ALBERT

Description: During the Hubble Space Telescope (HST) Second Servicing Mission (SM2), degradation of unsupported Teflon(R) FEP (fluorinated ethylene propylene), used as the outer layer of the multi-layer insulation (MLI) blankets, was evident as large cracks on the telescope light shield. A sample of the degraded outer layer was retrieved during the mission and returned to Earth for ground testing and evaluation. The results of the Teflon(R) FEP sample evaluation and additional testing of pristine Teflon(R) FEP led the investigative team to theorize that the HST damage was caused by thermal cycling with deep-layer damage from electron and proton radiation which allowed the propagation of cracks along stress concentrations, and that the damage increased with the combined total dose of electrons, protons, UV and x-rays along with thermal cycling. This paper discusses the testing and evaluation of the Teflon(R) FEP.

Description: Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.

Description: Accurate knowledge of the thermophysical properties of TPS (thermal protection system) materials is necessary for pre-flight design and post-flight data analysis. Thermal properties, such as thermal conductivity and the volumetric specific heat, can be estimated from transient temperature measurements using non-linear parameter estimation methods. Property values are derived by minimizing a functional of the differences between measured and calculated temperatures. High temperature thermal response testing of TPS materials is usually done in arc-jet or radiant heating facilities which provide a quasi one-dimensional heating environment. Last year, under the NASA-ASEE-Stanford Fellowship Program, my work focused on developing a radiant heating apparatus. This year, I have worked on increasing the fidelity of the experimental measurements, optimizing the experimental procedures and interpreting the data.

Description: NASA is seeking to develop thermal insulation material systems suitable for withstanding both extremely high temperatures encountered during atmospheric re-entry heating and aero- braking maneuvers, as well as extremely low temperatures existing in liquid fuel storage tanks. Currently, materials used for the high temperature insulation or Thermal Protection System (TPS) are different from the low temperature, or cryogenic insulation. Dual purpose materials are necessary to the development of reusable launch vehicles (RLV). The present Space Shuttle (or Space Transportation System, STS) employs TPS materials on the orbiter and cryo-insulation materials on the large fuel tank slung under the orbiter. The expensive fuel tank is jettisoned just before orbit is achieved and it burns up while re-entering over the Indian Ocean. A truly completely reusable launch vehicle must store aR cryogenic fuel internally. The fuel tanks will be located close to the outer surface. In fact the outer skin of the craft will probably also serve as the fuel tank enclosure, as in jet airliners. During a normal launch the combined TPS/cryo-insulation system will serve only as a low temperature insulator, since aerodynamic heating is relatively minimal during ascent to orbit. During re-entry, the combined TPS/cryo-insulation system will serve only as a high temperature insulator, since all the cryogenic fuel will have been expended in orbit. However, in the event of an.aborted launch or a forced/emergency early re-entry, the tanks will still contain fuel, and the TPS/cryo-insulation will have to serve as both low and high temperature insulation. Also, on long duration missions, such as to Mars, very effective cryo-insulation materials are needed to reduce bod off of liquid propellants, thereby reducing necessary tankage volume, weight, and cost. The conventional approach to obtaining both low and high temperature insulation, such as is employed for the X-33 and X-34 spacecraft, is to use separate TPS and cryo-insulation materials, which are connected by means of adhesives or stand-offs (spacers). Three concepts are being considered: (1) the TPS is bonded directly to the cryo-insulation which, in turn, is bonded to the exterior of the tank, (2) stand-offs are used to make a gap between the TPS and the cryo-insulation, which is bonded externally to the tank, (3) TPS is applied directly or with stand-offs to the exterior so the tank, and cryo-insulation is applied directly to the interior of the tank. Many potential problems are inherent in these approaches. For example, mismatch between coefficients of thermal expansion of the TPS and cryo-insulation, as well as aerodynamic loads, could lead to failure of the bond. Internal cryo-insulation must be prevent from entering the sump of the fuel turbo-pump. The mechanical integrity of the stand-off structure (if used) must withstand multiple missions. During ground hold (i.e., prior to launch) moisture condensation must be minimized in the gap between the cryo-insulation and the TPS. The longer term solution requires the development of a single material to act as cryo- insulation during ground hold and as TPS during re-entry. Such a material minimizes complexity and weight while improving reliability and reducing cost.

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 yr 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: During the Second Servicing Mission (SM2) of the Hubble Space Telescope (HST) severe degradation was observed on the outer layer of the thermal control blankets. Astronaut observations and photographs revealed large cracks in the metallized Teflon(R) FEP (fluorinated ethylene propylene), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. In an effort to understand what elements of the space environment might cause such damage, pristine Teflon(R) FEP was tested for durability to radiation and thermal cycling. Specimens were subjected to electron and proton fluences comparable to those experienced by HST and were subsequently thermal cycled in a custom-built rapid thermal cycle chamber. Tensile tests of the specimens showed that radiation followed by thermal cycling significantly reduced the ultimate strength and elongation of Teflon(R) FEP.

Description: As a reinforcement for structural composites, single crystal alumina fibers offer low density, high modulus, and high creep resistance. In this study, the laser heated float zone approach was employed to grow c-axis Al2O3 continuous fibers of high purity and high strength. A new melt modulation technique, laser scanning, avoids the formation of surface induced ripples and allows the growth of 50 micro-m diameter sapphire fibers with strengths (approx. 7 GPa) significantly greater than either commercially available fibers grown by the edge-defined film growth process (approx. 2-3 GPa) or laboratory fibers grown by stationary laser heating (approx. 5 GPa). The present work suggests that surface striations are the predominant defects controlling the tensile strength of laser-scanned fibers at room temperature. Several possible mechanisms for inducing surface striations are systematically discussed for several oxide fiber compositions.

Description: Ceramic thermal barrier coatings have attracted increased attention for diesel engine applications. The advantages of using the ceramic coatings include a potential increase in efficiency and power density and a decrease in maintenance cost. Zirconia-based ceramics are the most important coating materials for such applications because of their low thermal conductivity, relatively high thermal expansivity and excellent mechanical properties. However, durability of thick thermal barrier coatings (TBCS) under severe temperature cycling encountered in engine conditions, remains a major question. The thermal transients associated with the start/stop and no-load/full-load engine cycle, and with the in-cylinder combustion process, generate thermal low cycle fatigue (LCF) and thermal high cycle fatigue (HCF) in the coating system. Therefore, the failure mechanisms of thick TBCs are expected to be quite different from those of thin TBCs under these temperature transients. The coating failure is related not only to thermal expansion mismatch and oxidation of the bond coats and substrates, but also to the steep thermal stress gradients induced in the coating systems. Although it has been reported that stresses generated by thermal transients can initiate surface and interface cracks in a coating system, the mechanisms of the crack propagation and of coating failure under the complex LCF and HCF conditions are still not understood. In this paper, the thermal fatigue behavior of an yttria partially stabilized zirconia coating system under simulated LCF and HCF engine conditions is investigated. The effects of LCF and HCF on surface crack initiation and propagation are also discussed.

Description: The use of thermal barrier coatings (TBC's) in gas turbines has increased dramatically in recent years, due mainly to the need for component protection from ever increasing service temperatures. Oxidation of the bond coat has been identified as an important contributing factor to spallation of the ceramic top coat during service. Additional variables found to influence TBC thermal cycle life include bond coat coefficient of thermal expansion, creep behavior of both the ceramic and bond coat layers, and modulus of elasticity. The purpose of this work was to characterize the effects of oxidation on the stress states within the TBC system, as well as to examine the interaction of oxidation with other factors affecting TBC life.

Description: Thermal barrier coatings are important, and in some instances a necessity, for high temperature applications such as combustor liners, and turbine vanes and rotating blades for current and advanced turbine engines. Some of the insulating materials used for coatings, such as zirconia that currently has widespread use, are partially transparent to thermal radiation. A translucent coating permits energy to be transported internally by radiation, thereby increasing the total energy transfer and acting like an increase in thermal conductivity. This degrades the insulating ability of the coating. Because of the strong dependence of radiant emission on temperature, internal radiative transfer effects are increased as temperatures are raised. Hence evaluating the significance of internal radiation is of importance as temperatures are increased to obtain higher efficiencies in advanced engines.

Description: Four research areas at the NASA Lewis Research Center involving the tribology of space mechanisms are highlighted. These areas include: soluble boundary lubrication additives for perfluoropolyether liquid lubricants, a Pennzane dewetting phenomenon, the effect of ODC-free bearing cleaning processes on bearing lifetimes, and the development of a new class of liquid lubricants based on silahydrocarbons.

Description: Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF-HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damage at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, was observed especially for the combined LCF-HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Description: A reaction-bonded silicon carbide (RB-SiC) ceramic material (Carborundum's Cerastar RB-SIC) has been joined using a reaction forming approach. Microstructure and mechanical properties of three types of reaction-formed joints (350 micron, 50-55 micron, and 20-25 micron thick) have been evaluated. Thick (approximately 350 micron) joints consist mainly of silicon with a small amount of silicon carbide. The flexural strength of thick joints is about 44 plus or minus 2 MPa, and fracture always occurs at the joints. The microscopic examination of fracture surfaces of specimens with thick joints tested at room temperature revealed the failure mode to be typically brittle. Thin joints (〈50-55 micron) consist of silicon carbide and silicon phases. The room and high temperature flexural strengths of thin (〈50-55 micron) reaction-formed joints have been found to be at least equal to that of the bulk Cerastar RB-SIC materials because the flexure bars fracture away from the joint regions. In this case, the fracture origins appear to be inhomogeneities inside the parent material. This was always found to be the case for thin joints tested at temperatures up to 1350C in air. This observation suggests that the strength of Cerastar RB-SIC material containing a thin joint is not limited by the joint strength but by the strength of the bulk (parent) materials.

Description: As an ongoing effort to develop structural adhesives for high-performance aerospace applications, recent work has focused on phenylethynyl terminated imide (PETI) oligomers. The work reported herein involves the synthesis and characterization of a series of phenylethynyl containing oligomers designated LARC(TM) MPEI (modified phenylethynyl imide). These oligomers presumably contain mixtures of linear, branched and star-shaped molecules. The fully imidized polymers exhibited minimum melt viscosities as low as 600 poise at 335 C, significantly lower than equivalent molecular weight linear materials. Ti/Ti lap shear specimens processed at 288 C under 15 psi showed tensile shear strengths as high as approx. 6000 psi and 5200 psi at ambient temperature and 177 C respectively. The chemistry and properties of these new MPEIs are presented and compared with an optimized linear PETI, LARC(TM)PETI-5.

