ALBERT

Description: The present invention relates to polymer composite materials containing carbon nanotubes, particularly to those containing singled-walled nanotubes. The invention provides a polymer composite comprising one or more base polymers, one or more functionalized m-phenylenevinylene-2,5-disubstituted-p-phenylenevinylene polymers and carbon nanotubes. The invention also relates to functionalized m-phenylenevinylene-2,5-disubstituted-p-phenylenevinylene polymers, particularly to m-phenylenevinylene-2,5-disubstituted-p-phenylenevinylene polymers having side chain functionalization, and more particularly to m-phenylenevinylene-2,5-disubstituted-p-phenylenevinylene polymers having olefin side chains and alkyl epoxy side chains. The invention further relates to methods of making polymer composites comprising carbon nanotubes.

Description: Impact performance of 2-D woven SiC/SiC composites coated with 225 and 525 m thick environmental barrier coating (EBC) was investigated. The composites were fabricated by melt infiltration and the EBC was deposited by plasma spray. Impact tests were conducted at room temperature and at 1316 C in air using 1.59-mm diameter steel-balls at projectile velocities ranging from 110 to 375 m/s. Both microscopy and nondestructive evaluation (NDE) methods were used to determine the extent of damage in the substrate and coating with increasing projectile velocity. The impacted specimens were tensile tested at room temperature to determine their residual mechanical properties. At projectile velocities less than 125 m/s, no detectable damage was noticed in the MI SiC/SiC composites coated with 525 m EBC. With increase in projectile velocity beyond this value, spallation of EBC layers, delamination of fiber plies, and fiber fracture were detected. At a fixed projectile velocity, the composites coated with 525 m EBC showed less damage than the composite coated with 225 m EBC. Both types of EBC coated composites retained a large fraction of the baseline properties of as-fabricated composites and exhibited non-brittle failure after impact testing at projectile velocities up to 375 m/s. Exposure of impact tested specimens in a moisture environment at 1316 C for 500 hr indicated that the through-the-thickness cracks in the EBC coating and delamination cracks in the substrate generated after impact testing acted as conduits for internal oxidation.

Description: An approach for assessing the delamination propagation simulation capabilities in commercial finite element codes is presented and demonstrated. For this investigation, the Double Cantilever Beam (DCB) specimen and the Single Leg Bending (SLB) specimen were chosen for full three-dimensional finite element simulations. First, benchmark results were created for both specimens. Second, starting from an initially straight front, the delamination was allowed to propagate. The load-displacement relationship and the total strain energy obtained from the propagation analysis results and the benchmark results were compared and good agreements could be achieved by selecting the appropriate input parameters. Selecting the appropriate input parameters, however, was not straightforward and often required an iterative procedure. Qualitatively, the delamination front computed for the DCB specimen did not take the shape of a curved front as expected. However, the analysis of the SLB specimen yielded a curved front as was expected from the distribution of the energy release rate and the failure index across the width of the specimen. Overall, the results are encouraging but further assessment on a structural level is required.

Description: Alumina scale adhesion to high temperature alloys is known to be affected primarily by sulfur segregation and reactive element additions. However, adherent scales can become partially compromised by excessive strain energy and cyclic cracking. With time, exposure of such scales to moisture can lead to spontaneous interfacial decohesion, occurring while the samples are maintained at ambient conditions. Examples of this Moisture-Induced Delayed Spallation (MIDS) are presented for NiCrAl and single crystal superalloys, becoming more severe with sulfur level and cyclic exposure conditions. Similarly, delayed failure or Desk Top Spallation (DTS) results are reviewed for thermal barrier coatings (TBCs), culminating in the water drop failure test. Both phenomena are discussed in terms of moisture effects on bulk alumina and bulk aluminides. A mechanism is proposed based on hydrogen embrittlement and is supported by a cathodic hydrogen charging experiment. Hydroxylation of aluminum from the alloy interface appears to be the relevant basic reaction.

Description: The fatigue damage was characterized in specimens which consisted of a tapered composite flange bonded onto a composite skin. Quasi-static tension tests were performed first to determine the failure load. Subsequently, tension fatigue tests were performed at 40%, 50%, 60% and 70% of the failure load to evaluate the debonding mechanisms. For four specimens, the cycling loading was stopped at intervals. Photographs of the polished specimen edges were taken under a light microscope to document the damage. At two diagonally opposite corners of the flange, a delamination appeared to initiate at the flange tip from a matrix crack in the top 45deg skin ply and propagated at the top 45deg/-45deg skin ply interface. At the other two diagonally opposite corners, a delamination running in the bondline initiated from a matrix crack in the adhesive pocket. In addition, two specimens were cut longitudinally into several sections. Micrographs revealed a more complex pattern inside the specimen where the two delamination patterns observed at the edges are present simultaneously across most of the width of the specimen. The observations suggest that a more sophisticated nondestructive evaluation technique is required to capture the complex damage pattern of matrix cracking and multi-level delaminations.

