ARC) or differential scanning calorimetry (DSC) for measuring heat flow. Samples of HAN-TEAN containing the stabilizers were spiked with 50 ppm iron and the heat evolution monitored for a period of at least 30 days. Ten stabilizer combinations were tested and the rates of HAN-TEAN decomposition were lowered by 74 to 95 percent in the presence of iron.

Description: Permeation resistance was determined by measuring the breakthrough time and time-averaged vapor transmission rate of monomethylhydrazine (MMH) through two types of personal protective equipment (PPE). The two types of PPE evaluated were the totally encapsulating ILC Dover Chemturion Model 1212 chemical protective suit with accessories, and the FabOhio polyvinyl chloride (PVC) splash garment. Two exposure scenarios were simulated: (1) a saturated vapor exposure for 2 hours (h), and (2) a brief MMH 'splash' followed by a 2-h saturated vapor exposure. Time-averaged MMH concentrations inside the totally-encapsulating suit were calculated by summation of the area-weighted contributions made by each suit component. Results show that the totally encapsulating suit provides adequate protection at the new 10 ppb Threshold Limit Value Time-Weighted Average (TLV-TWA). The permeation resistance of the PVC splash garment to MMH was poorer than any of the totally encapsulating suit materials tested. Breakthrough occurred soon after initial vapor or 'splash' exposure.

Description: Multi-body launch vehicles require the use of Solid Film Lubricants (SFLs) to allow for unrestricted relative motion between structural assemblies and components during lift off and ascent into orbit. The Space Shuttle Solid Rocket Booster (SRB), uses a dual coat, ceramic-bonded high temperature SFL in several locations such as restraint hardware between the SRB aft skirt and the Mobile Launch Platform (MLP), the aft SRB/External Tank (ET) attach struts, and the forward skirt SRB/ET attach ball assembly. The proposed National Launch System (NLS) may require similar applications of SFLs for attachment and restraint hardware. A family of environmentally compatible nonlead/antimony bearing alternative SFLs have been developed including a compatible repair material. In addition, commercial applications for SFLs on transportation equipment, all types of lubricated fasteners, and energy related equipment allow for wide usage of these new lubricants. The new SFLs named BOOSTERLUBE is a family of single layer thin film (0.001 inch maximum) coatings that are a unique mixture of non-hazardous pigments in a compatible resin system that allows for low temperature curing (450 F). Significant savings in energy and processing time as well as elimination of hazardous material usage and disposal would result from the non-toxic onestep SFL application. Compatible air-dry field repair lubricants will help eliminate disassembly of launch vehicle restraint hardware during critical time sensitive assembly operations.

Description: Perfluoroakylpolyether (PFPE) greases are used extensively in critical flight hardware in a space environment. In the past, these greases have been processed using chlorofluorocarbon (CFC) based solvents. In response to the recent ban of CFC's, new formulations of environmentally friendly PFPE greases that are not processed with CFC based solvents were developed. The purpose of this study was to compare the performance of a new environmentally friendly formulation PFPE grease to a previously proven space compatible formulation PFPE grease. A one year test using 20 small electrical motors (two bearings per motor) was conducted in a high vacuum environment(2.0 x 10(exp 4)) Torr at a temperature of 90 C. Twenty bearings were lubricated with a new environmentally friendly formulation, and twenty bearings were lubricated with an old formulation. The mass of each lubricated bearing was measured both pre and post test. Along with mass loss measurements a profilometer trace was taken to measure post test wear of the bearings. In addition the bearings were visually examined and analyzed using an optical microscope.

Description: The use of molecular adsorbers, in order to aid in the reduction of the spacecraft contamination levels, is discussed. Molecular adsorbers are characterized by an extremely large surface area, molecularly-porous substructure, and processing charged sites capable of retaining molecular contaminant species. Molecular adsorbers were applied on two Hubble Space Telescope servicing missions, as well as on the tropical rainfall measuring mission. The use of molecular adsorbers carries the potential for low cost, easy fabrication and integration of reliable means for reducing the contamination level around spacecraft.

Description: Teflon(TM) fluorinated ethylene-propylene (FEP) is used on the exterior of spacecraft surfaces in the low earth orbit environment for thermal control. Silverized or aluminized Teflon(TM) FEP used in the Long Duration Exposure Facility (LDEF) and the Hubble Space Telescope (HST) provided evidence of the low earth orbit environments. Samples from the LDEF and HST were evaluated for solar induced embrittlement and for synergistic effects of solar degradation and atomic oxygen.

Description: The Environmental Chemistry and Compatability Team at The Marshall Space Flight Center conducts toxic offgassing analysis on materials and flight hardware for use in habitable environments aboard the Space Shuttle and the International Space Station. As part of Research and Development, the Toxic Offgassing Laboratory conducted a long term cure study on four polyurethane coatings which are slated for potential use on Space Station. This study demonstrates the effects of cure time and temperature on the total tox value (sum T) and the maximum usage weight for each coating. All analysis was conducted according to test procedures outlined specifically for Space Station environments. Therefore, the ratings and weight limits generated for these materials are most applicable to space environments. However, this test does give some indication of time frames for solvent removal and is therefore of interest to, the environmental community as a whole.

Description: Solid film adhesion testing was used to determine the effect different environmentally compliant cleaners have on the adhesion properties of solid film lubricants used for several NASA programs. In an action to remove ozone depleting chemicals from aerospace processes, a replacement cleaner must be identified that does not affect the adhesion of solid film lubricants used on flight critical NASA hardware. ASTM D251083 Standard Test Method for Adhesion of Solid Film Lubricants was used to evaluate the cleaners. Two different lubricants - Inlox 88 and Boosterlube - were tested using various commercially available cleaners. Inlox 88 is produced by E/M Corporation and is a liquid oxygen compatible lubricant used in the Space Shuttle Main Engine, and Boosterlube is a new lubricant being implemented for use on the Space Shuttle Solid Rocket Booster. These lubricants were selected because of their specific use on flight critical NASA components. Results of this testing are presented in the paper.

Description: The objectives of these experiments are to show that the area of biomaterials, especially dental materials (natural and synthetic), contain all of the elements of good and bad design, with the caveat that a person's health is directly involved. The students learn the process of designing materials for the complex interactions in the oral cavity, analyze those already used, and suggest possible solutions to the problems involved with present technology. The N.I.O.S.H. Handbook is used extensively by the students and judgement calls are made, even without extensive biology education.

Description: Experimental observations on the cyclic behavior of a NiTi alloy (Nitinol) at temperatures in the neighborhood of the A(sub f) (austenite finish) temperature are presented. The strongly heterogeneous nature of the deformation behavior of this material at temperatures within this regime during the first cycle is examined with emphasis placed on the difficulties that the existence of such phenomena pose on the formulation of realistic constitutive relations. It is further demonstrated that this heterogeneity of deformation persists on subsequent cycles with the result that the hysteretic cyclic behavior of these alloys can exhibit a point to point variation in an otherwise uniform geometry. The experimental observations on the deformation behavior of this alloy show that it is strongly dependent on temperature and prior deformation history of the sample, thus resulting in an almost intractable problem with respect to capturing an adequate constitutive description from either experiment or modeling.

Description: Plastic and rubber recycling is an effective means of reducing solid waste to the environment and preserving natural resources. A project aimed at developing a new composite material from recycled high density polyethylene (HDPE) and recycled rubber is currently being conducted at Eastern Illinois University. The recycled plastic pellets with recycled rubber particles are extruded into some HDPE/rubber composite strands. The strand can be further cut into pellets that can be used to fabricate other material forms or products. This experiment was inspired by the above-mentioned research activity. In order to measure Durometer hardness of the extruded composite, a specimen with relatively large dimensions was needed. Thus, compression molding was used to form a cylindrical specimen of 1 in. diameter and 1 in. thickness. The initial poor quality of the molded specimen prompted a need to optimize the processing parameters such as temperature, holding time, and pressure. Design of experiment (DOE) was used to obtain optimum combination of the parameters.

Description: The objective of this presentation was to point out the fact that there are many promising applications for smart structures technology on hypersonic vehicles. This is not inherently obvious due to the real and perceived operating environments of hypersonic vehicles. The idea behind this project was to talk to hypersonic vehicle designers and academics to find out what sort of problems could be solved with smart structures. Two main conclusions can be drawn: One is that the actual environment inside a hypersonic vehicle is not always as severe as it appears. The second is that the hypersonic community needs a different type of research done on a faster timetable in order to use smart structures technology. Vehicle design cycle times are such that a technology must be proven before the vehicle is designed.

Description: Materials Systems Inc. has developed a cost-effective technology for producing 1-3 piezoelectric ceramic/polymer composites for use in active surface control. MSI's 103 piezocomposite SonoPanel(TM) transducers consist of an array of piezoelectric ceramic rods arranged in a compliant polymer matrix. The standard SonoPanel(TM) composite consists of 15 volume percent PZT-5H rods 1.1 mm diameter x 6.3 mm long in a matrix of soft polyurethane. Stiff face plates are then bonded to the 1-3 composite sheet for stress amplification when used as a sensor and to enhance the surface response uniformity when used as an actuator. Many variations on this composite design have been produced for specific application requirements.

Description: Smart structures research and development, with the ultimate aim of rapid commercial and military production of these structures, are at the forefront of the Synthesis and Processing of Intelligent Cost-Effective Structures (SPICES) program. As part of this ARPA-sponsored program, MDA-E is using fiber placement processes to manufacture integrated smart structure systems. These systems comprise advanced composite structures with embedded fiber optic sensors, shape memory alloys, piezoelectric actuators, and miniature accelerometers. Cost-effective approaches and solutions to smart material synthesis in the fiber-placement process, based upon integrated product development, are discussed herein.

Description: Electrorheological fluids (ERF) are an intriguing class of non-Newtonian industrial fluids. They consist of fine dielectric particles suspended in liquids of low dielectric constants. The objectives of this research were to select a particulate system such that: (1) its density can be varied to match that of the selected liquid, and (2) the dielectric constant of the particles and the liquids should be such that the critical fields needed for asymptotic increase in viscosity are less than or equal to 10 KV/cm. Synthetic Zeolite particles were selected as the solute/suspensions. Octoil oil was selected as the solvent. The results are summarized here.