Description: As part of a program to develop high-performance/high-temperature structural resins for aeronautical applications, imide oligomers containing pendent and terminal phenylethynyl groups were prepared, characterized and the cured resins evaluated as composite matrices. The oligomers were prepared at a calculated number-average molecular weight of 5000 g/mol and contained 15-20 mol% pendent phenylethynyl groups. In previous work, an oligomer containing pendent and terminal phenylethynyl groups exhibited a high glass transition temperature (approximately 313 C), and laminates therefrom exhibited high compressive properties, but processability, fracture toughness, microcrack resistance and damage tolerance were less than desired. In an attempt to improve these deficiencies, modifications in the oligomeric backbone involving the incorporation of 1,3-bis(3-aminophenoxy)benzene were investigated as a means of improving processability and toughness without detracting from the high glass transition temperature and high compressive properties. The amide acid oligomeric solutions were prepared in N-methyl-2-pyrrolidinone and were subsequently processed into imide powder, thin films, adhesive tape and carbon fiber prepreg. Neat resin plaques were fabricated from imide powder by compression moulding. The maximum processing pressure was 1.4 MPa and the cure temperature ranged from 350 to 371 C for 1 h for the mouldings, adhesives, films and composites. The properties of the 1,3-bis(3-aniinophenoxy)benzene modified cured imide oligomers containing pendent and terminal phenylethynyl groups are compared with those of previously prepared oligomers containing pendent and terminal phenylethynyl groups of similar composition and molecular weight.

Description: A series of polyimides derived from a newly synthesized diamine, namely, 4,4-bis(4-aminophenoxy)-2,2-dimethylbiphenyl (BAPD), were developed and characterized. Their physical and thermal properties were compared to polyimides based on'commercially available 2,2-bis(4-(4-aminophenoxy)phenyl)propane (BAPP).

Description: Luminescent molecular probes imbedded in a polymer binder form a temperature or pressure paint. On excitation by light of the proper wavelength, the luminescence, which is quenched either thermally or by oxygen, is detected by a camera or photodetector. From the detected luminescent intensity, temperature and pressure can be determined. The basic photophysics, calibration, accuracy and time response of a luminescent paint is described followed by applications in low speed, transonic, supersonic and cryogenic wind tunnels and in rotating machinery.

Description: LARC(Trademark) MPEI-1 (Langley Research Center(Trademark) modified phenylethynyl imide-1) phenylethynyl containing aromatic polymide, is based on the reaction of biphenyl dianhydride (BPDA), 3,4'-oxydianiline (3,4'-ODA), 1,3-bis(3-aminophenoxy)benzene (APB), 2,4,6-triaminopyrimidine (TAP) and 4-phenylethynyl phthalic anhydride (PEPA), presumably resulting in a mixture of linear, branched and star shaped phenylethynyl containing imides which was evaluated as a matrix for high-performance composites. The poly(amid acid) solution of MPEI-1 in N-methypyrrolidinone was synthesized at 35% and 42% solids. Unidirectional prepreg was fabricated from these solutions and Hercules IM7 carbon fiber utilizing NASA- Langley's multipurpose prepreg machine. The temperature-dependent volatile depletion rates, thermal crystallization behavior and resin theology were characterized. Based on this information, a composite molding cycle was developed which yielded well consolidated, void-free laminates. Composite mechanical properties such as short beam shear strength, longitudinal and transverse flexural strength and flexural modulus, longitudinal tensile strength and notched and unnotched compression strengths were measured at room temperature (RT) and elevated temperatures. These mechanical properties are compared with those of IM7/LARC(Trademark) PETI-5 composites.

Description: Polyimides are finding increased applications in microelectronics due to their high thermal stability, good chemical resistance, good adhesion, low moisture absorption, good mechanical properties, and low coefficient of thermal expansion (CTE). Four series of random copolyimides were synthesized and characterized for potential application as encapsulants, stress-relief layers, and interlevel dielectrics. Several candidates exhibited good combinations of physical and mechanical properties with inherent viscosities from 1.21 to 1.42 dL/g, T(sub g)'s ranging from 251 to 277 C, 10% weight loss temperatures between 503 and 527 C, and CTEs ranging from 33 to 39 ppm/deg C. Mechanical properties at room temperature for the best candidates included tensile strengths of 17.8-21.3 ksi, moduli between 388 and 506 ksi, and elongations of 11-43%. Moisture absorption for these copolyimides ranged between 0.85 and 1.38 wt %.

Description: A Space Act Agreement between Kennedy Space Center and Surtreat Southeast, Inc., resulted in a new treatment that keeps buildings from corroding away over time. Structural corrosion is a multi-billion dollar problem in the United States. The agreement merged Kennedy Space Center's research into electrical treatments of structural corrosion with chemical processes developed by Surtreat. Combining NASA and Surtreat technologies has resulted in a unique process with broad corrosion-control applications.

Description: Imi-Tech Corporation, in cooperation with Johnson Space Center, introduced the Solimide AC-500 series of polyimide foam products designed to meet the needs of the aircraft/aerospace industry. These foams accomodate the requirements of state-of-the-art insulation systems. Solimide polyimide foams are currently used in defense, industrial and commercial applications.

Description: SRS Technologies is currently the only company licensed by Langley Research Center to produce colorless polyimides. They currently produce two polyimides, the LaRC-CP1 and LaRC-CP2 developed by Langley Research Center. These polyimides offer many advantages over other commercially available materials including excellent thermal stability, radiation resistance, solubility, and transparency. The SRS polyimides can be used in laminates, films, molded parts, and stock shapes. The polyimide technology has also helped the company further their development of solar arrays.

Description: Advanced Ceramics Research (ACR) of Tucson, Arizona, researches transforming scientific concepts into technological achievement. Through the SBIR (Small Business Innovative Research) program, ACR developed a high pressure and temperature fused deposition system, a prototyping system that is known as extrusion freeform fabrication. This system is useful in manufacturing prosthetics. ACR also developed a three-dimensional rapid prototyping process in which physical models are quickly created directly from computer generated models. Marshall Space Flight Center also contracted ACR to fabricate a set of ceramic engines to be appraised for a solar thermal rocket engine test program.

Description: Under a NASA SBIR (Small Business Innovative Research) contract with Johnson Space Center, Aspen Systems developed aerogel-based superinsulation. This super-insulation is an innovative, flexible cryogenic insulation with extremely low thermal conductivity. Potential commercial uses include cryogenic applications in the transportation, storage and transfer of cryogens; near room-temperature applications such as refrigerator insulation; and elevated temperature applications such as insulations for high- temperature industrial processes and furnaces.

Description: High-temperature, crosslinked polyimides are typically insoluble, intractible materials. Consequently, in these systems it has been difficult to follow high-temperature curing or long-term degradation reactions on a molecular level. Selective labeling of the polymers with carbon-13, coupled with solid nuclear magnetic resonance spectrometry (NMR), enables these reactions to be followed. We successfully employed this technique to provide insight into both curing and degradation reactions of PMR-15, a polymer matrix resin used extensively in aircraft engine applications.

Description: Major goals of NASA and the Integrated High Performance Turbine Engine Technology (IHPTET) initiative include improvements in the affordability of propulsion systems, significant increases in the thrust/weight ratio, and increases in the temperature capability of components of gas turbine engines. Members of NASA Lewis Research Center's HITEMP project worked cooperatively with Allison Advanced Development Corporation to develop a manufacturing method to produce low-cost components for gas turbine engines. Affordability for these polymer composites is defined by the savings in acquisition and life-cycle costs associated with engine weight reduction. To lower engine component costs, the Lewis/Allison team focused on chopped graphite fiber/polyimide resin composites. The high-temperature polyimide resin chosen, PMR-II-50, was developed at NASA Lewis.

Description: Composite parts of nonuniform thickness can be fabricated by in-situ automated tape placement (ATP) if the tape can be started and stopped at interior points of the part instead of always at its edges. This technique is termed start/stop-on-the-part, or, alternatively, tape-add/tape-drop. The resulting thermal transients need to be managed in order to achieve net shape and maintain uniform interlaminar weld strength and crystallinity. Starting-on-the-part has been treated previously. This paper continues the study with a thermal analysis of stopping-on-the-part. The thermal source is switched off when the trailing end of the tape enters the nip region of the laydown/consolidation head. The thermal transient is determined by a Fourier-Laplace transform solution of the two-dimensional, time-dependent thermal transport equation. This solution requires that the Peclet number Pe (the dimensionless ratio of inertial to diffusive heat transport) be independent of time and much greater than 1. Plotted isotherms show that the trailing tape-end cools more rapidly than the downstream portions of tape. This cooling can weaken the bond near the tape end; however the length of the affected region is found to be less than 2 mm. To achieve net shape, the consolidation head must continue to move after cut-off until the temperature on the weld interface decreases to the glass transition temperature. The time and elapsed distance for this condition to occur are computed for the Langley ATP robot applying PEEK/carbon fiber composite tape and for two upgrades in robot performance. The elapsed distance after cut-off ranges from about 1 mm for the present robot to about 1 cm for the second upgrade.

Description: This report deals with the surface chemistry, microstructure, bonding state, morphology, and friction and wear properties of cubic boron nitride (c-BN) films that were synthesized by magnetically enhanced plasma ion plating. Several analytical techniques - x-ray photoelectron spectroscopy, transmission electron microscopy and electron diffraction, Fourier transform infrared spectroscopy, atomic force microscopy, and surface profilometry - were used to characterize the films. Sliding friction experiments using a ball-on-disk configuration were conducted for the c-BN films in sliding contact with 440C stainless-steel balls at room temperature in ultrahigh vacuum (pressure, 10(exp -6), in ambient air, and under water lubrication. Results indicate that the boron-to-nitrogen ratio on the surface of the as-deposited c-BN film is greater than 1 and that not all the boron is present as boron nitride but a small percentage is present as an oxide. Both in air and under water lubrication, the c-BN film in sliding contact with steel showed a low wear rate, whereas a high wear rate was observed in vacuum. In air and under water lubrication, c-BN exhibited wear resistance superior to that of amorphous boron nitride, titanium nitride, and titanium carbide.