Description: The oxidation of SiC-protected carbon/carbon through machined slots and naturally occurring craze cracks in the SiC was studied. The slot and crack geometries were characterized, and the subsurface oxidation of the carbon/carbon substrate at temperatures of 1000 to 1300 C in air was assessed using weight change, x-ray computed tomography, and optical microscopy of sections. Rate constants were derived from these measurements and compared with a two-step diffusion control model of carbon oxidation. Oxidation kinetic measurements on both the specimens with machined slots and with naturally occurring craze cracks showed good agreement with the model.

Description: BN/SiC-coated Hi-Nicalon fiber-reinforced celsian matrix composites (CMC) were annealed for 100 h in air at various temperatures to 1200 C, followed by flexural strength measurements at room temperature. Values of yield stress and strain, ultimate strength, and composite modulus remain almost unchanged for samples annealed up to 1100 C. A thin porous layer formed on the surface of the 1100 C annealed sample and its density decreased from 3.09 to 2.90 g/cu cm. The specimen annealed at 1200 C gained 0.43 wt%, was severely deformed, and was covered with a porous layer of thick shiny glaze which could be easily peeled off. Some gas bubbles were also present on the surface. This surface layer consisted of elongated crystals of monoclinic celsian and some amorphous phase(s). The fibers in this surface ply of the CMC had broken into small pieces. The fiber-matrix interface strength was characterized through fiber push-in technique. Values of debond stress, alpha(sub d), and frictional sliding stress, tau(sub f), for the as-fabricated CMC were 0.31+/-0.14 GPa and 10.4+/-3.1 MPa, respectively. These values compared with 0.53+/-0.47 GPa and 8.33+/-1.72 MPa for the fibers in the interior of the 1200 C annealed sample, indicating hardly any change in fiber-matrix interface strength. The effects of thermal aging on microstructure were investigated using scanning electron microscopy. Only the surface ply of the 1200 C annealed specimens had degraded from oxidation whereas the bulk interior part of the CMC was unaffected. A mechanism is proposed explaining the various steps involved during the degradation of the CMC on annealing in air at 1200 C.

Description: An insulation composition that comprises at least one nitrile butadiene rubber (NBR) having an acrylonitrile content that ranges from approximately 26% by weight to approximately 35% by weight and polybenzoxazole (PBO) fibers. The NBR may be a copolymer of acrylonitrile and butadiene and may be present in the insulation composition in a range of from approximately 45% by weight to approximately 56% by weight of a total weight of the insulation composition. The PBO fibers may be present in a range of from approximately 3% by weight to approximately 10% by weight of a total weight of the insulation composition. A rocket motor including the insulation composition and a method of insulating a rocket motor are also disclosed.

Description: No abstract available

Description: Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.

Description: Ceramic matrix composites are suitable for high temperature structural applications such as turbine airfoils and hypersonic thermal protection systems. The employment of these materials in such applications is limited by the ability to process components reliable and to accurately monitor and predict damage evolution that leads to failure under stressed-oxidation conditions. Current nondestructive methods such as ultrasound, x-ray, and thermal imaging are limited in their ability to quantify small scale, transverse, in-plane, matrix cracks developed over long-time creep and fatigue conditions. Electrical resistance of SiC/SiC composites is one technique that shows special promise towards this end. Since both the matrix and the fibers are conductive, changes in matrix or fiber properties should relate to changes in electrical conductivity along the length of a specimen or part. The effect of matrix cracking on electrical resistivity for several composite systems will be presented and some initial measurements performed at elevated temperatures under stress-rupture conditions. The implications towards electrical resistance as a technique applied to composite processing, damage detection (health monitoring), and life-modeling will be discussed.

Description: The need for sensors to operate in harsh environments is illustrated by the need for measurements in the turbine engine hot section. The degradation and damage that develops over time in hot section components can lead to catastrophic failure. At present, the degradation processes that occur in the harsh hot section environment are poorly characterized, which hinders development of more durable components, and since it is so difficult to model turbine blade temperatures, strains, etc, actual measurements are needed. The need to consider ceramic sensing elements is brought about by the temperature limits of metal thin film sensors in harsh environments. The effort at the NASA Glenn Research Center (GRC) to develop high temperature thin film ceramic static strain gauges for application in turbine engines is described, first in the fan and compressor modules, and then in the hot section. The near-term goal of this research effort was to identify candidate thin film ceramic sensor materials and provide a list of possible thin film ceramic sensor materials and corresponding properties to test for viability. A thorough literature search was conducted for ceramics that have the potential for application as high temperature thin film strain gauges chemically and physically compatible with the NASA GRCs microfabrication procedures and substrate materials. Test results are given for tantalum, titanium and zirconium-based nitride and oxynitride ceramic films.