Description: The presence and importance of polycyclic aromatic hydrocarbons (PAHs, a large family of organic compounds containing carbon and hydrogen) in the interstellar medium has already been well established. The Astrochemistry Laboratory at NASA Ames Research Center (under the direction of Louis Allamandola and Scott Sandford) has been the center of pioneering work in performing spectroscopy on these molecules under simulated interstellar conditions, and consequently in the identification of these species in the interstellar medium by comparison to astronomically obtained spectra. My project this summer was twofold: (1) We planned on obtaining absorption spectra of a number of PAHs and their cations in cold (4K) Ne matrices. The purpose of these experiments was to increase the number of different PAHs for which laboratory spectra have been obtained under these simulated interstellar conditions; and (2) I was to continue the planning and design of a new laser facility that is being established in the Astrochemistry laboratory. The laser-based experimental set-up will greatly enhance our capability in examining this astrophysically important class of compounds.

Description: This laboratory procedure starts with a violet suspension of an 'alfin' catalyst being added to a bottle containing a solution of 1,3-butadiene in pentane. The bottle is corked and shaken for several seconds. The mixture sets to a gel, and within 2 minutes the contents erupt from the bottle.

Description: Electromechanical materials can be used in smart sensor and actuator devices. Yet none performing at low temperatures are available. To meet this need, Pb((MgNi)(1/3)Ta(2/3))03 was synthesized as an electrostrictive ceramic for applications in cryogenic environments. Employing the columbite precursor route, samples with 0% to 100% Ni substitution for Mg were prepared, but only samples with Ni-substitutions less than or equal to 20% yielded primarily the desired perovskite phase. For these compositions the temperature of highest permittivity decreased linearly with increasing Ni content to yield a minimum value of -124 C for 20% Ni-substitution. This composition showed good relaxor dielectric behavior with a maximum relative permittivity of 5890 at 1 kHz. Additionally, in samples with excess MgO, the magnitude of permittivity doubled. In this effort, Pb((MgNi)(1/3)Ta(2/3))03 (PMNiTa) was fabricated to lower its transition temperature by substituting Ni for Mg successively.

Description: The ultimate goal of the research in smart structures and smart materials is the development of a new generation of products/devices which will perform better than products/devices built from passive materials. There are a few examples of multilayer polymer systems which function as smart structures, e.g. a synthetic muscle which is a multilayer assembly of a poly(ethylene) layer, a gold layer, and a poly(pyrrole) layer immersed in a liquid electrolyte. Oxidation and reductions of the active pyrrole layer causes the assembly to reversibly deflect and mimic biological muscles. The drawback of such a setup is slow response times and the use of a liquid electrolyte. We have developed multifunctional polymers which will eliminate the use of a liquid electrolyte, and also because the functionalities of the polymers are within a few hundred angstroms, an improved response time to changes in the external field should be possible. Such multifunctional polymers may be classified as the futuristic 'smart materials.' These materials are composed of a number of different functionalities which work in a synergistic fashion to function as a device. The device performs on the application of an external field and such multifunctional polymers may be scientifically labeled as 'field responsive polymers.' Our group has undertaken a systematic approach to develop functional and multifunctional polymers capable of functioning as field responsive polymers. Our approach utilizes multicomponent polymer systems (block copolymers and graft copolymers), the strategy involves the preparation of block or graft copolymers where the functionalities are limited to different phases in a microphase separated system. Depending on the weight (or volume) fractions of each of the components, different microstructures are possible. And, because of the intimate contact between the functional components, an increase in the synergism between the functionalities may be observed. In this presentation, three examples of multifunctional polymers developed in our labs will be reported. The first class of multifunctional polymers are the microphase separated mixed (ionic and electronic) conducting or MIEC block copolymers. The second class being developed in our labs are the biocompatible conductive materials and the conductive fluids. The final class may be considered microwave active smart polymers.

Description: The objective of the research effort at Rutgers is the development of lead zirconate titanate (PZT) ceramic/polymer composites with different designs for transducer applications including hydrophones, biomedical imaging, non-destructive testing, and air imaging. In this review, methods for processing both large area and multifunctional ceramic/polymer composites for acoustic transducers were discussed.

Description: The High Speed Civil Transport (HSCT) will have to be designed to withstand high aerodynamic load at supersonic speeds (panel flutter) and high acoustic load (acoustic or sonic fatigue) due to fluctuating boundary layer or jet engine acoustic pressure. The thermal deflection of the skin panels will also alter the vehicle's configuration, thus it may affect the aerodynamic characteristics of the vehicle and lead to poor performance. Shape memory alloys (SMA) have an unique ability to recover large strains completely when the alloy is heated above the characteristic transformation (austenite finish T(sub f)) temperature. The recovery stress and elastic modulus are both temperature dependent, and the recovery stress also depends on the initial strain. An innovative concept is to utilize the recovery stress by embedding the initially strained SMA wire in a graphite/epoxy composite laminated panel. The SMA wires are thus restrained and large inplane forces are induced in the panel at elevated temeperatures. By embedding SMA in composite panel, the panel becomes much stiffer at elevated temperatures. That is because the large tensile inplane forces induced in the panel from the SMA recovery stress. A stiffer panel would certainly yield smaller dynamic responses.

Description: This presentation covers the use of smart materials in Naval Research Laboratory (NRL) research for sensors, actuators, and modeling and control. Emphasis is on optical fiber Bragg gratings, piezoelectric actuators, shape memory alloy actuators, and polymer matrix and interfaces.

Description: This overview of the presentation covers Langley's smart materials infrastructure, materials research, applications, and summary. Langley's infrastructure consists of fabrication and characterization of smart structures. Materials researched include ceramics, polymers, and polymer-ceramic composites. Applications include interior aircraft noise suppression, aircraft engine noise reduction, active flutter damping of aircraft wings for better performance, active shape control of polymeric reflectors, and aircraft wing distortion to eliminate control surfaces.

Description: The National Aeronautics and Space Administration (NASA), Kennedy Space Center (KSC) Materials Science Division conducted a study to evaluate alternative solvents for CFC-113 in precision cleaning and verification on typical samples that are used in the KSC environment. The effects of AK-225(R), Vertrel(R), MCA, and HFE A 7100 on selected metal and polymer materials were studied over 1, 7 and 30 day test times. This report addresses a study on the compatibility aspects of replacement solvents for materials in aerospace applications.

Description: The NASA White Sands Test Facility (WSTF) is developing cleaning and verification processes to replace currently used chlorofluorocarbon-l13- (CFC-113-) based processes. The processes being evaluated include both aqueous- and solvent-based techniques. Replacement technologies are being investigated for aerospace hardware and for gauges and instrumentation. This paper includes the findings of investigations of aqueous cleaning and verification of aerospace hardware using known contaminants, such as hydraulic fluid and commonly used oils. The results correlate nonvolatile residue with CFC 113. The studies also include enhancements to aqueous sampling for organic and particulate contamination. Although aqueous alternatives have been identified for several processes, a need still exists for nonaqueous solvent cleaning, such as the cleaning and cleanliness verification of gauges used for oxygen service. The cleaning effectiveness of tetrachloroethylene (PCE), trichloroethylene (TCE), ethanol, hydrochlorofluorocarbon 225 (HCFC 225), HCFC 141b, HFE 7100(R), and Vertrel MCA(R) was evaluated using aerospace gauges and precision instruments and then compared to the cleaning effectiveness of CFC 113. Solvents considered for use in oxygen systems were also tested for oxygen compatibility using high-pressure oxygen autogenous ignition and liquid oxygen mechanical impact testing.

Description: Amorphous polyarylene ether ketones were examined in the glassy state by positron annihilation lifetime spectroscopy ( PALS ) and in the melt by standard rheological techniques. Specimens were well-characterized fractions of two isomeric structures. PALS clearly shows that the polymer with meta linkages in its backbone contains larger voids (greater than 0.25 nm radius). Thus despite their similar bulk densities, the two materials must pack very differently on a local scale. On the other hand, the free volumes inferred from the WLF treatment of melt viscosity data are practically identical in both materials ca. 4% at T(sub g). The comparison between techniques sheds some light on the distribution of free volume.

Description: The need for fast electro-optic switches and modulators for optical communication, and laser frequency conversion has created a demand for new second-order non-linear optical materials. One approach to produce such materials is to align chromophores with large molecular hyperpolarizabilities in polymers. Recently fulvenes and benzofulvenes which contain electron donating groups have been shown to exhibit large second-order non-linear optical properties. The resonance structures shown below suggest that intramolecular charge transfer (ICT) should be favorable in omega - (hydroxyphenyl)benzofulvenes and even more favorable in omega-omega - (phenoxy)benzofulvenes because of the enhanced donor properties of the O group. This ICT should lead to enormously enhanced second-order hyperpolarizability. We have prepared all three new omega - (hydroxyphenyl)benzofulvenes by the condensation of indene with the appropriate hydroxyaryl aldehyde in MeOH or MeOH/H2O under base catalysis. In a similar fashion we have prepared substituted benzofulvenes with multipal donor groups. Preliminary studies show that some of our benzofulvene derivatives exhibit second order harmonic generation (SHG). Measurements were carried out by preparing host-guest polymers. The results of our work on benzofulvene derivatives in host-guest polymers when covalently bonded in the polymer will be described.

Description: In this work a series of polyimides are investigated which exhibit a strong piezoelectric response and polarization stability at temperatures in excess of 100 C. This work was motivated by the need to develop piezoelectric sensors suitable for use in high temperature aerospace applications.

Description: Adapting procedures widely used in the metallographic characterization of metals and alloys, the microstructural preparation and examination of three polymer-matrix composites (PMC's) is described. The materials investigated contained either hollow ceramic filler particles or woven, continuous carbon/graphite fibers. Since the two particulate composites were considered to be isotropic, only one sample orientation was prepared. For the fiber composite, both longitudinal and planar orientations were studied. Once prepared, the samples were examined using reflected light microscopy. A number of microstructural features were evaluated qualitatively, including porosity and cracks, filler-matrix interfacial bonding, filler particle characteristics (shape, size, size distribution, and loading variation) and fiber characteristics (orientation, packing variation, and discontinuities).