Description: Due to the strict regulations on the usage of heavy metals as the additives in the coating industries, the search for effective organic corrosion inhibitors in replace of those metal additives has become essential. Electrically conducting polymers have been shown to be effective for corrosion prevention but the poor solubility of these intractable polymers has been a problem. We have explored a polyaniline/4-dodecylphenol complex (PANi/DDPh) to improve the dissolution and it has been shown to be an effective organic corrosion inhibitor. With the surfactant, DDPh, PANi could be diluted into the coatings and the properties of the coatings were affected. Emeraldine base (EB) form of PANi was also found to be oxidized by the hardener. The oxidized form of polyaniline provides improved corrosion protection of metals than that of emeraldine base since the value of the standard electrode potential for the oxidized form of PANi is higher than that of EB. Additionally, the surfactant improves the wet adhesion property between the coating and the metal surface.

Description: In the present work, the process parameter dependent optical and structural properties of MgO-Al(2)O(3)-ZrO(2) ternary mixed-composite material have been investigated. Optical properties were derived from spectrophotometric measurements. The surface morphology, grain size distributions, crystallographic phases and process dependent material composition of films have been investigated through the use of Atomic Force Microscopy (AFM), X-ray diffraction analysis and Energy Dispersive X- ray (EDX) analysis. EDX analysis made evident the correlation between the optical constants and the process dependent compositions in the films. It is possible to achieve environmentally stable amorphous films with high packing density under certain optimized process conditions.

Description: Marshall Space Flight Center (MSFC) is interested in developing hard thin film coating for bearings. The wearing of the bearing is an important problem for space flight engine. Hard thin film coating can drastically improve the surface of the bearing and improve the wear-endurance of the bearing. However, many fundamental problems in surface physics, plasma deposition, etc, need further research. The approach is using Electron Cyclotron Resonance Chemical Vapor Deposition (ECRCVD) to deposit hard thin film on stainless steel bearing. The thin films in consideration include SiC, SiN and other materials. An ECRCVD deposition system is being assembled at MSFC.

Description: Many spacecraft thermal control coatings in low Earth orbit (LEO) can be affected by solar ultraviolet radiation and atomic oxygen. Ultraviolet radiation can darken some polymers and oxides commonly used in thermal control materials. Atomic oxygen can erode polymer materials, but it may reverse the ultraviolet-darkening effect on oxides. Maintaining the desired solar absorptance for thermal control coatings is important to assure the proper operating temperature of the spacecraft. Thermal control coatings to be used on the International Space Station (ISS) were evaluated for their performance after exposure in the NASA Lewis Research Center's Atomic Oxygen-Vacuum Ultraviolet Exposure (AO-VUV) facility. This facility simulated the LEO environments of solar vacuum ultraviolet (VUV) radiation (wavelength range, 115 to 200 nanometers (nm)) and VUV combined with atomic oxygen. Solar absorptance was measured in vacuo to eliminate the "bleaching" effects of ambient oxygen on VUV-induced degradation. The objective of these experiments was to determine solar absorptance increases of various thermal control materials due to exposure to simulated LEO conditions similar to those expected for ISS. Work was done in support of ISS efforts at the requests of Boeing Space and Defense Systems and Lockheed Martin Vought Systems.

Description: Constant ramp strength tests on unidirectional thermoplastic composite specimens oriented in the 90 deg. direction were conducted at constant temperatures ranging from 149 C to 232 C. Ramp rates spanning 5 orders of magnitude were tested so that failures occurred in the range from 0.5 sec. to 24 hrs. (0.5 to 100,000 MPa/sec). Below 204 C, time-temperature superposition held allowing strength at longer times to be estimated from strength tests at shorter times but higher temperatures. The data indicated that a 50% drop in strength might be expected for this material when the test time is increased by 9 orders of magnitude. The shift factors derived from compliance data applied well to the strength results. To explain the link between compliance and strength, a viscoelastic fracture model was investigated. The model, which used compliance as input, was found to fit the strength data only if the critical fracture energy was allowed to vary with temperature reduced stress rate. This variation in the critical parameter severely limits its use in developing a robust time-dependent strength model. The significance of this research is therefore seen as providing both the indication that a more versatile acceleration method for strength can be developed and the evidence that such a method is needed.

Description: PMR-15 is a processable, high-temperature polymer developed at the NASA Lewis Research Center in the 1970's principally for aeropropulsion applications. Use of fiber-reinforced polymer matrix composites in these applications can lead to substantial weight savings, thereby leading to improved fuel economy, increased passenger and payload capacity, and better maneuverability. PMR-15 is used fairly extensively in military and commercial aircraft engines components seeing service temperatures as high as 500 F (260 C), such as the outer bypass duct for the F-404 engine. The current world-wide market for PMR-15 materials (resins, adhesives, and composites) is on the order of $6 to 10 million annually.

Description: Members of NASA Lewis Research Center's Tribology and Surface Science Branch are applying high-level computational chemistry techniques to the development of new lubrication systems for space applications and for future advanced aircraft engines. The next generation of gas turbine engines will require a liquid lubricant to function at temperatures in excess of 350 C in oxidizing environments. Conventional hydrocarbon-based lubricants are incapable of operating in these extreme environments, but a class of compounds known as the perfluoropolyether (PFAE) liquids (see the preceding illustration) shows promise for such applications. These commercially available products are already being used as lubricants in conditions where low vapor pressure and chemical stability are crucial, such as in satellite bearings and composite disk platters. At higher temperatures, however, these compounds undergo a decomposition process that is assisted (catalyzed) by metal and metal oxide bearing surfaces. This decomposition process severely limits the applicability of PFAE's at higher temperatures. A great deal of laboratory experimentation has revealed that the extent of fluid degradation depends on the chemical properties of the bearing surface materials. Lubrication engineers would like to understand the chemical breakdown mechanism to design a less vulnerable PFAE or to develop a chemical additive to block this degradation.

Description: Boron nitride (BN) is a prime candidate for fiber coatings in silicon carbide (SiC) fiber-reinforced SiC matrix composites. The properties of BN allow the fiber to impart beneficial composite properties to the matrix, even at elevated temperatures. The problem with BN is that it is readily attacked by oxygen. Although BN is an internal component of the composite, a matrix crack or pore can create a path for hot oxygen to attack the BN. This type of attack is not well understood. A variety of phenomena have been observed. These include borosilicate glass formation, volatilization of the BN, and under some conditions, preservation of the BN. In this study at the NASA Lewis Research Center, a series of BN materials and BN-containing model composites were methodically examined to understand the various issues dealing with the oxidation of BN in composites. Initial studies were done with a series of monolithic BN materials prepared by hot pressing and chemical vapor deposition (CVD). From these studies, we found that BN showed a strong orientation effect in oxidation and was extremely sensitive to the presence of water vapor in the environment. In addition, CVD material deposited at a high temperature showed much better oxidation behavior than CVD material deposited at a lower temperature.

Description: In this presentation, a plan to develop methods for applying pressure-sensitive paint to rotorcraft will be described. These methods are needed because flows over rotor blades are typically very complex and poorly understood and because conventional methods for measuring unsteady pressures on rotor blades (using unsteady pressure transducers provide grossly inadequate spatial resolution. Since PSP is a surface, rather than a point, measurement technique, it has the potential to significantly increase the spatial resolution )f pressure measurements on rotor blades. PSP techniques currently in use at Ames were developed for measuring steady pressures on rigid, complex airplane configurations in large, production wind tunnels. Applying PSP to rotorcraft requires a significant departure from these techniques. First and most importantly new, fast-responding and self-referencing pressure paints are required. The paints must be fast (98% response in 1-5 msec) to resolve flow unsteadiness; they must be self-referencing (or "binary") to account for changes in incident light intensity due to deflection of flexible rotors. Self-referencing paints have been used at Ames for some time; however, these paints have response times that are far too long for unsteady applications. Flash illumination is required to resolve flow unsteadiness and to minimize image blurring due to relative motion between the model and the camera. Current practice at Ames is to use continuous illumination Finally, "in situ" paint calibration versus measurements by pressure transducers, which is current Ames practice, is not practical because of the difficulty and expense of installing transducers in rotor blades. Instead, the paint must be calibrated "a priori" in a calibration chamber. A sequence of five experiments that systematically isolates and addresses the problems involved in making PSP measurements on rotor blades has been planned. These are: (1) measurements on a rigid rotor in hover; (2) measurements on a flexible rotor in hover; measurements of paint response time in a calibration apparatus; (4) measurements on a rigid, two-dimensional oscillating airfoil; and (5) measurements on a flexible rotor in forward flight. Experiments were recently conducted at Ames where PSP measurements were made on a rigid oscillating airfoil (experiment type 4) and on a flexible rotor in hover (experiment type 2). Preliminary results from these experiments will be discussed.

Description: Pure aerogels, though familiar in the laboratory for decades as exotic lightweight insulators with unusual physical properties, have had limited industrial applications due to their low strength and high brittleness. Composites formed of aerogels and the ceramic fiber matrices used as space shuttle tiles bypass the fragility of pure aerogels and can enhance the performance of space shuttle tiles in their harsh operating environment. Using a layer of aerogel embedded in a tile may open up a wide range of applications where thermal insulation, gas convection control and mechanical strength matter.

Description: The brightness signal from a pressure-sensitive paint varies inversely with absolute pressure. Consequently high signal-to-noise ratios are required to resolve aerodynamic pressure fields at low speeds, where the pressure variation around an object might only be a few percent of the mean pressure. This requirement is unavoidable, and implies that care must be taken to minimize noise sources present in the measurement. This paper discusses and compares the main noise sources in low speed PSP testing using the "classical" intensity-based single-luminophore technique. These are: temperature variation, model deformation, and lamp drift/paint degradation. Minimization of these error sources from the point of view of operation in production wind tunnels is discussed, with some examples from recent tests in NASA Ames facilities.