Description: A composite thermal protection structure, for applications such as atmospheric re-entry vehicles, that can withstand temperatures as high as 3600.degree F. The structure includes an exposed surface cap having a specially formulated coating, an insulator base adjacent to the cap with another specially formulated coating, and one or more pins that extend from the cap through the insulator base to tie the cap and base together, through ceramic bonding and mechanical attachment. The cap and insulator base have corresponding depressions and projections that mate and allow for differences in thermal expansion of the cap and base.

Description: A composite thermal protection structure, for applications such as atmospheric re-entry vehicles, that can withstand temperatures as high as 3600.degree. F. The structure includes an exposed surface cap having a specially formulated coating, an insulator base adjacent to the cap with another specially formulated coating, and one or more pins that extend from the cap through the insulator base to tie the cap and base together, through ceramic bonding and mechanical attachment. The cap and insulator base have corresponding depressions and projections that mate and allow for differences in thermal expansion of the cap and base. A thin coating of a reaction cured glass formulation is optionally provided on the structure to allow reduce oxidization and/or to reduce catalytic efficiency.

Description: A ceramic matrix composite material is disclosed having non-oxide ceramic fibers, which are formed in a complex fiber architecture by conventional textile processes; a thin mechanically weak interphase material, which is coated on the fibers; and a non-oxide or oxide ceramic matrix, which is formed within the interstices of the interphase-coated fiber architecture. During composite fabrication or post treatment, the interphase is allowed to debond from the matrix while still adhering to the fibers, thereby providing enhanced oxidative durability and damage tolerance to the fibers and the composite material.

Description: NASA initiated an effort to determine if the aging of Kevlar 49/Epoxy composite overwrapped pressure vessels (COPV) affected their performance. This study briefly reviews the history and certification of composite pressure vessels employed on NASA Orbiters. Tests to evaluate overwrap tensile strength changes compared 30 year old samples from Orbiter vessels to new Kevlar/Epoxy pressure vessel materials. Other tests include transverse compression and thermal analyses (glass transition and moduli). Results from these tests do not indicate a noticeable effect due to aging of the overwrap materials.

Description: Two-dimensional woven SiC/SiC composites fabricated by melt infiltration method were impact tested at room temperature and at 1316 C in air using 1.59-mm diameter steel-ball projectiles at velocities ranging from 115 to 400 m/s. The extent of substrate damage with increasing projectile velocity was imaged and analyzed using optical and scanning electron microscopy, and non-destructive evaluation (NDE) methods such as pulsed thermography, and computed tomography. The impacted specimens were tensile tested at room temperature to determine their residual mechanical properties. Results indicate that at 115 m/s projectile velocity, the composite showed no noticeable surface or internal damage and retained its as-fabricated mechanical properties. As the projectile velocity increased above this value, the internal damage increased and mechanical properties degraded: At velocities 〉300 m/s, the projectile penetrated through the composite, but the composite retained approx.50% of the ultimate tensile strength of the as-fabricated composite and exhibited non-brittle failure. Predominant internal damages are delamination of fiber plies, fiber fracture and matrix shearing.

Description: Recent research and development activities in joining and integration of carbon-carbon (C/C) composites to metals such as Ti and Cu-clad-Mo for thermal management applications are presented with focus on advanced brazing techniques. A wide variety of carbon-carbon composites with CVI and resin-derived matrices were joined to Ti and Cu-clad Mo using a number of active braze alloys. The brazed joints revealed good interfacial bonding, preferential precipitation of active elements (e.g., Ti) at the composite/braze interface. Extensive braze penetration of the inter-fiber channels in the CVI C/C composites was observed. The chemical and thermomechanical compatibility between C/C and metals at elevated temperatures is assessed. The role of residual stresses and thermal conduction in brazed C/C joints is discussed. Theoretical predictions of the effective thermal resistance suggest that composite-to-metal brazed joints may be promising for lightweight thermal management applications.

Description: The electric resistance of woven SiC fiber reinforced SiC matrix composites were measured under tensile loading conditions. The results show that the electrical resistance is closely related to damage and that real-time information about the damage state can be obtained through monitoring of the resistance. Such self-sensing capability provides the possibility of on-board/in-situ damage detection or inspection of a component during "down time". The correlation of damage with appropriate failure mechanism can then be applied to accurate life prediction for high-temperature ceramic matrix composites.