Description: The use of the magnetostrictive material Terfenol-D as a motion source in active vibration control (AVC) systems are being studied. Currently it is of limited use due to the nonlinear nature of the strain versus magnetization curve and the magnetic hysteresis in the Terfenol-D. One manifestation of these nonlinearities is waveform distortion in the output velocity of the transducer. For Terfenol-D to be used in ever greater numbers of AVC systems, these nonlinearities must be addressed. In this study the nonlinearities are treated as disturbances to a linear system. The acceleration output is used in simple analog and digital feedback control schemes to improve linearity of the transducer. In addition, the use of a Terfenol-D actuator in an AVC system is verified. Both analog and digital controllers are implemented and results compared. A cantilever beam system is considered for AVC applications. The second thrust of this presentation is the reduction of harmonic distortions. Two conclusions can be reached from this work. One, the linearization of Terfenol-D transducers is possible with the use of feedback controllers, both digital and analog. Second, Terfenol-D is a viable motion source in active vibration control systems utilizing either analog or digital controllers.

Description: At Kennedy Space Center (KSC), Thiokol Corporation provides the engineering to assemble and prepare the Space Shuttle Reusable Solid Rocket Motor (RSRM) for launch. This requires hand cleaning over 86 surfaces including metals, adhesives, rubber and electrical insulations, various painted surfaces and thermal protective materials. Due to the phase-out of certain ozone depleting chemical (ODC) solvents, all RSRM hand wipe operations being performed at KSC using l,l,1-trichloroethane (TCA) were eliminated. This presentation summarizes the approach used and the data gathered in the effort to eliminate TCA from KSC hand wipe operations.

Description: New environmental regulations have forced extensive evaluations of many different cleaning agents for use in oxygen systems. This is no simple process because pure oxygen is a very strong oxidizer, and when placed in contact with a foreign substance, the combination may be explosive. This foreign substance can easily be a cleaning agent residue left over in the oxygen system after cleaning. This paper focuses on the factors that must be considered when selecting a cleaning agent for oxygen systems, as well as the approval processes which are currently being utilized by NASA for oxygen compatibility of materials. This paper will provide a working description of how to begin selecting a cleaning agent for oxygen systems. The paper will present the following: Background information on the necessity of a stringent selection process for oxygen system cleaners; Specifications and regulations concerning cleaning for oxygen service; Changing oxygen cleaning specifications given current environmental concerns; Testing for cleanliness in oxygen systems, Cleaning agents that have been tested for oxygen systems, including an extensive list of some of the newer 'environmentally friendly' cleaning agents; and Test results and conclusions from the testing. The paper will also provide instructions on the proper procedures for obtaining NASA approval on a candidate oxygen systems cleaning agent.

Description: Computational methods are described to probabilistically simulate fracture in bolted composite structures. Progressive fracture is simulated via an innovative approach independent of stress intensity factors and fracture toughness. The effect on structure damage of design variable uncertainties is quantified. The Fast Probability Integrator is used to assess the scatter in the composite structure response before and after damage. Sensitivity of the response to design variables is evaluated. The methods are demonstrated for bolted joint polymer matrix composite panels under end loads. The effects of fabrication process are included in the simulation of damage in the bolted panel. The results show that the most effective way to reduce the end displacement at fracture is to control the load and ply thickness.

Description: For high-speed entry of space vehicles into atmospheric environments, ablation is a practical method for alleviating severe aerodynamic heating. Several studies have been undertaken on steady or quasi-steady ablation. However, ablation is a very complicated phenomenon in which a nonequilibrium chemical process is associated with an aerodynamic process that involves changes in body shape with time. Therefore, it seems realistic to consider that ablation is an unsteady phenomenon. In the design of an ablative heat-shield system, since the ultimate purpose of the heat shield is to keep the internal temperature of the space vehicle at a safe level during entry, the transient heat conduction characteristics of the ablator may be critical in the selection of the material and its thickness. This note presents an experimental study of transient ablation of Teflon, with particular emphasis on the change in body shape, the instantaneous internal temperature distribution, and the effect of thermal expansion on ablation rate.

Description: The purpose of this paper is to evaluate the statistical molecular contamination data with a goal to improve spacecraft contamination control. The statistical data was generated in typical thermal vacuum tests at the National Aeronautics and Space Administration, Goddard Space Flight Center (GSFC). The magnitude of material outgassing was measured using a Quartz Crystal Microbalance (QCM) device during the test. A solvent rinse sample was taken at the conclusion of the each test. Then detailed qualitative and quantitative measurements were obtained through chemical analyses. All data used in this study encompassed numerous spacecraft tests in recent years.

Description: A study was carried out to identify, develop, and benchmark simulation techniques needed for optimum thermal protection system (TPS) material selection and sizing for reusable launch vehicles. Fully viscous, chemically reacting, Navier-Stokes flow solutions over the Langley wing-body single stage to orbit (SSTO) configuration were generated and coupled with an in-depth conduction code. Results from the study provide detailed TPS heat shield materials selection and thickness sizing for the wing-body SSTO. These results are the first ever achieved through the use of a complete, trajectory based hypersonic, Navier-Stokes solution database. TPS designs were obtained for both laminar and turbulent entry trajectories using the Access-to-Space baseline materials such as tailorable advanced blanket insulation. The TPS design effects (materials selection and thickness) of coupling material characteristics to the aerothermal environment are illustrated. Finally, a sample validation case using the shuttle flight database is included.

Description: Experimentally, many of the functions of electrical circuits have been demonstrated using optical circuits and, in theory, all of these functions may be accomplished using optical devices made of nonlinear optical materials. Actual construction of nonlinear optical devices is one of the most active areas in all optical research being done at this time. Physical vapor transport (PVT) is a promising technique for production of thin films of a variety of organic and inorganic materials. Film optical quality, orientation of microcrystals, and thickness depends critically on type of material, pressure of buffer gas and temperature of deposition. An important but understudied influence on film characteristics is the effect of gravity-driven buoyancy. Frazier, Hung, Paley, Penn and Long have recently reported mathematical modelling of the vapor deposition process and tested the predictions of the model on the thickness of films grown by PVT of 6-(2-methyl-4-nitroanilino)-2,4-hexadiyn-l-ol (DAMNA). In an historic experiment, Debe, et. al. offered definitive proof that copper phthalocyanine films grown in a low gravity environment are denser and more ordered than those grown at 1 g. This work seeks to determine the influence on film quality of gravity driven buoyancy in the low pressure PVT film growth of metal-free phthalocyanine.

Description: An investigation on the outgassing of a pigment employed as a fluorescent medium in conformal coatings has been performed. The conformal coatings in question are used to protect printed wiring boards from environmental hazards such as dust and moisture. The pigment is included in the coating at low concentration to allow visual inspection of the conformal coating for flaw detection. Calcofluor, the fluorescent pigment has been found to be a significant outgasser under vacuum conditions and a potential source of contamination to flight hardware. A minimum acceptable concentration of Calcofluor for flaw detection is desirable. Tests have been carried out using a series of Solithane(TM) conformal coating samples, with progressively lower Calcofluor concentrations, to determine the minimum required concentration of Calcofluor. It was found that the concentration of Calcofluor could be reduced from 0.115% to 0.0135% without significant loss in the ability to detect flaws, while at the same time significant reductions in Calcofluor outgassing and possible contamination of systems could be realized.

Description: Electrochemical impedance spectroscopy (EIS) was used to investigate the corrosion protection performance of twenty nine proprietary conductive polymer coatings for cold rolled steel under immersion in 3.55 percent NaCl. Corrosion potential as well as Bode plots of the data were obtained for each coating after one hour immersion, All coatings, with the exception of one, have a corrosion potential that is higher in the positive direction than the corrosion potential of bare steel under the same conditions. Group A consisted of twenty one coatings with Bode plots indicative of the capacitive behavior characteristic of barrier coatings. An equivalent circuit consisting of a capacitor in series with a resistor simulated the experimental EIS data for these coatings very well. Group B consisted of eight coatings that exhibited EIS spectra showing an inflection point which indicates that two time constants are present. This may be caused by an electrochemical process taking place which could be indicitive of coating failing. These coatings have a lower impedance that those in Group A.

Description: Diffusing-wave spectroscopy measurements show that ordinarily solid aqueous foams flow by a series of stick-slip avalanche-like rearrangements of neighboring bubbles from one tight packing configuration to another. Contrary to a recent prediction, the distribution of avalanche sizes do not obey a power-law distribution characteristic of self-organized criticality. This can be understood from a simple model of foam mechanics based on bubble-bubble interactions.

Description: Prior studies have shown that free radicals generated by heating polyimides above 300 C are stable at room temperature and are involved in thermo-oxidative degradation in the presence of oxygen gas. Electron Paramagnetic Resonance Imaging (EPRI) is a technique to determine the spatial distribution of free radicals. X-band (9.5 GHz) EPR images of PMR-15 polyimide were obtained with a spatial resolution of about 0.18 mm along a 2 mm dimension of the sample. In a polyimide sample that was not thermocycled, the radical distribution was uniform along the 2 mm dimension of the sample. For a polyimide sample that was exposed to thermocycling in air for 300 one-hour cycles at 335 C, one-dimensional EPRI showed a higher concentration of free radicals in the surface layers than in the bulk sample. A spectral-spatial two-dimensional image showed that the EPR lineshape of the surface layer remained the same as that of the bulk. These EPRI results suggest that the thermo-oxidative degradation of PMR-15 resin involves free radicals present in the oxygen-rich surface layer.

Description: In recent years, a great deal of interest has been directed toward the use of organic materials in the development of high-efficiency optoelectronic and photonic devices. There is a myriad of possibilities among organics which allow flexibility in the design of unique structures with a variety of functional groups. The use of nonlinear optical (NLO) organic materials such as thin-film waveguides allows full exploitation of their desirable qualities by permitting long interaction lengths and large susceptibilities allowing modest power input. There are several methods in use to prepare thin films, such as Langmuir-Blodgett (LB) and self-assembly techniques, vapor deposition, growth from sheared solution or melt, and melt growth between glass plates. Organics have many features that make them desirable for use in optical devices such as high second- and third-order nonlinearities, flexibility of molecular design, and damage resistance to optical radiation. However, their use in devices has been hindered by processing difficulties for crystals and thin films. In this chapter, we discuss photonic and optoelectronic applications of a few organic materials and the potential role of microgravity on processing these materials. It is of interest to note how materials with second- and third-order nonlinear optical behavior may be improved in a diffusion-limited environment and ways in which convection may be detrimental to these materials.