Description: The FT-IR, XPS and UV spectra of fluoropolymer films (SPTFE-I) deposited by argon ion-beam sputtering of polytetrafluoroethylene (PTFE) were obtained and compared with prior corresponding spectra of fluoropolymer films (SPTFE-P) deposited by argon rf plasma sputtering of PTFE. Although the F/C ratios for SPTFE-I and -P (1.63 and 1.51) were similar, their structures were quite different in that there was a much higher concentration of CF2 groups in SPTFE-I than in SPTFE-P, ca. 61 and 33% of the total carbon contents, respectively. The FT-IR spectra reflect that difference, that for SPTFE-I showing a distinct doublet at 1210 and 1150 per centimeter while that for SPTFE-P presents a broad, featureless band at ca. 1250 per centimeter. The absorbance of the 1210-per centimeter band in SPTFE-I was proportional to the thickness of the film, in the range of 50-400 nanometers. The SPTFE-I was more transparent in the UV than SPTFE-P at comparable thickness. The mechanism for SPTFE-I formation likely involves "chopping off" of oligomeric segments of PTFE as an accompaniment to "plasma" polymerization of TFE monomer or other fluorocarbon fragments generated in situ from PTFE on impact with energetic Ar ions. Data are presented for SPTFE-I deposits and the associated Ar(+) bombarded PTFE targets where a fresh target was used for each run or a single target was used for a sequence of runs.

Description: Fairings composed of Rigid Fibrous Insulations (RSI) were fabricated, instrumented, and coated using techniques that were recently developed at NASA Ames Research Center. These RSI components are part of a specific assembly of materials which were built onto a wing of a Pegasus flight vehicle. The assembly was designed to collect aerothermal data during a designated mission to deliver a satellite to earth orbit. The objective of the flight experiment is to validate the theory of boundary layer transition at flight speeds in excess of Mach 3. The actual flight experiment is scheduled to occur during the summer of 1998. Fabrication and installation methodologies will be discussed with a brief description of the wing glove assembly.

Description: Fullerenes possess remarkable properties and many investigators have examined the mechanical, electronic and other characteristics of carbon SP2 systems in some detail. In addition, C-60 can be functionalized with many classes of molecular fragments and we may expect the caps of carbon nanotubes to have a similar chemistry. Finally, carbon nanotubes have been attached to t he end of scanning probe microscope (Spill) tips. Spills can be manipulated with sub-angstrom accuracy. Together, these investigations suggest that complex molecular machines made of fullerenes may someday be created and manipulated with very high accuracy. We have studied some such systems computationally (primarily functionalized carbon nanotube gears and computer components). If such machines can be combined appropriately, a class of materials may be created that can sense their environment, calculate a response, and act. The implications of such hypothetical materials are substantial.

Description: Z-Scan measurements were performed on Au/SiO2 composite films produced by a co-sputtering technique and compared with effective medium theories which consider the full complex nature of chi(3).

Description: International Space Station Alpha (ISSA) will provide a platform not only for materials research but also a possible means to produce products in space which cannot be easily produced on the ground. Some products may even be superior to those now produced in unit gravity due to the lack of gravity induced convection effects. Our research with ZrF4-BaF2-LaF3-AlF3-NaF (ZBLAN glass) has shown that gravity does indeed play a major role in the crystallization behavior of this material. At the present time ZBLAN is being produced on earth in fiber optic form for use in surgical lasers and fiber optic lasers among other applications. High attenuation coefficients, however, have kept this material from being used in other applications such as long haul data transmission links. The high attenuation coefficients are due to impurities which can be removed through improved processing techniques and crystals which can only be removed or prevented from forming by processing in a reduced gravity environment.

Description: High temperature thermoplastic polyimide polymers are incorporated in engineering structures in the form of matrix materials in advanced fiber composites and adhesives in bonded joints. Developing analytical tools to predict long term performance and screen for final materials selection for polymers is the impetus for intensive studies at NASA and major industry based airframe developers. These fiber-reinforced polymeric composites (FRPCs) combine high strength with lightweight. In addition, they offer corrosion and fatigue resistance, a reduction in parts count, and new possibilities for control through aeroelastic tailoring and "smart" structures containing fully-integrated sensors and actuators. However, large-scale acceptance and use of polymer composites has historically been extremely slow. Reasons for this include a lack of familiarity of designers with the materials; the need for new tooling and new inspection and repair infrastructures; and high raw materials and fabrication costs.

Description: The purpose of the work is to demonstrate that the flat test panel substrate temperatures are consistent with analysis predictions for MCC-1 applied to a aluminum substrate. The testing was performed in an aerothermal facility on samples of three different thicknesses of MCC-1 on an aluminum substrate. The results of the test were compared with a Transient Thermal model. The key assumptions of the Transient Thermal model were: (1) a one-dimensional heat transfer; (2) a constant ablation recession rate (determined from pre and post-test measurements); (3) ablation temperature of 540 degrees F; (4) Char left behind the ablation front; and (5) temperature jump correction for incident heat transfer coefficient. Two methods were used to model the heating of bare MCC-1: (1) Directly input surface temperature as a function of time; and (2) Aerothermal heating using calibration plate data and subtracting the radiation losses to tunnel walls. The results are presented as graphs. This article is presented in Viewgraph format.

Description: The friction and wear behavior of seven space lubricants was investigated under boundary lubrication conditions using a vacuum four-ball tribometer. Three of the lubricants were perfluoropolyethers (143AC, S-200, and Z-25). Three were synthetic hydrocarbons (a multiply alkylated cyclopentane, 2001a), and a formulated version with an antiwear and an antioxidant additive (2001). The third hydrocarbon was an unformulated polyalphaolefin (PAO-100). An unformulated silahydrocarbon (SiHC) was also evaluated. Test conditions included: a pressure less than 6.7 x 10(exp 4) Pa, a 200 N load, a sliding velocity of 28.8 mm/sec (100 RPM), and room temperature (approx. 23 C). The wear rate for each lubricant was determined from the slope of wear volume as a function of sliding distance. The lowest wear rate (0.033 x 10(exp-9) cu mm/mm) was obtained with the silahydrocarbon. The formulated synthetic hydrocarbon had a wear rate off O.037 x 10(exp -9)cu mm/mm, which was a 36% reduction compared to the unformulated fluid. The polyalphaolefin had the highest wear rate of the non-PFPE fluids. Of the perfluoropolyethers (PFPEs), wear rates decreased by about 50% from Z-25 (1.7 x 10(exp -9)cu mm/mm) to S-200 (0.70 x 10(exp -9)cu mm/mm) to 143AC (0.21 x 10(exp -9)cu mm/mm).

Description: Surfaces of the aluminized Teflon FEP multi-layer thermal insulation on the Hubble Space Telescope (HST) were found to be cracked and curled in some areas at the time of the second servicing, mission in February 1997, 6.8 years after HST was deployed in low Earth orbit (LEO). As part of a test program to assess environmental conditions which would produce embrittlement sufficient to cause cracking of Teflon on HST, samples of Teflon FEP with a backside layer of vapor deposited aluminum were exposed to vacuum ultraviolet (VUV) and soft x-ray radiation of various energies using facilities at the National Synchrotron Light Source. Brookhaven National Laboratory. Samples were exposed to synchrotron radiation of narrow energy bands centered on energies between 69 eV and 1900 eV. Samples were analyzed for ultimate tensile strength and elongation. Results will be compared to those of aluminized Teflon FEP retrieved from HST after 3.6 years and 6.8 years on orbit and will he referenced to estimated HST mission doses of VUV and soft x-ray radiation.

Description: During the Second Servicing Mission (SM2) of the Hubble Space Telescope (HST) severe degradation was observed on the outer layer of the thermal control blankets. Astronaut observations and photographs revealed large cracks in the metallized Teflon FEP (fluorinated ethylene propylene), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. In an effort to understand what elements of the space environment might cause such damage, pristine Teflon' FEP was tested for durability to radiation and thermal cycling. Specimens were subjected to electron and proton fluences comparable to those experienced by HST and were subsequently thermal cycled in a custom-built rapid thermal cycle chamber. Tensile tests of the specimens showed that radiation followed by thermal cycling significantly reduced the ultimate strength and elongation of Teflon FEP.

Description: The formation of volatile Si-O-H species from silica occurs in water-vapor containing environments such as combustion environments. In this paper the pressure and temperature dependence of known Si-O-H species are surveyed. Trends based on the number of water molecules incorporated in the Si-O-H species are identified. Larger molecules (more OH groups) tend to have a higher pressure dependence and lower temperature dependence. These trends are then used to identify possible unknown species observed in high pressure fuel-rich combustion environments.

Description: The room temperature physical and mechanical properties of silicon carbide fiber-reinforced reaction-bonded silicon nitride matrix composites (SiC/RBSN) were measured, and the composite microstructure was analyzed. The composites consist of nearly 24 vol% of aligned Hi-Nicalon SiC fiber yarns in a approx. 30 vol% porous silicon nitride matrix. The fiber yarns were coated by chemical vapor deposition with a 0.8 mm layer of boron nitride (BN) followed by a 0.2 mm layer of SiC. In the as-fabricated condition, both 1-D and 2-D composites exhibited high strength and graceful failure, and showed improved properties w en compared with unreinforced matrix of comparable density. No indication of reaction between the SiC fiber and BN coating was noticed, but the outer SiC layer reacted locally with the nitridation enhancing additive in the RBSN matrix. A comparison is made between the predicted and measured values of matrix cracking strength.

Description: The development of modeling approaches for the failure analysis of ceramic-based material systems used in high temperature environments was the primary objective of this research effort. These materials have the potential to support many key engineering technologies related to the design of aeropropulsion systems. Monolithic ceramics exhibit a number of useful properties such as retention of strength at high temperatures, chemical inertness, and low density. However, the use of monolithic ceramics has been limited by their inherent brittleness and a large variation in strength. This behavior has motivated material scientists to reinforce the monolithic material with a ceramic fiber. The addition of a second ceramic phase with an optimized interface increases toughness and marginally increases strength. The primary purpose of the fiber is to arrest crack growth, not to increase strength. The material systems of interest in this research effort were laminated ceramic matrix composites, as well as two- and three- dimensional fabric reinforced ceramic composites. These emerging composite systems can compete with metals in many demanding applications. However, the ongoing metamorphosis of ceramic composite material systems, and the lack of standardized design data has in the past tended to minimize research efforts related to structural analysis. Many structural components fabricated from ceramic matrix composites (CMC) have been designed by "trial and error." The justification for this approach lies in the fact that during the initial developmental phases for a material system fabrication issues are paramount. Emphasis is placed on demonstrating feasibility rather than fully understanding the processes controlling mechanical behavior. This is understandable during periods of rapid improvements in material properties for any composite system. But to avoid the ad hoc approach, the analytical methods developed under this effort can be used to develop rational structural design protocols.