Description: The Solid Rocket Boosters (SRB's) used to launch the Space Shuttle are coated with a layer of ablative material to prevent thermal damage when they reenter the earth's atmosphere. The coating consists of a mixture of cork, glass, and resin. A new coating (Marshall Convergent Coating, MCC-2) was recently developed that is environmentally complaint. The coating must meet certain minimum thickness standards in order to protect the SRB. The coating is applied by a robot controlled nozzle that moves from the bottom to top, as the rocket part rotates on a table. Several coats are applied, building up to the desired thickness. Inspectors do a limited amount of destructive 'wet' testing. This involves an inspector inserting a rod in the wet coating and removing the rod. This results in a hole that, of course, must be patched later. The material is cured and the thickness is measured. There is no real-time feedback as the coating is being applied. Although this might seem like the best way to control thickness, the problems with 'blowback' (reflected material covering the sensor) are formidable, and have not been solved. After the thermal coating is applied, a protective top coat is applied. The SRB part is then placed in a oven and baked to harden the surface. The operations personnel then measure the thickness of the layer using the Kaman 7200 Displacement Measuring System. The probe is placed on the surface. One person (the inspector) reads the instrument, while another(the technician) records the thickness. Measurements are taken at one foot intervals. After the measurements are taken, the number of low readings is tabulated. If more than 10 percent of the points fall below the minimum value, there is a design review, and the part may be stripped of coating, and a new coating is applied. There is no other analysis.

Description: The oxidative degradation of PMR (for polymerization of monomeric reactants) polyimides at elevated temperatures was followed by cross-polarized magic angle spinning (Cp-MAS) NMR. C-13 labeling of selected sites in the polymers allowed for direct observation of the transformations arising from oxidation processes. As opposed to model compound studies, the reactions were followed directly in the polymer. The labeling experiments confirm the previously reported oxidation of the methylene carbon to ketone in the methylenedianiline portion of the polymer chain. They also show the formation of two other oxidized species, acid and ester, from this same carbon. In addition, the technique provides the first evidence of the kind of degradation reactions that are occurring in the nadic end caps. Several PMR formulations containing moieties determined to be present after oxidation, as suggested by the labeling study, were synthesized. Weight loss, FTIR, and natural abundance NMR of these derivatives were followed during aging. In this way, weight loss could be related to the observed transformations.

Description: Electrostatic discharge (ESD) has been shown to be the primary cause of several glitches in spacecraft operations. It appears that charged particles encountered in the natural environment in certain orbits can collect on the outer surfaces of a spacecraft, building up a charge of several thousand volts. If the potential exceeds the breakdown voltage of the charged material, then an ESD will occur. ESD events involving relatively low voltages, on the order of 100 V, have been shown to damage electronic components. When ESD occurs, electronic and electrical components can be damaged, computer instructions can be garbled, and ablation of material from the spacecraft may occur; degrading both the performance of the thermal control blankets, and the cleanliness of any surfaces on which the detritus becomes deposited. There appear to be six ways to prevent or mitigate the effects of ESD: (1) Choose an orbit where charging is not a problem; (2) Carry extra electromagnetic shielding; (3) Provide redundancy in components and programming; (4) Provide for active dissipation of the charge, by generating a plasma with which to bathe susceptible surfaces; (5) Provide for passive dissipation from a plasma contactors on the susceptible surfaces; and (6) Provide thermal control blankets that do not hold a charge, i.e., that are conductive enough to bleed a charge off harmlessly. These six options are discussed in detail in Losure (1996). Of these six options, number 1 is not always practical, given other requirements of the mission; 2, 3, 4 and 5 will require that extra mass in the form of shielding, etc., be carried by the spacecraft. The most attractive option from a mass and energy point of view seems to be that of finding a material which matches the other performance characteristics of the current thermal control blankets without their tendency to build up an electrostatic charge. The goal of this paper is to describe and justify a testing program which will lead to the approval of materials of this kind.

Description: The evolution of the transient extensional stresses in dilute and semi-dilute viscoelastic polymer solutions are measured with a filament stretching rheometer of a design similar to that first introduced by Sridhar, et al. The solutions are polystyrene-based (PS) Boger fluids that are stretched at constant strain rates ranging from 0.6 less than or equal to epsilon(0) less than or equal to 4s(exp -1) and to Hencky strains of epsilon greater than 4. The test fluids all strain harden and Trouton ratios exceeding 1000 are obtained at high strains. The experimental data strain hardens at lower strain levels than predicted by bead-spring FENE models. In addition to measuring the transient tensile stress growth, we also monitor the decay of the tensile viscoelastic stress difference in the fluid column following cessation of uniaxial elongation as a function of the total imposed Hencky strain and the strain rate. The extensional stresses initially decay very rapidly upon cessation of uniaxial elongation followed by a slower viscoelastic relaxation, and deviate significantly from FENE relaxation predictions. The relaxation at long times t is greater than or equal to 5 s, is compromised by gravitational draining leading to non-uniform filament profiles. For the most elastic fluids, partial decohension of the fluid filament from the endplates of the rheometer is observed in tests conducted at high strain rates. This elastic instability is initiated near the rigid endplate fixtures of the device and it results in the progressive breakup of the fluid column into individual threads or 'fibrils' with a regular azimuthal spacing. These fibrils elongate and bifurcate as the fluid sample is elongated further. Flow visualization experiments using a modified stretching device show that the instability develops as a consequence of an axisymmetry-breaking meniscus instability in the nonhomogeneous region of highly deformed fluid near the rigid endplate.

Description: Lewis Research Center developed a process for achieving diamond- hard coatings for aerospace systems. The technique involves coating the material with a film of diamond-like carbon (DLC) using direct ion deposition. An ion generator creates a stream of ions from a hydrocarbon gas source; the carbon ions impinge directly on the target substrate and 'grow' into a thin DLC film. In 1988, Air Products and Chemicals, Inc. received a license to the NASA patent. Diamonex, an Air Products spinoff company, further developed the NASA process to create the DiamondHard technology used on the Bausch & Lomb Ray- Ban Survivors sunglasses. The sunglasses are scratch-resistant and shed water more easily, thus reducing spotting.

Description: Sun Coast Chemicals was originally contracted by Lockheed Martin Space Operations to formulate a spray lubricant free of environmental drawbacks for the Mobile Launch Platform used to haul the Space Shuttle from the Kennedy Space Center Vehicle Assembly Building to a launch pad. From this work, Sun Coast introduced Train Track Lubricant, Penetrating Spray Lube, and Biodegradable Hydraulic Fluid. Based on the original lubricant work, two more products have also been introduced. First, the X-1R Super Gun Cleaner and Lubricant protects guns from rust and corrosion caused by environmental conditions. Second, the X-1R Tackle Pack, endorsed by both fresh and saltwater guides and certain reel manufacturers, penetrates, cleans, reduces friction, lubricates, and provides extra protection against rust and corrosion.

Description: Gentax Corporation's triaxal fabrics are woven from three separate yarn sets whose intersections form equilateral triangles. This type of weave, derived from space shuttle pressure suits, assures practically equal strength in every direction; has essentially no bias, or weak dimension offering greater resistance to tear and shear along with significant weight reduction. Applications of the Triax line include inflatable equipment, life vests, aircraft evacuation slides, helicopter flotation devices, tension structures, safety clothing and sailcloth for boats. Ability to accept compound curvatures with no distortion of the weave configuration makes it useful in manufacturing molded composites.

Description: Ferrofluids offered vast-problem solving potential. Under license for the NASA technology, Dr. Ronald Moskowitz and Dr. Ronald Rosensweig formed Ferrofluids Corporation. First problem they found a solution for was related to the manufacture of semiconductor "chips" for use in electronic systems. They developed a magnetic seal composed of ferrofluid and a magnetic circuit. Magnetic field confines the ferrofluid in the regions between the stationary elements and the rotary shaft of the seal. Result is a series of liquid barriers that totally bar passage of contaminants. Seal is virtually wear-proof and has a lifetime measured in billions of shaft revolutions. It has reduced maintenance, minimizes "downtime" of production equipment, and reduces the cost of expensive materials that had previously been lost through seal failures. Products based on ferrofluid are exclusion seals for computer disc drives and inertia dampers for stepper motors. Uses are performance-improving, failure-reducing coolants for hi-fi loudspeakers. Other applications include analytical instrumentation, medical equipment, industrial processes, silicon crystal growing furnaces, plasma processes, fusion research, visual displays, and automated machine tools.

Description: Fabricated by Expanded Rubber & Plastics Corporation, Temper Foam provides better impact protection for airplane passengers and enhances passenger comfort on long flights because it distributes body weight and pressure evenly over the entire contact area. Called a "memory foam" it matches the contour of the body pressing against it and returns to its original shape once the pressure is removed. As a shock absorber, a three-inch foam pad has the ability to absorb the impact of a 10-foot fall by an adult. Applications include seat cushioning for transportation vehicles, padding for furniture and a variety of athletic equipment medical applications including wheelchair padding, artificial limb socket lining, finger splint and hand padding for burn patients, special mattresses for the bedridden and dental stools. Production and sales rights are owned by Temper Foam, Inc. Material is manufactured under license by the Dewey and Almy Division of Grace Chemical Corporation. Distributors of the product are Kees Goebel Medical Specialties, Inc. and Alimed, Inc. They sell Temper Foam in bulk to the fabricators who trim it to shapes required by their customers.