Description: Highly transparent coatings with a maximum sheet resistivity between 10(exp 8) and 10(exp 9) ohms/square are desired to prevent charging of solar arrays for low Earth polar orbit and geosynchronous orbit missions. Indium tin oxide (ITO) and magnesium fluoride (MgF2) were ion beam sputter co-deposited onto fused silica substrates and were evaluated for transmittance, sheet resistivity and the effects of simulated space environments including atomic oxygen (AO) and vacuum ultraviolet (VUV) radiation. Optical properties and sheet resistivity as a function of MgF2 content in the films will be presented. Films containing 8.4 wt.% MgF2 were found to be highly transparent and provided sheet resistivity in the required range. These films maintained a high transmittance upon exposure to AO and to VUV radiation, although exposure to AO in the presence of charged species and intense electromagnetic radiation caused significant degradation in film transmittance. Sheet resistivity of the as-fabricated films increased with time in ambient conditions. Vacuum beat treatment following film deposition caused a reduction in sheet resistivity. However, following vacuum heat treatment, sheet resistivity values remained stable during storage in ambient conditions.

Description: Samples of International Space Station (ISS) thermal control coatings were exposed to simulated low Earth orbit (LEO) environmental conditions to determine effects on optical properties. In one test, samples of the white paint coating Z-93P were coated with outgassed products from Tefzel(R) (ethylene tetrafluoroethylene copolymer) power cable insulation as-may occur on ISS. These samples were then exposed, along with an uncontaminated Z-93P witness sample, to vacuum ultraviolet (VUV) radiation to determine solar absorptance degradation. The Z-93P samples coated with Tefzel(R) outgassing products experienced greater increases in solar absorptance than witness samples not coated with Tefzel(R) outgassing products. In another test, samples of second surface silvered Teflon(R) FEP (fluorinated ethylene propylene), SiO. (where x=2)-coated silvered Teflon(R) FEP, and Z-93P witness samples were exposed to the combined environments of atomic oxygen and VLTV radiation to determine optical properties changes due to these simulated ISS environmental effects. This test verified the durability of these materials in the absence of contaminants.

Description: Ceramic joining is recognized as one of the enabling technologies for the application of silicon carbide-based materials in a number of high temperature applications. An affordable, robust technique for the joining of silicon carbide-based ceramics has been developed. This technique is capable of producing joints with tailorable thickness and composition. Microstructure and mechanical properties of reaction formed joints in a reaction bonded silicon carbide have been reported. These joints maintain their mechanical strengths at high temperatures (up to 1350 C) in air. This technique is capable of joining large and complex shaped ceramic components.

Description: Metallized Teflon fluorinated ethylene propylene (FEP) thermal control insulation is mechanically degraded if exposed to a sufficient fluence of soft x-ray radiation. Soft x-ray photons (4-8 A in wavelength or 1.55 - 3.2 keV) emitted during solar flares have been proposed as a cause of mechanical properties degradation of aluminized Teflon FEP thermal control insulation on the Hubble Space Telescope (HST). Such degradation can be characterized by a reduction in elongation-to-failure of the Teflon FEP. Ground laboratory soft x-ray exposure tests of aluminized Teflon FEP were conducted to assess the degree of elongation degradation which would occur as a result of exposure to soft x-rays in the range of 3-10 keV. Tests results indicate that soft x-ray exposure in the 3-10 keV range, at mission fluence levels, does not alone cause the observed reduction in elongation of flight retrieved samples. The soft x-ray exposure facility design, mechanical properties degradation results and implications will be presented.

Description: The FT-IR (Fourier Transform Infrared), UV (Ultraviolet) and XPS (X Ray Photoelectron Spectroscopy) spectra of fluoropolymer films (SPTFE) deposited by rf (radio frequency) plasma sputtering of polytetrafluoroethylene (PTFE), using Ne, Kr and Xe as sputtering gases, were obtained and compared with prior spectra for SPTFE formed using He and Ar. The F/C (fluorine / carbon) ratios for SPTFE films (1.44-1.55), obtained at a rf power of 10 W, were essentially the same for all five rare gases, there being no trend of decreasing fluorine content in the SPTFE product with increasing atomic weight of the sputtering gas - contrary to the momentum transfer notion advanced by M. E. Ryan, et al. Increasing rf power from 10 to 50 W resulted in successively lower F/C ratios for SPTFE (e.g., from 1.55 to 1.21 in the case of Xe plasma-sputtered PTFE), accompanied by sputtering of the glass reactor and deposition of fragments of sodium aluminum silicate occurring at 40 W and above. In order to achieve a "Teflon-like" SPTFE structure (i.e., products with as high a F/C ratio as possible) in a given plasma reactor, an optimum rf power must be found, which in the present case was approximately 10 W.

Description: The development of high energy cryogenic upper stages is essential for the efficient delivery of large payloads to various destinations envisioned in future programs. A key element in such upper stages is cryogenic fluid management (CFM) advanced development/technology. Due to the cost of and limited opportunities for orbital experiments, ground testing must be employed to the fullest extent possible. Therefore, a system level test bed termed the Multipurpose Hydrogen Test Bed (MHTB), which is representative in size and shape (3 meter diameter by 3 meter long with a volume of 18 cubic meters) of a fully integrated space transportation vehicle liquid hydrogen propellant tank has been established. To date, upper stage studies have often baselined the foam/multilayer insulation (FMLI) combination concept; however, hardware experience with the concept is minimal and was therefore selected for the MHTB. The foam element (isofoam SS-1 171 with an average thickness of 3.5 centimeters) is designed to protect against ground hold/ascent flight environments, and allows for the use of a dry nitrogen purge as opposed to the more complex/heavy helium purge subsystem normally required with MLI in cryogenic applications. The MLI (45 layers of Double Aluminized Mylar with Dacron spacers) provides protection in the vacuum environment of space and is designed for an on-orbit storage period of 45 days. Several unique features were incorporated in the MLI concept and included: variable density MLI (reduces weight and radiation losses by changing the layer density), larger but fewer DAM perforations for venting during ascent to orbit (reduces radiation losses), and roll wrap installation of the MLI with a commercially established process to lower assembly man-hours and reduce seam heat leak. Thermal performance testing of the MHTB TCS was conducted during three test series conducted between September 1995 and May 1996. Results for the ground hold portion of the tests were as expected producing an average heat leak of 63 WattS/M2 at an average foam surface temperature of 170 K. The results of the simulated orbit hold test interval produced heat leaks ranging from 0.085 to 0.22 Watts/squareM at warm boundary temperatures of 164K and 305K, respectively. When compared to the performance for a traditional MLI system, a 60% reduction in orbital heat leak or boiloff was measured. Overall, the MHTB TCS demonstrated satisfactory performance for all mission phases required of a cryogenic upper stage.

Description: The nonlinear optical properties of metal-free phthalocyanine (MFPC) thin films were examined using the second harmonic at 532 nm from a pulsed Nd:YAG laser, and the cw He-Ne , and Ar+ lasers. The He-Ne laser transmission at fixed input intensity was found to increase temporally within a time scale of twelve hours. The origin of this temporal change of transmission is discussed. The third order nonlinear susceptibilities (chi (exp(3))) by four-wave mixing were measured for films of different thickness. The saturation intensity of MFPC, and its absorption cross section, at 633 nm from a He-Ne laser, are reported. An optical bistability was recorded using a He-Ne laser. An AND logic gate was also demonstrated in the system. These phenomena in the system are attributed to refractive index modulation by thermal excitations.

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. Future launch systems may require similar applications of SFLs for attachment and restraint hardware. A family of environmentally compatible non-lead/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's of these new lubricants. The new SFLs trade 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 (450F). Significant savings in energy and processing time as well as elimination of hazardous material usage and disposal would result from the non-toxic one-step SFL application. Compatible air-dry field repair lubricants will help eliminate disassembly of launch vehicle restraint hardware during critical time sensitive assembly operations.

Description: Changes in the pressure of hydrogen, helium and neon due to diffusion through the wall of silica crystal growth ampoules at elevated temperatures were determined experimentally. We show that, while both He- and Ne-losses closely follow conventional model of diffusive gas permeation through the wall, hydrogen losses, in particular at low fill pressures, can be much larger. This is interpreted in terms of the high solubility of hydrogen in silica glasses.

Description: Processing of Lunar/Mars raw materials into usable structural and thermal components for use on a Lunar/Mars base will be essential for human habitation. One such component will be glass fiber which can be used in a number of applications. Glass fiber has been produced from two lunar soil simulants. These two materials simulate lunar mare and lunar highlands soil compositions. Short fibers containing recrystallized areas were produced from the as-received simulants. Doping the highland simulant with 8 weight percent boria yielded a material which could be spun continuously. The effects of lunar gravity on glass fiber formation were studied utilizing NASA's KC 135 aircraft. Gravity was found to play a role in crystallization and final fiber diameter.

Description: Tooling technology applications for composite structures fabrication have been expanded at MSFC's Productivity Enhancement Complex (PEC). Engineers from NASA/MSFC and Lockheed Martin Corporation have developed a tooling foam for use in composite materials processing and manufacturing that exhibits superior thermal and mechanical properties in comparison with other tooling foam materials. This tooling foam is also compatible with most preimpregnated composite resins such as epoxy, bismaleimide, phenolic and their associated cure cycles. MARCORE tooling foam has excellent processability for applications requiring either integral or removable tooling. It can also be tailored to meet the requirements for composite processing of parts with unlimited cross sectional area. A shelf life of at least six months is easily maintained when components are stored between 50F - 70F. The MARCORE tooling foam system is a two component urethane-modified polyisocyanurate, high density rigid foam with zero ozone depletion potential. This readily machineable, lightweight tooling foam is ideal for composite structures fabrication and is dimensionally stable at temperatures up to 350F and pressures of 100 psi.

Description: There is a current lack of environmentally acceptable foams to insulate Long-Duration Human Spaceflight Missions, including the experimental Express Rack for the Space Station. A recent 60-day manned test in a sealed chamber at Johnson Space Center (JSC) was nearly aborted, because of persistently high formaldehyde concentrations in the chamber. Subsequent investigation showed that the source was melamine foam (used extensively for acoustic insulation). The thermal and acoustic potential for melamine-foam substitutes is evaluated for scale-up to a silica-based foam and aerogel, which is environmentally benign for long duration space flight. These features will be discussed in reference to an aerogel prototype to: 1) assemble material strength data for various formulated aerogels, both silica and organic carbon aerogels; 2) assemble the aerogel into panels of mylar/vacuum-encapsulated rigid boards which can be molded in various shapes and rigidities; and 3) describe a process for space applications for formaldehyde-free, long duration thermal and acoustic insulators.

Description: A series of low speed (M less than 0.2) experiments using University of Washington Fib-07 Pressure Sensitive Paint (PSP) have been conducted at NASA Ames on a NACA 0012 airfoil. Significant improvements in results have been shown: PSP calibration errors of the improved data (with pressure taps as a reference) now agree with theoretical error limits. Additional measurements on the 0012 airfoil using Temperature Sensitive Paint have been made. These TSP measurements now fully quantify the impact of temporal temperature changes on model surfaces on PSP measurements. Finally, simultaneous PSP - TSP measurements have been performed, allowing in-situ temperature correction of PSP data with good results.

Description: Thermal barrier coating (TBC) durability is closely related to design, processing and microstructure of the coating Z, tn systems. Two important issues that must be considered during the design of a thermal barrier coating are thermal expansion and modulus mismatch between the substrate and the ceramic layer, and substrate oxidation. In many cases, both of these issues may be best addressed through the selection of an appropriate bond coat system. In this study, a low thermal expansion and layer-graded bond coat system, that consists of plasma-sprayed FeCoNiCrAl and FeCrAlY coatings, and a high velocity oxyfuel (HVOF) sprayed FeCrAlY coating, is developed to minimize the thermal stresses and provide oxidation resistance. The thermal expansion and oxidation behavior of the coating system are also characterized, and the strain isolation effect of the bond coat system is analyzed using the finite element method (FEM). Experiments and finite element results show that the layer-graded bond coat system possesses lower interfacial stresses. better strain isolation and excellent oxidation resistance. thus significantly improving the coating performance and durability.

Description: Significant progress has been made on the analysis of the June, 1991 storm. We have completed the analysis of the CRRES and DMSP data sets. We have been able to follow the evolution during the storm of the inner edge of the electric field patterns in the dusk sector and its relation to electron boundaries, ion boundaries and the ring current. Whereas the CRRES data provide radial cuts out through the plasmasphere every I 0 hours, DMSP provides snapshots every orbit of the potential and particle boundaries. Electric field and energetic particle measurements from CRRES and ion drifts and energetic particle measurements from DMSP provide the principal data sets. The combined data set provides high resolution definition of the boundary motions over the phases of the storm. L shell differences between the DMSP and CRRES particle boundaries are easily explained by inflation of the dusk sector by the ring current. The electric field boundaries are typically associated with the ion boundary and the inner edge of the ring current except during rapid increases in the cross-polar cap potential. A significant fraction of the dusk cell potential is found inside the plasmasheet electron inner edge. Twice during the storm this potential exceeded 60 kV. A paper (copy attached) has been prepared (Burke et al., 1998) and submitted to JGR. An invited paper will be presented by Burke at the spring AGU meeting. An abstract has also been submitted to the COSPAR meeting for presentation by Maynard. New simulations have been carried out with the Rice Convection Model for the magnetic storm of June 4-5, 1991, and comparisons have been made with CRRES and DMSP data.

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-vacuum 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-vacuum reflectance technique to investigate UV activated reflectance recovery. Both samples showed minimal UV activated reflectanc6 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: During the Hubble Space Telescope (HST) Second Servicing Mission (SM2), degradation of unsupported Teflon' FEP (fluorinated ethylene propylene), used as the outer layer of the multi-layer insulation (MLI) blankets, was evident as large cracks on the telescope light shield. A sample of the degraded outer layer was retrieved during the mission and returned to Earth for ground testing and evaluation. The results of the Teflon FEP sample evaluation and additional testing of pristine Teflon FEP led the investigative team to theorize that the HST damage was caused by thermal cycling with deep-layer damage from electron and proton radiation which allowed the propagation of cracks along stress concentrations, and that the damage increased with the combined total dose of electrons, protons, LTV and x-rays along with thermal cycling. This paper discusses the testing and evaluation of the Teflon FEP.

Description: This paper discusses the application of Convergent Spray Technologies (TM) Spray Process to the development and successful implementation of Marshall Convergent Coating (MCC-1) as a primary Thermal Protection System (TPS) for the Space Shuttle Solid Rocket Boosters (SRBs). This paper discusses the environmental and process benefits of the MCC-1 technology, shows the systematic steps taken in developing the technology, including statistical sensitivity studies of about 35 variables. Based on the process and post-flight successes on the SRB, it will be seen that the technology is "field-proven". Application of this technology to other aerospace and commercial programs is summarized to illustrate the wide range of possibilities.

Description: During the Second Servicing Mission (SM2) of the Hubble Space Telescope (HST) severe degradation was observed on the outer layer of the thermal control blankets. Astronaut observations and photographs revealed large cracks in the metallized Teflon' FEP (fluorinated ethylene propylene), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. In an effort to understand what elements of the space environment might cause such damage, pristine Teflon(registered trademark) FEP was tested for durability to radiation and thermal cycling. Specimens were subjected to electron and proton fluences comparable to those experienced by HST and were subsequently thermal cycled in a custom-built rapid thermal cycle chamber. Tensile tests of the specimens showed that radiation followed by thermal cycling significantly reduced the ultimate strength and elongation of Teflon(registered trademark) FEP.

Description: This document contains papers from the 1997 Thermal Barrier Coatings Workshop, sponsored by the TBC Interagency Coordination Committee. The Workshop was held in Fort Mitchell, Kentucky, May 19-21, 1997. The papers cover the topics of heat transfer and conductivity of thermal barrier coatings, failure mechanisms and characterization of the coatings as well as characterization of coating deposition methods. Speakers included research, development and user groups in academia, industry and government.

Description: Development of thermally stable optical materials for nonlinear optics have recently focused on the covalent incorporation of NLO chromophores into high performance polymers, especially thermally stable and processable polyamides. One key aspect for the incorporation of robust NLO chromophores into high Tg polymers is to sustain poling induced order. Other advantages include high loading level of chromophores, and elimination of possible phase separation as well as chromophore sublimation at processing or working temperature. We have prepared several polyimide based polymers which are covalently linked with thermally stable chromophores that we have developed, since polyamides generally exhibit high Tg and good film transparency. Here, we report the development and subsequent incorporation of indoline based chromophores into polyamides, leading to thermally stable NLO polymers.

Description: Trivalent europium ions are an important luminophore for lighting and display. The emission of (5)D0 to (7)F2 transition exhibits a red color at about 610 nm, which is very attractive and fulfills the requirement for most red-emitting phosphors including lamp and cathode ray phosphorescence materials. Various EU(3+) doped phosphors have been developed, and luminescence properties have been extensively studied. On the other hand, sol-gel technology has been well developed by chemists. In recent years, applications of this technology to optical materials have drawn a great attention. Sol-gel technology provides a unique way to obtain homogeneous composition distribution and uniform doping, and the processing temperature can be very low. In this work, EU(3+) doped SiO2 thin films and glasses were prepared by sol-gel technology and their spectroscopic properties were investigated.

Description: Amorphous silicon films (a-Si:H) have been routinely deposited on a variety of substrates. Surface and interfacial studies were carried out with a PHI 5600 X-ray photo electron spectrometer. Co-deposition with fluorine yielded films having oxygen present as bulk oxide. The higher the fluorine content, the greater the amount of bulk oxygen observed. The presence of oxygen may be a contributing factor to inconsistent film properties of fluorine doped silicon materials, reported else where. A definite chemical interface between a layer containing fluorine and a layer made from pure silane has been delineated.

Description: High purity ZTA ceramic powders with and without yttria were produced using metal alkoxide precursors. ZTA ceramic powders with varying volume percents of zirconia were prepared (7, 15, and 22%). Aluminum tri-sec butoxide, zirconium propoxide, and yttrium isopropoxide were the reagents used. Synthesis conditions were varied to control the hydrolysis and the aging conditions for the sol to gel transition. FTIR analysis and theological characterization were used to follow the structural evolution during the sol to gel transition. The greater extent of hydrolysis and the build-up of structure measured from viscoelastic properties were consistent. Heat treatment was conducted to produce submicron grain fully crystalline ZTA ceramic powders. In all experimental cases a-alumina and tetragonal zirconia phases were confirmed even in the absence of yttria.

Description: Pd/SiC has been used as a hydrogen and a hydrocarbon gas sensor operated at high temperature. UHV (Ultra High Vacuum)-Scanning Tunneling Microscopy (STM), Atomic Force Microscopy (AFM) and X-ray Photoelectron Spectroscopy (XPS) techniques were applied to study the relationship between the morphology and chemical compositions for Pd ultra-thin films on SiC (less than 30 angstroms) at different annealing temperatures. Pd ultra-thin film on 6H-SiC was prepared by the RF sputtering method. The morphology from UHV-STM and AFM shows that the Pd thin film was well deposited on SiC substrate, and the Pd was partially aggregated to round shaped participates at an annealing temperature of 300 C. At 400 C, the amount of surface participates decreases, and some strap shape participates appear. From XPS, Pd2Si was formed on the surface after annealing at 300 C, and all Pd reacted with SiC to form Pd2Si after annealing at 400 C. The intensity of the XPS Pd peak decreases enormously at 400 C. The Pd film diffused into SiC, and the Schottky barrier height has almost no changes. The work shows the Pd sicilides/SiC have the same electronic properties with Pd/SiC, and explains why the Pd/SiC sensor still responds to hydrogen at high operating temperatures.

Description: A modified dc-diode plating system, utilizing a metallic screen cage as a cathode and referred as SCREEN CAGE ION PLATING (SCIP), is used to deposit Ag and Au lubricating films on Si3N4 and SiC surfaces. When deposition is performed in Ar or N2, glow discharge, the surface displays poor adhesive strength (less than 5 MPa). A dramatic increase in adhesive strength (less than 80 MPa) is achieved when plating is performed in a reactive 50% 02 + 50% Ar glow discharge. The excited/ionized oxygen species (O2(+)/O(+) in the glow discharge contribute to the oxidation of the Si3N4 or SiC surfaces as determined by X-ray Photoelectron Spectroscopy (XTS) depth profiling. The reactively sputter-oxidized S3N4 or SiC surfaces and the activated-oxidized-metastable Ag or Au species formed in the plasma cooperatively contribute to the increased adherence. As a result, the linear thermal expansion coefficient mismatch at the interface is reduced. These lubricating Ag and Au films under sliding conditions reduce the friction coefficient by a factor of 2-1/2 to 4.