Description: Advanced Flexible Reusable Surface Insulation, developed by Ames Research Center, protects the Space Shuttle from the searing heat that engulfs it on reentry into the Earth's atmosphere. Initially integrated into the Space Shuttle by Rockwell International, production was transferred to Hi-Temp Insulation Inc. in 1974. Over the years, Hi-Temp has created many new technologies to meet the requirements of the Space Shuttle program. This expertise is also used commercially, including insulation blankets to cover aircrafts parts, fire barrier material to protect aircraft engine cowlings and aircraft rescue fire fighter suits. A Fire Protection Division has also been established, offering the first suit designed exclusively by and for aircraft rescue fire fighters. Hi-Temp is a supplier to the Los Angeles City Fire Department as well as other major U.S. civil and military fire departments.

Description: Under a Space Act Agreement between Boeing North America and BSR Products, Space Shuttle Thermal Protection System (TPS) materials are now used to insulate race cars. BSR has created special TPS blanket insulation kits for use on autos that take part in NASCAR events, and other race cars through its nationwide catalog distribution system. Temperatures inside a race car's cockpit can soar to a sweltering 140 to 160 degrees, with the extreme heat coming through the engine firewall, transmission tunnel, and floor. It is common for NASCAR drivers to endure blisters and burns due to the excessive heat. Tests on a car insulated with the TPS material showed a temperature drop of some 50 degrees in the driver's cockpit. BSR-TPS Products, Inc. now manufactures insulation kits for distribution to race car teams around the world.

Description: The bibliography contains citations concerning the design, development, fabrication, and evaluation of thick film electronic devices. Thick film solar cells, thick films for radiation conduction, deposition processes, conductive inks are among the topics discussed. Applications in military and civilian avionics are examined.

Description: In a similar approach to that used for the previously issued correlation report for Coflon (CAPP/M.10), this report aims to identify any correlations between mechanical property changes and chemical/morphological changes for Tefzel, using information supplied in other MERL and TRI project reports (plus latest data which will be included in final reports for Phase 1). Differences identified with Coflon behaviour will be of scientific interest as well as appropriate to project applications, as Tefzel and Coflon are chemical isomers. Owing to the considerable chemical resistance of Tefzel, much of its testing so far has been based on mechanical properties. Where changes have occurred, chemical analysis can now be targeted more effectively. Relevant test data collated here include: tensile modulus and related properties, permeation coefficients, % crystallinity, and other observations where significant. Fluids based on methanol and amine (Fluid G), a mixture of methane, carbon dioxide and hydrogen sulphide gases plus an aqueous amine solution (Fluid F), and an aromatic oil mix of heptane, cyclohexane, toluene and I-propanol (Fluid 1) have affected Tefzel to varying degrees, and are discussed in some detail herein.

Description: Several different cryogenic tank concepts are being considered for reusable launch vehicles (RLV'S) . Though different tank concepts are being considered, many will require that the cryogenic insulation be evacuated and be bonded to a structure. In this work, an attempt was made to evaluate the effectiveness of maintaining a vacuum on a specimen where foam or honeycomb core was encased within Gr/Ep. In addition to these tests, flatwise adhesion pull off tests were performed at room temperature with PR 1664, EA 9394, FM-300, Crest 3170, and HT 435 adhesives. The materials bonded included Gr/Ep, Gr/BMI, Al, and stainless steel facesheets, and Ti honeycomb, Hexcel honeycomb, and Rohacell foam core materials.

Description: This report summarizes the evaluation and testing of high emissivity protective coatings applied to flexible insulations for the Reusable Launch Vehicle technology program. Ceramic coatings were evaluated for their thermal properties, durability, and potential for reuse. One of the major goals was to determine the mechanism by which these coated blanket surfaces become brittle and try to modify the coatings to reduce or eliminate embrittlement. Coatings were prepared from colloidal silica with a small percentage of either SiC or SiB6 as the emissivity agent. These coatings are referred to as gray C-9 and protective ceramic coating (PCC), respectively. The colloidal solutions were either brushed or sprayed onto advanced flexible reusable surface insulation blankets. The blankets were instrumented with thermocouples and exposed to reentry heating conditions in the Ames Aeroheating Arc Jet Facility. Post-test samples were then characterized through impact testing, emissivity measurements, chemical analysis, and observation of changes in surface morphology. The results show that both coatings performed well in arc jet tests with backface temperatures slightly lower for the PCC coating than with gray C-9. Impact testing showed that the least extensive surface destruction was experienced on blankets with lower areal density coatings.

Description: The study of long term near ultra-violet (NUV) effects in a vacuum atmosphere, is a crucial element for space applications. NUV radiation causes significant changes in the reflectance of many coatings and types of materials. An ultra high vacuum NUV system was assembled in order to investigate various coatings and materials in this hostile environment. The vacuum is an ion pump that maintains a minimum vacuum in the mid 10(exp -9) range. The system has a base pressure of 10(exp -9) torr and this base pressure is maintained with the ion pump. The NUV exposure was maintained at 2-3 suns which allows accelerated NUV exposure without overheating the samples. The goal of this test was to maintain an intensity of 3.4 x 10(exp -2) Watts/cm(exp 2) which equals 2.9 NUV suns. An NUV sun is defined as 1.16 Watts/cm(exp 2) integrated over wavelength of 200-400 nanometers.

Description: Lightweight, monolithic ceramics resistant to oxidation in air at high temperatures are made by impregnating a porous carbon preform with a sol which contains a mixture of tetraethoxysilane, dimethyldiethoxysilane and trimethyl borate. The sol is gelled and dried on the carbon preform to form a ceramic precursor. The precursor is pyrolyzed in an inert atmosphere to form the ceramic which is made of carbon, silicon, oxygen and boron. The carbon of the preform reacts with the dried gel during the pyrolysis to form a component of the resulting ceramic. The ceramic is of the same size, shape and form as the carbon precursor. Thus, using a porous, fibrous carbon precursor, such as a carbon felt, results in a porous, fibrous ceramic. Ceramics of the invention are useful as lightweight tiles for a reentry spacecraft.

Description: Apparatus and method are disclosed for producing oxides of metals and of metal alloys. The metal or alloy is placed in an oxygen atmosphere in a combustion chamber and ignited. Products of the combustion include one or more oxides of the metal or alloy in powdered form. In one embodiment of the invention a feeder is provided whereby material to be oxidized by combustion can be achieved into a combustion chamber continuously. A product remover receives the powder product of the combustion.

Description: Future reusable space vehicles will be in service much more frequently than current space shuttles. Therefore, rapid reconditioning of spacecraft will be required. Currently, the waterproofing of space shuttles after each re-entry takes 72 hours and requires substantial labor. In addition, the currently used waterproofing reagent, DiMethylEthoxySilane (DMES), is considered toxic, and ethanol fumes are released during its hydrolytic activation. Consequently, a long time period, which is not acceptable for future operations, is needed to ensure that 0 the excess volatile compounds are removed before further maintenance of the space vehicle can be performed. The objective of this project was to assist NASA Ames in finding improved waterproofing systems by identifying suitable waterproofing agents that can be applied by vapor phase deposition and will be less toxic, bond more rapidly to the insulation material surface, and potentially have higher thermal stability than the DMES system. Several approaches to achieve faster waterproofing with less toxicity were assessed using the following alternatives: Reactive volatile compounds that are rapidly deposited by chemical bonding at the surface and leave no toxic volatiles. Reactive reagents that are the least toxic. Nonvolatile reagents that are very reactive and bond strongly to the insulating material surface. Three specific types of potential reagents were chosen for evaluation in this project: 1. Volatile reagents with Si-Cl functional groups for vapor deposition 2. Volatile reagents with Si-H functional groups for vapor deposition 3. Nonvolatile oligomeric or polymeric reactive siloxanes that are assumed to have higher thermal stability and/or strong bonding to the insulating material. The chemistry involved in the project was targeted at the generation of intermediates having reactive Si-OH bonds for the formation of either volatile species or polymeric species that bond rapidly to the surface and also cure rapidly. We focused on two chemical reactions@-hydrolysis of Si-Cl bonds and catalytic dehydrocoupling of Si-H bonds.

Description: A two phase HfB2-SiB4 material which is useful as a high temperature oxidation resistant coating. This invention relates to ceramic coatings and more particularly to ceramic coatings containing metal borides. Boride materials are known to have good oxidation resistance, with HfB2 considered to be the best pure boride for oxidation applications. It has been shown that the addition of 10 to 20 percent SiC to HfB2 increases the oxidation resistance. The HfB2-SiC materials are prepared by hot pressing powder mixtures. Hot pressing powder mixtures has limited ability to produce fine grained multiphase materials due to particle coarsening during the sintering process. Additionally, the purity of the final monolithic structure is limited to the purity of the starting powders. Chemical vapor deposition (CVD) offers a method of producing highly pure multiphase ceramics, with better control of microstructure. Researchers have tried to produce HfB2-SiC coatings by CVD but without success.

Description: The present invention discloses a method of removing organic protective coatings from a painting. In the present invention degraded protective coatings such as lacquers, acrylics, natural resins, carbons, soot, and polyurethane are safely removed from the surface of a painting without contact to the surface of the painting. This method can be used for restoration of paintings when they have been damaged, through age, fire, etc.

Description: A hypervelocity impact (HVI) Whipple Shield and a method for shielding a wall from penetration by high velocity particle impacts where the Whipple Shield is comprised of spaced apart inner and outer metal sheets or walls with an intermediate cloth barrier arrangement comprised of ceramic cloth and high strength cloth which are interrelated by ballistic formulae.

Description: This paper details a comparison analysis of the zinc oxide pigmented white thermal control paints Z-93 and Z-93P. Both paints were simultaneously exposed to combined space environmental effects and analyzed using an in-vacuo reflectance technique. The dose applied to the paints was approximately equivalent to 5 years in a geosynchronous orbit. This comparison analysis showed that Z-93P is an acceptable substitute for Z-93. Irradiated samples of Z-93 and Z-93P were subjected to additional exposures of ultraviolet (UV) radiation and analyzed using the in-vacuo reflectance technique to investigate UV activated reflectance recovery. Both samples showed minimal UV activated reflectance recovery after an additional 190 equivalent sun hour (ESH) exposure. Reflectance response utilizing nitrogen as a repressurizing gas instead of air was also investigated. This investigation found the rates of reflectance recovery when repressurized with nitrogen are slower than when repressurized with air.