Description: As an ongoing effort to develop structural adhesives for high performance aerospace applications, recent work has focused on phenylethynyl terminated imide (PETI) oligomers. The work reported herein involves the synthesis and characterization of a series of phenylethynyl containing oligomers designated LARC (TM) MPEI (Modified Phenylethynyl Terminated Polyimide). These oligomers contain mixtures of linear, branched and star-shaped molecules. The fully imidized polymers exhibited minimum melt viscosity as low as 600 poise at 335 C. Ti/Ti lap shear specimens processed at 288 C under 15 psi showed tensile shear strength of approx. 6000 psi and 5200 psi at ambient and 350 F temperatures, respectively. The chemistry and properties of these new MPEIs are presented and compared to an optimized linear PETI, LaRC(Tm) -PETI-5.

Description: A cryogenic pressure box test facility has been designed and fabricated for use at NASA Langley Research Center (LaRC) to subject 5 ft x 6 ft curved panels to cryogenic temperatures and biaxial tensile loads. The cryogenic pressure box is capable of testing curved panels down to -423 F (20 K) with 54 psig maximum pressure. The key challenge in the design and fabrication of the pressure box was the development of a seal that could remain flexible at -423 F and contain 60 psi gaseous helium as the pressurization gas. A C-shaped seal was developed using a Gore-tex woven fabric. Mechanical testing of the fabric at room and elevated temperature, liquid nitrogen temperature, and liquid helium temperature demonstrated the strength and creep resistance of the material over the desired operating range. A small scale cryogenic pressure box was used to test prototype seals at cryogenic temperatures up to 60 psi. Preliminary tests indicated that excessive leakage was present through the seal. As a result, an aluminized mylar liner was placed inside the Gore-tex seal to reduce leakage through the seal. The final seal configuration resulted in minimal pressure loss during seal testing.

Description: Tensile strengths of as-received Hi-Nicalon fibers and those having a dual BN/SiC surface coating, deposited by chemical vapor deposition, have been measured at room temperature. These fibers were also treated with HF for 24 h followed by tensile strength measurements. Strengths of uncoated and BN/SiC coated Hi-Nicalon fibers extracted from celsian matrix composites, by dissolving away the matrix in HF for 24 h, were also determined. The average tensile strength of uncoated Hi-Nicalon was 3.19 +/- 0.73 GPa with a Weibull modulus of 5.41. The Hi-Nicalon/BN/SiC fibers showed an average strength of 3.04 q 0.53 GPa and Weibull modulus of 6.66. After HF treatments, the average strengths of the uncoated and BN/SiC coated Hi-Nicalon fibers were 2.69 +/- 0.67 GPa and 2.80 +/- 0.53 GPa and the Weibull moduli were 4.93 and 5.96, respectively. The BN/SiC coated fibers extracted from the celsian matrix composite exhibited a strength of 2.38 +/- 0.40 GPa and a Weibull modulus of 7.15. The strength of the uncoated Hi-Nicalon fibers in the composite was so severely degraded that they disintegrated into small fragments during extraction with HF. The uncoated fibers probably undergo mechanical surface damage during hot pressing of the composites. Also, the BN layer on the coated fibers acts as a compliant layer which protects the fibers from mechanical damage during composite processing. The elemental composition and thickness of the fiber coatings were deten-nined using scanning Auger analysis. Microstructural analyses of the fibers and the coatings were done by scanning electron microscopy and transmission electron microscopy. Strengths of fibers calculated using average and measured fiber diameters were in good agreement. Thus, the strength of fibers can be evaluated using an average fiber diameter instead of the measured diameter of each filament.

Description: A revolution in diamond technology is in progress as the low-pressure process becomes an industrial reality. It will soon be possible to take advantage of the demanding properties of diamond to develop a myriad of new applications, particularly for self-lubricating, wear, and superhard coatings. The production of large diamond films or sheets at low cost, a distinct possibility in the not-too-distant future, may drastically change tribology technology, particularly solid lubricants and lubricating materials and systems. This chapter reviews the structures and properties of natural and synthetic diamond to gain a better understanding of the tribological properties of diamond and related materials to be described in the following chapters. Atomic and crystal structure, impurities, mechanical properties, and indentation hardness of diamond are described.

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 advanced into a combustion chamber continuously. A product remover receives the powder product of the combustion.

Description: Aging characteristics of four poly(amide acid) solutions were followed using gel permeation chromatography. NASA LaRC(Tm) PETI-5 was found to be the most stable over a period of about 270 days.

Description: In the process of the present invention, a non-polar, aprotic solvent is removed from an oligomer/polymer solution by freeze-drying in order to produce IPNs and semi-IPNs. By thermally quenching the solution to a solid in a short length of time, the size of the minor constituent-rich regions is greatly reduced as they are excluded along with the major constituent from the regions of crystallizing solvent. The use of this process sequence of controlling phase morphology provides IPNs and semi-IPNs with improved fracture toughness, microcracking resistance, and other physical-mechanical properties as compared to IPNs and semi-IPNs formed when the solvent is evaporated rather than sublimed.

Description: A method for creating a composite form of coating from a sprayable solution of soluble polyimides and particle materials that are uniformly dispersed within the solution is described. The coating is formed by adding a soluble polyimide to a solvent, then stirring particle materials into the solution. The composite solution is sprayed onto a substrate and heated in an oven for a period of time in order to partially remove the solvent. The process may be repeated until the desired thickness or characteristic of the coating is obtained. The polyimide is then heated to at least 495 F, so that it is no longer soluble.

Description: Tough, soluble, aromatic, thermoplastic copolyimides were prepared by reacting 4,4'-oxydiphthalic anhydride, 3,4,3',4'-biphenyltetracarboxylic dianhydride and 3,4'-oxydianiline. These copolyimides were found to be soluble in common amide solvents such as N,N'-dimethyl acetamide, N-methylpyrrolidinone, and dimethylformamide allowing them to be applied as the fully imidized copolymer and to be used to prepare a wide range of articles.

Description: Stress rupture creep tests were performed on uncoated and Cu-30vol%Cr coated NARloy-Z copper alloy specimens exposed to air at 482 C to 704 C. The results showed that creep failure in air of unprotected NARloy-Z was precipitated by brittle intergranular surface cracking produced by strain assisted grain boundary oxidation (SAGBO) which in turn caused early onset of tertiary creep. For the protected specimens, the Cu-Cr coating remained adherent throughout the tests and was effective in slowing down the rate of oxygen absorption, particularly at the higher temperatures, by formation of a continuous chromium oxide scale. As the result of reducing oxygen ingress, the coating prevented SAGBO initiated early creep failure, extended creep deformation and increased the creep rupture life of NARloy-Z over the entire 482 C to 704 C test temperature range.

Description: The desirable properties of ceramics at high temperatures have generated interest in their use for structural applications such as in advanced turbine systems. Design lives for such systems can exceed 10,000 hours. The long life requirement necessitates subjecting the components to relatively low stresses. The combination of high temperatures and low stresses typically places failure for monolithic ceramics in the creep regime. The objective of this paper is to present a design methodology for predicting the lifetimes of structural components subjected to creep rupture conditions. This methodology utilized commercially available finite element packages and takes into account the time-varying creep strain distributions (stress relaxation). The creep life of a component is discretized into short time steps, during which the stress and strain distributions are assumed constant. The damage is calculated for each time step based on a modified Monkman-Grant creep rupture criterion. Failure is assumed to occur when the normalized accumulated damage at any point in the component is greater than or equal to unity. The corresponding time will be the creep rupture life for that component. Examples are chosen to demonstrate the CARES/CREEP (Ceramics Analysis and Reliability Evaluation of Structures/CREEP) integrated design programs, which is written for the ANSYS finite element package. Depending on the component size and loading conditions, it was found that in real structures one of two competing failure modes (creep or slow crack growth) will dominate. Applications to benechmark problems and engine components are included.

Description: Polymers containing covalently bonded nonlinear optical (NLO) chromophores are expected to possess special properties such as greater stability, better mechanical processing, and easier film formation than their non-polymeric equivalent. For the present work, polymethylmethacrylate (PMMA) was selected as the basic polymer unit on which to incorporate different NLO chromophores. The NLO components were variations of DIVA {[2-methoxyphenyl methylidene]-propanedinitrile} which we prepared from vanillin derivatives and malononitrile. These were esterified with methacrylic acid and polymerized either directly or with methyl methacrylate to form homopolymers or copolymers respectively. Characterization of the polymers and NLO property studies are underway.

Description: The following tasks were performed at NCA&TSU during the second year in performance of the grant. LaRC-LV-1 13 resin was synthesized at NCA&TSU. In order to perform the synthesis, glassware and needed apparatus were purchased with grant funds along with the appropriate monomers. It was found that the LaRC-LV-1 13 resin was easily synthesized by the NMP solvent/toluene imminization/distilled water precipitation process. However, in use this resin exhibited a bubbling/foaming behavior during cure that was detrimental leading to the production of composite panels having a high void content. Composite panels were fabricated using compression molding and resin transfer molding (RTM) techniques. Initial fiber volume determinations were computed at NCA&TSU along with NASA-Langley measured c-scans on the panels produced. The initial results indicated a unsatisfactory level of approximately 20% by volume of voids. Testing of uniaxial coupons in compression to failure also agreed with these results. The uniaxial coupons delaminated as the major mode of failure indicative of an unacceptably low level of resin and to much void content in the final composites produced. In discussions with Dr. Brian Jensen, it was suggested the void fraction needs to be reduced to at least 2% by volume for a useful composite. The panels produced used both resin synthesized at NASA-Langley and NCA&TSU. In reviewing our progress over the past year, it was noted that the resin as formulated by the current synthesis process bubbled at elevated temperature. This was especially observed in neat resin slugs cured at the recommended one, four and eight hour cure temperatures. Pressurized cures where then performed with pressures up to 200 psi and simultaneously the lowest eight hour cure temperatures. Although this procedure reduced the amount of bubbles to some extent in the neat resin slugs it did not completely eliminate them. The cure reaction appears to be very energetic even at the lowest recommended cure temperature. Currently, the pressurized cure apparatus developed at NCA&TSU is limited to 200 psi.