Description: A tribometer for the evaluation of liquid lubricants in vacuum is described. This tribometer is essentially a thrust bearing with three balls and flat races having contact stresses and ball motions similar to those in an angular contact ball bearing operating in the boundary lubrication regime. The friction coefficient, lubrication lifetime, and species evolved from the liquid lubricant by tribodegradation can be determined. A complete analysis of the contact stresses and energy dissipation together with experimental evidence supporting the analysis are presented.

Description: Macro voids are undesirable large pores in membranes used for purification. They form when membranes are cast as thin films on a smooth surface by evaporating solvent (acetone) from a polymer solution. There are two un-tested hypotheses explaining the growth of macro voids. One states that diffusion of the non-solvent (water) is solely responsible, while the other states that solutocapillary convection is the primary cause of macro void growth. Solutocapillary convection is flow-caused by a concentration induced surface-tension gradient. Macrovoid growth in the former hypothesis is gravity independent, while in the latter it is opposed by gravity. To distinguish between these two hypotheses, experiments were designed to cast membranes in zero-gravity. A semi-automated apparatus was designed and built for casting membranes during the 20 secs of zero-g time available in parabolic aircraft flight such as NASA's KC-135. The phase changes were monitored optically, and membrane morphology was evaluated by scanning electron microscopy (SEM). These studies appear to be the first quantitative studies of membrane casting in micro-gravity which incorporate real-time data acquisition. Morphological studies of membranes cast at 0, 1, and 1.8 g revealed the presence of numerous, sparse and no macrovoids respectively. These results are consistent with the predictions of the solutocapillary hypothesis of macrovoid growth.

Description: A method is provided for closing out the edges of a flexible ceramic insulation member including inner and outer mold line covering layers. A rigid, segmented, ceramic frame is placed round the edges of the insulation member and exposed edges of the inner and outer mold line covering layers are affixed to the ceramic frame. In one embodiment wherein the covering layers comprise fabrics, the outer fabric is bonded to the top surface and to grooved portion of the side surface of the frame. In another embodiment wherein the outer cover layer comprises a metallic foil, clips on the edges of the frame are used to engage foil extensions. The ceramic frame is coated with a high emittance densifier coating.

Description: Understanding interfacial microstructural evolution during environmental testing and use is critical to the development of stable continuous fiber ceramic composites (CFCC's) for their use in 'corrosive' environments. The use of advanced characterization techniques is required to track subtle microstructural changes. These techniques must be coordinated with other CFCC tasks to completely evaluate their interfacial behavior.

Description: Tensile strengths of as-received HPZ fiber and those surface coated with BN, BN/SiC, and BN/Si3N4 have been determined at room temperature using a two-parameter Weibull distribution. Nominally approx. 0.4 micron BN and 0.2 micron SiC or Si3N4 coatings were deposited on the fibers by chemical vapor deposition using a continuous reactor. The average tensile strength of uncoated HPZ fiber was 2.0 +/- 0.56 GPa (290 +/- 81 ksi) with a Weibull modulus of 4.1. For the BN coated fibers, the average strength and the Weibull modulus increased to 2.39 +/- 0.44 GPa (346 +/- 64 ksi) and 6.5, respectively. The HPZ/BN/SiC fibers showed an average strength of 2.0 +/- 0.32 GPa (290 +/- 47 ksi) and Weibull modulus of 7.3. Average strength of the fibers having a dual BN/Si3N4 surface coating degraded to 1.15 +/- 0.26 GPa (166 +/- 38 ksi) with a Weibull modulus of 5.3. The chemical composition and thickness of the fiber coatings were determined using scanning Auger analysis. Microstructural analysis of the fibers and the coatings was carried out by scanning electron microscopy and transmission electron microscopy. A microporous silica-rich layer approx. 200 nm thick is present on the as-received HPZ fiber surface. The BN coatings on the fibers are amorphous to partly turbostratic and contaminated with carbon and oxygen. Silicon carbide coating was crystalline whereas the silicon nitride coating was amorphous. The silicon carbide and silicon nitride coatings are non-stoichiometric, non-uniform, and granular. Within a fiber tow, the fibers on the outside had thicker and more granular coatings than those on the inside.

Description: Shape memory alloys (SMA) exhibiting the superelastic or one-way effects can produce large recoverable strains upon application of a stress. In single crystals this stress and resulting strain are very orientation dependent. We show experimental stress/strain curves for a Ni-Al single crystal for various loading orientations. Also shown are model predictions; the open and closed circles indicate recoverable strains obtained at various stages in the transformation process. Because of the strong orientation dependence of shape memory properties, crystallographic texture can be expected to play an important role in the mechanical behavior of polycrystalline SMA. It is desirable to formulate a constitutive model to better understand and exploit the unique properties of SMA.

Description: A major limitation in use of electromagnetic and/or magnetomechanical models for design of Terfenol-D actuators is the lack of reliable material property data for Terfenol-D. In particular data on the performance of Terfenol-D as employed in a transducer, operating under real world dynamic conditions is needed. To provide this information, Terfenol-D rod properties need to be measured under as run prestressed and magnetically biased states. Using a Terfenol-D actuator, the following properties can be measured and/or calculated: mechanical quality factor, speed of sound in the material, the resonant frequency, the anti-resonant frequency, two magnetic permeabilities (one at constant stress and one at constant strain), two Young's moduli (one at constant amplitude applied magnetic field and one at constant amplitude magnetic flux density in the material), the magnetomechanical coupling, and the axial strain coefficient. The development of the material properties measurements and calculations is based on the model of low signal, linear, magnetostriction from Clark, the linear transduction equations for a transducer from Hunt, and a one degree of freedom mechanical model of the transducer. The electrical impedance and admittance mobility loops are used to determine the resonant, anti-resonant, and half power point frequencies. The rest of the material properties indicated above can then be calculated using these frequencies, acceleration from an accelerometer mounted on the actuator arm, and readily measurable transducer and Terfenol-D rod parameters.

Description: An analytical assessment has been made of the reliability of using integrated microactuators and sensors in the form of piezoceramics and piezopolymers as joint integrity monitors in trussed systems. The concept is first implemented for a simple structure which consists of two truss members with a 45 deg lift angle joined at the apex. A piezoceramic patch (or piezopolymer film) bonded on the surface of one of the members at a location near the joint is used as a collocated actuator/sensor. The overall structural dynamic response under an excitation was modeled by finite element method. Different degrees of nodal constraints at the joints representing various degrees of joint integrity are employed. The resulting dynamic response showed distinct responses for varying joint stiffnesses. Parallel experimental work on a truss model using a multichannel data acquisition system and a digital signal analyzer confirms the results from analysis. We further studied the sensitivity of the micro-sensors to the behavior of joints of large arch truss structure. Results obtained for large trusses with many degrees of freedom indicate optimum locations of sensors for which the dynamic response signatures are distinct and distinguishable for relatively small changes in joint integrity and/or structural geometry. Computations based on finite element modeling show that locating the single actuator/sensor at the joint corresponding to the first loss of static stability appear optimal. Hence, static stability analysis of complex trusses can give us a good indication of the optimum placement of sensors for maximum response. This observation is important if few distributed sensors and actuators are available for placement in constructed facilities made from large trusses with many degrees of freedom. As an extension of this work a dynamic response signature identification technique to monitor in-service degradation of joints is under development for application to the monitoring of the integrity of adhesive joints in composite structures.

Description: This chapter presents an introduction and historical background to the field of tribology, especially solid lubrication and lubricants and sets them in the perspective of techniques and materials in lubrication. Also, solid and liquid lubrication films are defined and described.

Description: This study deals with the corrosion of near stoichiometric mullite (3Al2O3-2SiO2) by pure dry hydrogen gas. Exposure of the mullite samples was at temperatures of 1050 and 1250 C for times up to 500 hours. Preferential attack of the alumino-silicate glass present in the grain boundaries of the mullite occurred after 125 hours at 1250 C. Hydrogen scrubbing of the SiO2 from the glassy grain boundaries and the mullite grains yielded a porous alumina-rich surface. The room temperature strength increased after short exposure times at 1250 C (up to 125 hours), then decreased by 53 percent after exposure for 500 hours. At 1050 C, all exposure times (25 to 500 hours) decreased the strength. After 500 hours in hydrogen at 1050 C, the room temperature strength of mullite decreased 22 percent. We also observed a rapid 25 percent strength loss after short exposure times at 1050 C. This is attributed to the calcium/hydrogen assisted crystallization of the glassy, grain-boundary phase.

Description: A low-density resin impregnated ceramic article advantageously employed as a structural ceramic ablator comprising a fired preform of ceramic fibers. The fibers of the ceramic preform are coated with an organic resin film. The organic resin can be a thermoplastic resin or a cured thermosetting resin. In one embodiment, the resin is uniformly distributed within the ceramic article. In a second embodiment, the resin is distributed so as to provide a density gradient along at least one direction of the ceramic article. The resin impregnated ceramic article is prepared by providing a fired preform of ceramic fibers; immersing the preform of ceramic fibers in a solution of a solvent and an organic resin infiltrant; and removing the solvent to form a resin film on the ceramic fibers.

Description: The aim of the present work was to identify key variables in rapid weldbonding of thermoplastic tow (ribbon) and their relationship to matrix polymer properties and to ribbon microstructure. Theoretical models for viscosity, establishment of ply-ply contact, instantaneous (Velcro) bonding, molecular interdiffusion (healing), void growth suppression, and gap filling were reviewed and synthesized. Consideration of the theoretical bonding mechanisms and length scales and of the experimental weld/peel data allow the prediction of such quantities as the time and pressure required to achieve good contact between a ribbon and a flat substrate, the time dependence of bond strength, pressures needed to prevent void growth from dissolved moisture and conditions for filling gaps and smoothing overlaps.

Description: In the low-Earth-orbit environment, solar ultraviolet (UV) radiation embrittles polymer materials through bond breaking and crosslinking. This UV embrittlement increases the surface hardness of the polymer. Before the durability of polymer materials in the low- Earth-orbit environment can be predicted, the extent of UV embrittlement needs to be determined. However, traditional techniques for measuring the microhardness of materials cannot be employed to measure changes in the hardness of UV-embrittled surfaces because traditional techniques measure bulk hardness and are not sensitive enough to surface changes. A unique technique was used at the NASA Lewis Research Center to quantify polymer surface damage that had been induced by UV radiation. The technique uses an atomic force microscope (AFM) to measure surface microhardness. An atomic force microscope measures the repulsive forces between the atoms in a microscopic cantilevered tip and the atoms on the surface of a sample. Typically, an atomic force microscope produces a topographic image of a surface by monitoring the movement of the tip over features of the surface. The force applied to the cantilevered tip, and the indention of the tip into the surface, can be measured. The relationship between force and distance of indentation, the quantity force/distance (newtons/meter), provides a measure of the surface hardness. Under identical operating conditions, direct comparisons of surface hardness values can be made.

Description: Because of their light weight and impact resistance, transparent plastic structures are becoming increasingly desirable for use not only on aircraft but also in terrestrial applications such as automotive windshields and ophthalmic lenses. However, plastics are typically soft and scratch readily, reducing their transparency with use. At the NASA Lewis Research Center, reactively deposited aluminum oxide coatings as thin as 12,000 angstroms have been demonstrated to provide improved resistance to most scratches encountered during normal use. The properties of the coating can be adjusted to tailor the surface to meet other needs, such as water shedding. These adjustments can be made during the deposition process so that multiple manufacturing steps are eliminated.

Description: This work was undertaken in support of the Low Cost Ceramic Composite Virtual Company, (LC^3), whose members include Northrop Grumman Corporation, AlliedSignal Inc., and Allison Advanced Development Company. LC^3 is a cost-shared effort funded by the Advanced Research Projects Agency (ARPA) and the LC^3 participants to develop a low-cost fabrication methodology for manufacturing ceramic matrix composite structural components. The program, which is being administered by the U.S. Air Force Wright Laboratory Materials Directorate, is focused on demonstrating a ceramic matrix composite turbine seal for a regional aircraft engine. This part is to be fabricated by resin transfer molding of a siloxane polymer into a fiber preform that will be transformed into a ceramic by pyrolytic conversion.

Description: Ceramic-matrix composites strengthened by suitable fiber additions are being developed for high-temperature use, particularly for aerospace applications. New oxide-based fibers, such as mullite, are particularly desirable because of their resistance to high-temperature oxidative environments. Mullite is a candidate material in both fiber and matrix form. The primary objective of this work was to determine the growth characteristics of single-crystal mullite fibers produced by the laser-heated floating zone method. Directionally solidified fibers with nominal mullite compositions of 3Al2O3 2SiO2 were grown by the laser-heated floating zone method at the NASA Lewis Research Center. SEM analysis revealed that the single-crystal fibers grown in this study were strongly faceted and that the facets act as critical flaws, limiting fiber strength. The average fiber tensile strength is 1.15 GPa at room temperature. The mullite fibers exhibit superior strength retention (80 percent of their room temperature tensile strength at 1450 C). Examined by transmission electron microscopy, these mullite single crystals are free of dislocations, low-angle boundaries, and voids. In addition, they show a high degree of oxygen vacancy ordering. High-resolution digital images from an optical microscope furnish evidence of the formation of a liquid-liquid miscibility gap during crystal growth. These images represent the first experimental evidence of liquid immiscibility for these compositions and temperatures. Continuing investigation with controlled seeding of mullite single crystals is planned.

Description: Molecular modeling and dielectric measurements are being used to identify mechanisms governing piezoelectric behavior in polyimides such as dipole orientation during poling, as well as degree of piezoelectricity achievable. Molecular modeling on polyimides containing pendant, polar nitrile (CN) groups has been completed to determine their remanent polarization. Experimental investigation of their dielectric properties evaluated as a function of temperature and frequency has substantiated numerical predictions. With this information in hand, we are then able to suggest changes in the molecular structures, which will then improve upon the piezoelectric response.

Description: Positrons provide a versatile probe for monitoring microstructural features of molecular solids. In this paper, we report on positron lifetime measurements in two different types of polymers. The first group comprises polyacrylates processed on earth and in space. The second group includes fully-compatible and totally-incompatible Semi-Interpenetrating polymer networks of thermosetting and thermoplastic polyimides. On the basis of lifetime measurements, it is concluded that free volumes are a direct reflection of physical/electromagnetic properties of the host polymers.

Description: Reported herein is an overview of the research being conducted within the Materials Division at NASA Langley Research Center on the development of smart material technologies for advanced airframe systems. The research is a part of the Aircraft Morphing Program which is a new six-year research program to develop smart components for self-adaptive airframe systems. The fundamental areas of materials research within the program are computational materials; advanced piezoelectric materials; advanced fiber optic sensing techniques; and fabrication of integrated composite structures. This paper presents a portion of the ongoing research in each of these areas of materials research.

Description: The Aerospace Industry is experiencing growing demand for high performance polymer foam. The X-33 program needs structural foam insulation capable of retaining its strength over a wide range of environmental conditions. The High Speed Research Program has a need for low density core splice and potting materials. This paper reviews the state of the art in foam materials and describes experimental work to fabricate low density, high shear strength foam which can withstand temperatures from -220 C to 220 C. Commercially available polymer foams exhibit a wide range of physical properties. Some with densities as low as 0.066 g/cc are capable of co-curing at temperatures as high as 182 C. Rohacell foams can be resin transfer molded at temperatures up to 180 C. They have moduli of elasticity of 0.19 MPa, tensile strengths of 3.7 Mpa and compressive strengths of 3.6 MPa. The Rohacell foams cannot withstand liquid hydrogen temperatures, however Imi-Tech markets Solimide (trademark) foams which withstand temperatures from -250 C to 200 C, but they do not have the required structural integrity. The research activity at NASA Langley Research Center focuses on using chemical blowing agents to produce polyimide thermoplastic foams capable of meeting the above performance requirements. The combination of blowing agents that decompose at the minimum melt viscosity temperature together with plasticizers to lower the viscosity has been used to produce foams by both extrusion and oven heating. The foams produced exhibit good environmental stability while maintaining structural properties.

Description: Composite films consisting of diamond crystallites and hard amorphous films such as diamond-like carbon, titanium nitride, and titanium oxide are provided as protective coatings for metal substrates against extremely harsh environments. A composite layer having diamond crystallites and a hard amorphous film is affixed to a metal substrate via an interlayer including a bottom metal silicide film and a top silicon carbide film. The interlayer is formed either by depositing metal silicide and silicon carbide directly onto the metal substrate, or by first depositing an amorphous silicon film, then allowing top and bottom portions of the amorphous silicon to react during deposition of the diamond crystallites, to yield the desired interlayer structure.

Description: The permeation of a mixture of CH4 and CO2 (97% CH4 and 3% CO2) saturated with water vapour through Tefzel has been studied at 950 C and 25 and 50 bars. Tefzel is the Du Pont trademark of an ETFE (ethylenetetrafluorethylene) which is a copolymer of ethylene and tetrafluorethylene. This material might be used as inner plastic lining of flexible pipes. For methane and carbon dioxide, the permeability of Tefzel is higher than the deplasticized PVDF (Polyvinylidenefluoride), but lower than the plasticized PVDF. For water, the situation seems to be the other way round; Tefzel has a lower permeability than deplasticized PVDF. Whether the permeability tests on Tefzel at higher temperatures and pressures will be pursued or not, will be considered by the steering committee of the CAPP project in May.

Description: Polymer matrix composites are increasingly used in demanding structural applications in which they may be exposed to harsh environments. The durability of such materials is a major concern, potentially limiting both the integrity of the structures and their useful lifetimes. The goal of the current investigation is to develop a mechanism-based model of the chemical degradation which occurs, such that given the external chemical environment and temperatures throughout the laminate, laminate geometry, and ply and/or constituent material properties, we can calculate the concentration of diffusing substances and extent of chemical degradation as functions of time and position throughout the laminate. This objective is met through the development and use of analytical models, coupled to an analysis-driven experimental program which offers both quantitative and qualitative information on the degradation mechanism. Preliminary analyses using coupled diffusion/reaction model are used to gain insight into the physics of the degradation mechanisms and to identify crucial material parameters. An experimental program is defined based on the results of the preliminary analysis which allows the determination of the necessary material coefficients. Thermogravimetric analyses are carried out in nitrogen, air, and oxygen to provide quantitative information on thermal and oxidative reactions. Powdered samples are used to eliminate diffusion effects. Tests in both inert and oxidative environments allow the separation of thermal and oxidative contributions to specimen mass loss. The concentration dependency of the oxidative reactions is determined from the tests in pure oxygen. Short term isothermal tests at different temperatures are carried out on neat resin and unidirectional macroscopic specimens to identify diffusion effects. Mass loss, specimen shrinkage, the formation of degraded surface layers and surface cracking are recorded as functions of exposure time. Geometry effects in the neat resin, and anisotropic diffusion effects in the composites, are identified through the use of specimens with different aspect ratios. The data is used with the model to determine reaction coefficients and effective diffusion coefficients. The empirical and analytical correlations confirm the preliminary model results which suggest that mass loss at lower temperatures is dominated by oxidative reactions and that these reaction are limited by diffusion of oxygen from the surface. The mechanism-based model is able to successfully capture the basic physics of the degradation phenomena under a wide range of test conditions. The analysis-based test design is successful in separating out oxidative, thermal, and diffusion effects to allow the determination of material coefficients. This success confirms the basic picture of the process; however, a more complete understanding of some aspects of the physics are required before truly predictive capability can be achieved.