Description: We focus on two distinct materials science problems that arise in two distinct microgravity environments: In space and within the space of a polymeric network. In the former environment, we consider a near eutectic alloy film in contact with its vapor which, when evaporating on earth, will experience compositionally induced buoyancy driven convection. The latter will significantly influence the morphology of the crystallized end member. In the absence of gravity, the morphology will be dominated by molecular diffusion and Marangoni driven viscous flow, and we study these phenomena theoretically and experimentally. The second microgravity environment exists in liquids, gels, and other soft materials where the small mass of individual molecules makes the effect of gravity negligible next to the relatively strong forces of intermolecular collisions. In such materials, an essential question concerns how to relate the molecular dynamics to the bulk rheological behavior. Here, we observe experimentally the diffusive motion of a single molecule in a single polymer filament, embedded within a polymer network and find anomalous diffusive behavior.

Description: An attempt was made to determine elevated-temperature, 'ultra'-fast fracture strengths of one alumina, two silicon nitrides and one silicon carbide by using constant stress-rate ('dynamic fatigue') testing with a series of 'ultra'-fast test rates. Of the materials tested, the alumina exhibited a convergence of strength at stress rates below 3.3 x 10(exp 4) MPa/s. The strength approached approximately the room-temperature inert strength. By contrast, the silicon nitrides and silicon carbide did not reveal a strength approach, but exhibited elevated-temperature strengths 10 and 20% lower than their respective room-temperature strengths. Although the analytical results imply that the elevated-temperature 'inert' strength of a ceramic material can be obtained by using sufficiently high stress rates, the experimental testing rates were only sufficient to demonstrate convergence for the alumina.

Description: Thin film coatings have the capability of obtaining a wide range of thermal radiative properties, but the development of thin film coatings can sometimes be difficult and costly when trying to achieve highly specular surfaces. Given any space mission's then-nal control requirements, there is often a need for a variation of solar absorptance (alpha(sub s)), emittance (epsilon) and/or highly specular surfaces. The utilization of thin film coatings is one process of choice for meeting challenging thermal control requirements because of its ability to provide a wide variety of alpha(sub s)/epsilon ratios. Thin film coatings' radiative properties can be tailored to meet specific thermal control requirements through the use of different metals and the variation of dielectric layer thickness. Surface coatings can be spectrally selective to enhance radiative coupling and decoupling. The application of lacquer to a surface can also provide suitable specularity for thin film application without the cost and difficulty associated with polishing.

Description: During the Hubble Space Telescope (HST) second servicing mission (SM2), astronauts noticed that the multilayer insulation (MLI) covering the telescope was damaged. Large pieces of the outer layer of MLI (aluminized Teflon fluorinated ethylene propylene (Al-FEP)) were torn in several locations around the telescope. A piece of curled up Al-FEP was retrieved by the astronauts and was found to be severely embrittled, as witnessed by ground testing. Goddard Space Flight Center (GSFC) organized a HST MLI Failure Review Board (FRB) to determine the damage mechanism of FEP in the HST environment, and to recommend replacement insulation material to be installed on HST during the third servicing mission (SM3) in 1999. Candidate thermal control replacement materials were chosen by the FRB and tested for environmental durability under various exposures and durations. This paper describes durability testing of candidate materials which were exposed to charged particle radiation, simulated solar flare x-ray radiation and thermal cycling under load. Samples were evaluated for changes in solar absorptance and tear resistance. Descriptions of environmental exposures and durability evaluations of these materials are presented.

Description: A series of experimental and numerical investigations to develop a more complete understanding of the reactive fluid dynamics of chemical vapor deposition were conducted. In the experimental phases of the effort, a horizontal CVD reactor configuration was used for the growth of InP at UVA and for laser velocimetry measurements of the flow fields in the reactor at LaRC. This horizontal reactor configuration was developed for the growth of III-V semiconductors and has been used by our research group in the past to study the deposition of both GaAs and InP. While the ultimate resolution of many of the heat and mass transport issues will require access to a reduced-gravity environment, the series of groundbased research makes direct contributions to this area while attempting to answer the design questions for future experiments of how low must gravity be reduced and for how long must this gravity level be maintained to make the necessary measurements. It is hoped that the terrestrial experiments will be useful for the design of future microgravity experiments which likely will be designed to employ a core set of measurements for applications in the microgravity environment such as HOLOC, the Fluid Physics/Dynamics Facility, or the Schlieren photography, the Laser Imaging Velocimetry and the Laser Doppler Velocimetry instruments under development for the Advanced Fluids Experiment Module.

Description: Our research resulted in several discoveries which contributed to understanding the origin and operation of life. (1) Most importantly, we discovered a new pathway of prebiotic amino acid synthesis in which formaldehyde and glycolaldehyde (formose reaction substrates) react with ammonia to give alanine and homoserine in the presence of thiol catalysts. The thiol-dependent synthesis of amino acids undoubtedly occurs via amino acid thioester intermediates capable of forming peptides. This 'one-pot' reaction system operates under mild aqueous conditions, and like modern amino acid biosynthesis, uses sugar intermediates which are converted to amino acids by energy-yielding redox disproportionation. Preliminary evidence suggests that this type of process can be "evolved" by a serial transfer methods that lead to enrichment of autocatalytic molecules. (2) We established that prebiotic peptide polymers can be made by condensation of amino acid thioesters (homocysteine thiolactone and S-(N-beta-orotidyl- diaminopropionic acid) ethanethiol), and that prebiotic polydisulfide polymers can be generated by oxidation of dithiols with iron(III) in minerals. (3) In our analysis of metabolism we discovered the primary energy source of biosynthesis -- chemical energy made available by the redox disproportionation of substrate carbon groups. We concluded that the energy and reactivity of sugars make them the optimal substrate for the origin and operation of terrestrial (or extraterrestrial) life. (4) Since it is likely that the use of optimal sugar substrates in biosynthesis sets the average oxidation number of functional biocarbon throughout the Universe near 0.0 (the reduction level of formaldehyde), we proposed that a line(s) in the microwave spectrum of formaldehyde could be rationally selected as a frequency for interstellar communication that symbolizes life. (5) Finally, in preparation for the analysis of Martian meteorite samples, we upgraded our HPLC system to one femtomole sensitivity, and developed a new electrophoretic method of sample preparation for HPLC analysis of the meteoritic amino acids. In a sample of the KT boundary layer from Sussex Wyoming, we found about 300 picomoles per gram of meteoritic alpha-aminoisobutyric acid per gram of KT layer.

Description: The desirable properties of ceramics at high temperatures have generated interest in their use for structural application such as in advanced turbine engine systems. Design lives for such systems can exceed 10,000 hours. The long life requirement necessitates subjecting the components to relatively low stresses. The combination of high temperatures and low stresses typically places failure for monolithic ceramics in the creep regime. The objective of this paper is to present a design methodology for predicting the lifetimes of structural components subjected to creep rupture conditions. This methodology utilizes commercially available finite element packages and takes into account the time-varying creep strain distributions (stress relaxation). The creep life, of a component is discretized into short time steps, during which the stress and strain distributions are assumed constant. The damage is calculated for each time step based on a modified Monkman-Grant creep rupture criterion. Failure is assumed to occur when the normalized accumulated damage at any point in the component is greater than or equal to unity. The corresponding time will be the creep rupture life for that component. Examples are chosen to demonstrate the Ceramics Analysis and Reliability Evaluation of Structures/CREEP (CARES/CREEP) integrated design program, which is written for the ANSYS finite element package. Depending on the component size and loading conditions, it was found that in real structures one of two competing failure modes (creep or slow crack growth) will dominate. Applications to benchmark problems and engine components are included.

Description: Ceramic joining is recognized as one of the enabling technologies for the successful utilization of silicon carbide-based monolithic ceramic and fiber reinforced composite components in a number of demanding and high temperature applications in aerospace and ground-based systems. An affordable, robust ceramic joining technology (ARCJoinT) for joining of silicon carbide-based ceramics and fiber reinforced composites has been developed. This technique is capable of producing joints with tailorable thickness and composition. A wide variety of silicon carbide-based ceramics and composites, in different shapes and sizes, have been joined using this technique. The room and high temperature mechanical properties and fractography of ceramic joints have been reported. In monolithic silicon carbide ceramics, these joints maintain their mechanical strength up to 1350 C in air. There is no change in the mechanical strength of joints in silicon carbide matrix composites up to 1200 C in air. In composites, simple butt joints yield only about 20% of the ultimate strength of the parent materials. This technology is suitable for the joining of large and complex shaped ceramic and composite components, and with certain modifications, can be applied to repair of ceramic components damaged in service.

Description: Polydiacetylenes (PDAS) are attractive materials for both electronic and photonic applications because of their highly conjugated electronic structures. They have been investigated for applications as both one-dimensional (linear chain) conductors and nonlinear optical (NLO) materials. One of the chief limitations to the use of PDAs has been the inability to readily process them into useful forms such as films and fibers. In our laboratory we have developed a novel process for obtaining amorphous films of a PDA derived from 2-methyl4-nitroaniline using photodeposition with Ultraviolet (UV) light from monomer solutions onto transparent substrates. Photodeposition from solution provides a simple technique for obtaining PDA films in any desired pattern with good optical quality. This technique has been used to produce PDA films that show potential for optical applications such as holographic memory storage and optical limiting, as well as third-order NLO applications such as all-optical refractive index modulation, phase modulation and switching. Additionally, copolymerization of diacetylenes with other monomers such as methacrylates provides a means to obtain materials with good processibility. Such copolymers can be spin cast to form films, or drawn by either melt or solution extrusion into fibers. These films or fibers can then be irradiated with UV to photopolymerize the diacetylene units to form a highly stable cross-linked PDA-copolymer network. If such films are electrically poled while being irradiated, they can achieve the asymmetry necessary for second-order NLO applications such as electro-optic switching. On Earth, formation of PDAs by the above mentioned techniques suffers from defects and inhomogeneities caused by convective flows that can arise during processing. By studying the formation of these materials in the reduced-convection, diffusion-controlled environment of space we hope to better understand the factors that affect their processing, and thereby, their nature and properties. Ultimately it may even be feasible to conduct space processing of PDAs for technological applications.