Description: Bonding labs at both MSFC and the northern Utah production plant prepare bond test specimens which simulate or witness the production of NASA's Reusable Solid Rocket Motor (RSRM). The current process for preparing the bonding surfaces employs 1,1,1-trichloroethane vapor degreasing, which simulates the current RSRM process. Government regulations (e.g., the 1990 Amendments to the Clean Air Act) have mandated a production phase-out of a number of ozone depleting compounds (ODC) including 1,1,1-trichloroethane. In order to comply with these regulations, the RSRM Program is qualifying a spray-in-air (SIA) precision cleaning process using Brulin 1990, an aqueous blend of surfactants. Accordingly, surface preparation prior to bonding process simulation test specimens must reflect the new production cleaning process. The Bonding Lab Statistical Process Control (SPC) program monitors the progress of the lab and its capabilities, as well as certifies the bonding technicians, by periodically preparing D6AC steel tensile adhesion panels with EA-91 3NA epoxy adhesive using a standardized process. SPC methods are then used to ensure the process is statistically in control, thus producing reliable data for bonding studies, and identify any problems which might develop. Since the specimen cleaning process is being changed, new SPC limits must be established. This report summarizes side-by-side testing of D6AC steel tensile adhesion witness panels and tapered double cantilevered beams (TDCBs) using both the current baseline vapor degreasing process and a lab-scale spray-in-air process. A Proceco 26 inches Typhoon dishwasher cleaned both tensile adhesion witness panels and TDCBs in a process which simulates the new production process. The tests were performed six times during 1995, subsequent statistical analysis of the data established new upper control limits (UCL) and lower control limits (LCL). The data also demonstrated that the new process was equivalent to the vapor degreasing process.

Description: Transparent polymer films are currently considered for use as solar concentrating lenses for spacecraft power and propulsion systems. These polymer films concentrate solar energy onto energy conversion devices such as solar cells and thermal energy systems. Conversion efficiency is directly related to the polymer transmission. Space environmental effects will decrease the transmission and thus reduce the conversion efficiency. This investigation focuses on the effects of ultraviolet and charged particle radiation on the transmission of selected transparent polymers. Multiple candidate polymer samples were exposed to near ultraviolet (NUV) radiation to screen the materials and select optimum materials for further study. All materials experienced transmission degradation of varying degree. A method was developed to normalize the transmission loss and thus rank the materials according to their tolerance of NUV. Teflon(Tm) FEP and Teflon(Tm) PFA were selected for further study. These materials were subjected to a combined charged particle dose equivalent to 5 years in a typical geosynchronous Earth orbit (GEO). Results from these NUV screening tests and the 5 year GEO equivalent dose are presented.

Description: A process for preparing a tough, soluble, aromatic, thermoplastic copolyimide is provided. The process comprises the steps of (a) providing 4.4'-oxydiphthalic anhydride to 3,4,3',4'-biphenyltetracarboxylic dianhydride at a mole ratio ranging from about 25 mole percent to 75 mole percent to 75 mole percent to about 25 mole percent; (b) adding 3,4'-oxydianiline to form a mixture; (c) adding a polar aprotic or polar protic solvent to the mixture to form a solution having a percentage of solids capable of maintaining polymer solubility; (d) stirring the solution to allow it to react; (e) adding an azeotropic solvent to the solution and heating to remove water; (f) cooling the solution of step (e) to room temperature and recovering the tough, soluble, aromatic, thermoplastic copolyimide.

Description: Preliminary results of shearographic inspections of the test panels simulating the Space Shuttle's external tank (ET) spray on foam insulation (SOFI) are presented. Debonding of SOFI may introduce flight debris that may damage the orbiter's thermal protection system (TPS) exposing the orbiter (as well as the ET) to thermal loading. It is estimated that 90 percent of the TPS damage on the orbiter's 'belly' results from debonded SOFI during ascent. A series of test panels were fabricated, with programmed debonds of different geometries and sizes, to determine the sensitivity of shearography as a function of debond size, SOFI thickness,'and vacuum excitation. Results show that a Probability of Detection (POD) of 0.95 or better can be expected for debonds with a diameter equal to the SOFI thickness as less than 0.4-psi pressure reduction. More testing will be required to validate the laser shearography imaging process for certifying its use in nondestructive evaluation (NDE) of Space Shuttle space flight components.

Description: As part of a program to develop structural adhesives for high performance aerospace applications, several phenylethynyl containing oligomer blends of Larc(TM) MPEI and a reactive plasticizer designated LaRC LV-1 21 were prepared and evaluated. The fully imidized blends exhibited minimum melt viscosity as low as 1000 poise at 371 C. Ti/Ti lap shear specimens fabricated at 316 C under 15 psi gave RT strength of approx. 4300 psi and no change in strength was observed at 177 C. The chemistry and properties of this new MPEI as well as some blends of MPEI with LV-121 are presented and compared to the linear version, LARC(TM)-PETI-5.

Description: Monoclinic celsian of Ba(0.75)Sr(0.25)Al2Si2O8 (BSAS-1) and B(0.85)Sr(O.15)Al2Si2O8 (BSAS-2) compositions have been synthesized from metal carbonates and oxides by solid state reaction. A mixture of BaCO3, SrCO3, Al2O3, and SiO2 powders was precalcined at approx. 900-940 C to decompose the carbonates followed by hot pressing at approx. 1300 C. The hot pressed BSAS-1 material was almost fully dense and contained the monoclinic celsian phase, with complete absence of the undesirable hexacelsian as indicated by x-ray diffraction. In contrast, a small fraction of hexacelsian was still present in hot pressed BSAS-2. However, on further heat treatment at 1200 C for 24 h, the hexacelsian phase was completely eliminated. The average linear thermal expansion coefficients of BSAS-1 and BSAS-2 compositions, having the monoclinic celsian phase, were measured to be 5.28 x 10(exp -6)/deg C and 5.15 x 10(exp -6)/deg C, respectively from room temperature to 1200 C. The hot pressed BSAS-1 celsian showed room temperature flexural strength of 131 MPa, elastic modulus of 96 GPa and was stable in air up to temperatures as high as approx. 1500 C.

Description: Friction and wear behavior of ion-beam-deposited diamondlike carbon (DLC) films coated on chemical-vapor-deposited (CVD), fine-grain diamond coatings were examined in ultrahigh vacuum, dry nitrogen, and humid air environments. The DLC films were produced by the direct impact of an ion beam (composed of a 3:17 mixture of Ar and CH4) at ion energies of 1500 and 700 eV and an RF power of 99 W. Sliding friction experiments were conducted with hemispherical CVD diamond pins sliding on four different carbon-base coating systems: DLC films on CVD diamond; DLC films on silicon; as-deposited, fine-grain CVD diamond; and carbon-ion-implanted, fine-grain CVD diamond on silicon. Results indicate that in ultrahigh vacuum the ion-beam-deposited DLC films on fine-grain CVD diamond (similar to the ion-implanted CVD diamond) greatly decrease both the friction and wear of fine-grain CVD diamond films and provide solid lubrication. In dry nitrogen and in humid air, ion-beam-deposited DLC films on fine-grain CVD diamond films also had a low steady-state coefficient of friction and a low wear rate. These tribological performance benefits, coupled with a wider range of coating thicknesses, led to longer endurance life and improved wear resistance for the DLC deposited on fine-grain CVD diamond in comparison to the ion-implanted diamond films. Thus, DLC deposited on fine-grain CVD diamond films can be an effective wear-resistant, lubricating coating regardless of environment.

Description: A resilient braided rope seal for use in high temperature applications. The resilient braided rope seal includes a center core of fibers, a resilient 5 member overbraided by at least one layer of braided sheath fibers tightly packed together. The resilient member adds significant stiffness to the seal while maintaining resiliency. Furthermore, the seal permanent set and hysteresis are greatly reduced. Finally, improved load capabilities are provided.

Description: An investigation was conducted to examine the surface chemistry, friction, and wear behavior of untreated and annealed tungsten disulfide (WS2) coatings in sliding contact with a 6-mm-diameter 440C stainless-steel ball. The WS2 coatings and annealing were performed using the pulsed-laser-deposition technique. All sliding friction experiments were conducted with a load of 0.98 N (100 g), an average Hertzian contact pressure of 0.44 GPa, and a constant rotating speed of 120 rpm. The sliding velocity ranged from 31 to 107 mm/s because of the range of wear track radii involved in the experiments. The experiment was performed at room temperature in three environments: ultrahigh vacuum (vacuum pressure, 7X(exp -10) Pa), dry nitrogen (relative humidity, less than 1 percent), and humid air (relative humidity, 15 to 40 percent). Analytical techniques, including scanning electron microscopy (SEM), energy-dispersive x-ray spectroscopy (EDX), x-ray photo electron spectroscopy (XPS), surface profilometry, and Vickers hardness testing, were used to characterize the tribological surfaces of WS2 coatings. The results of the investigation indicate that the laser annealing decreased the wear of a WS2 coating in an ultrahigh vacuum. The wear rate was reduced by a factor of 30. Thus, the laser annealing increased the wear life and resistance of the WS2 coating. The annealed WS 2 coating had a low coefficient of friction (less than O.1) and a low wear rate ((10(exp -7) mm(exp 3)/N-m)) both of which are favorable in an ultrahigh vacuum.

Description: With the expanding use of polymeric materials as composite matrices, adhesives, coatings and films, the need to develop low cost, automated fabrication processes to produce consistently high quality parts is critical. Essential to the development of reliable, automated, intelligent processing is the ability to continuously monitor the changing state of the polymeric resin in-situ in the fabrication tool. This final report discusses work done on developing dielectric sensing to monitor polymeric material cure and which provides a fundamental understanding of the underlying science for the use of frequency dependent dielectri sensors to monitor the cure process.

Description: Thermoset polyimides have great potential for successfully meeting tough stress and temperature challenges in the advanced aircraft development program. However, studies of structure-property relationships in these materials have not been very successful so far. Positron lifetime spectroscopy (PLS) has been used to investigate free volumes and associated parameters in a series of variable, segmental molecular weight samples. The free volume correlates well with the molecular weight M(sub c), the cross-link density v, and the coefficient of thermal expansion (CTE) of these materials. Currently, no other techniques are available for direct measurement of these parameters, particularly for polymers in solid phase. Experimental results and their interpretations are presented.

Description: Zerodur is a low coefficient of thermal expansion glass-ceramic material. This property makes Zerodur an excellent material for high precision optical substrates. Functioning as a high precision optical substrate, a material must be dimensionally stable in the system operating environment. Published data indicate that Zerodur is dimensionally unstable when exposed to large doses of ionizing radiation. The dimensional instability is discussed as an increase in Zerodur density. This increase in density is described as a compaction. Experimental data showing proton-induced compaction of Zerodur is presented. The dependence of compaction on proton dose was determined to be a power law relationship.