Description: Anticipating the implementation of advanced SiC/SiC composites into turbine section components of future aero-propulsion engines, the primary objective of this on-going study is to develop physics-based analytical and finite-element modeling tools to predict the effects of constituent creep on SiC/SiC component service life. A second objective is to understand how to possibly manipulate constituent materials and processes in order to minimize these effects. Focusing on SiC/SiC components experiencing through-thickness stress gradients (e.g., airfoil leading edge), prior NASA creep modeling studies showed that detrimental residual stress effects can develop globally within the component walls which can increase the risk of matrix cracking. These studies assumed that the SiC/SiC composites behaved as isotropic viscoelastic continuum materials with creep behavior that was linear and symmetric with stress and that the creep parameters could be obtained from creep data as experimentally measured in-plane in the fiber direction of advanced thin-walled 2D SiC/SiC panels. The present study expands on those prior efforts by including constituent behavior with non-linear stress dependencies in order to predict such key creep-related SiC/SiC properties as time-dependent matrix stress, constituent creep and content effects on composite creep rates and rupture times, and stresses on fiber and matrix during and after creep.

Description: The Multi-Factor Interaction Model (MFIM) is used to evaluate the divot weight (foam weight ejected) from the launch external tanks. The multi-factor has sufficient degrees of freedom to evaluate a large number of factors that may contribute to the divot ejection. It also accommodates all interactions by its product form. Each factor has an exponent that satisfies only two points the initial and final points. The exponent describes a monotonic path from the initial condition to the final. The exponent values are selected so that the described path makes sense in the absence of experimental data. In the present investigation, the data used was obtained by testing simulated specimens in launching conditions. Results show that the MFIM is an effective method of describing the divot weight ejected under the conditions investigated.

Description: Composite skin/stringer flange debond specimens manufactured from composite prepreg containing interleaf layers with a polymer based healing agent encapsulated in thin walled spheres were tested. As a crack develops and grows in the base polymer, the spheres fracture releasing the healing agent. The agent reacts with catalyst and polymerizes healing the crack. In addition, through-thickness reinforcement, in the form of pultruded carbon z-pins were included near the flange tips to improve the resistance to debonding. Specimens were manufactured with 14 plies in the skin and 10 plies in the stiffener flange. Three-point bend tests were performed to measure the skin/stiffener debonding strength and the recovered strength after healing. The first three tests performed indicated no healing following unloading and reloading. Micrographs showed that delaminations could migrate to the top of the interleaf layer due to the asymmetric loading, and hence, bypass most of the embedded capsules. For two subsequent tests, specimens were clamped in reverse bending before reloading. In one case, healing was observed as evidenced by healing agent that leaked to the specimen edge forming a visible "scar". The residual strength measured upon reloading was 96% of the original strength indicating healing had occurred. Hence, self-healing is possible in fiber reinforced composite material under controlled conditions, i.e., given enough time and contact with pressure on the crack surfaces. The micro-encapsulation technique may prove more robust when capsule sizes can be produced that are small enough to be embedded in the matrix resin without the need for using an interleaf layer. However, in either configuration, the amount of healing that can occur may be limited to the volume of healing agent available relative to the crack volume that must be filled.

Description: This viewgraph presentation describes the obsolescence of chrome and cadmium papers. The supplier obsolescence of the Randolph TT-P-1757 zinc chromate primer and continental coatings zinc chromate paste is also presented.

Description: Recent advances in improving efficiency of thermoelectric materials are linked to nanotechnology. Thermodynamically driven spinodal decomposition was utilized to synthesize bulk nanocomposites. TiO2/SnO2 system exhibits a large spinodal region, ranging from 15 to 85 mole % TiO2. The phase separated microstructures are stable up to 1400 C. Semiconducting TiO2/SnO2 powders were synthesized by solid state reaction between TiO2 and SnO2. High density samples were fabricated by pressureless sintering. Self assemble nanocomposites were achieved by annealing at 1000 to 1350 C. X-ray diffraction reveal phase separation of (Ti(x)Sn(1-x))O2 type phases. The TiO2/SnO2 nanocomposites exhibit n-type behavior; a power factor of 70 (mu)W/m sq K at 1000 C has been achieved with penta-valent doping. Seebeck, thermal conductivity, electrical resistivity and microstructure will be discussed in relation to composition and doping.

Description: Anticipating the implementation of advanced SiC/SiC ceramic composites into the hot section components of future gas turbine engines, the primary objective of this on-going study is to develop physics-based analytical and finite-element modeling tools to predict the effects of constituent creep on SiC/SiC component service life. A second objective is to understand how to possibly select and manipulate constituent materials, processes, and geometries in order to minimize these effects. In initial studies aimed at SiC/SiC components experiencing through-thickness stress gradients, creep models were developed that allowed an understanding of detrimental residual stress effects that can develop globally within the component walls. It was assumed that the SiC/SiC composites behaved as isotropic visco-elastic materials with temperature-dependent creep behavior as experimentally measured in-plane in the fiber direction of advanced thin-walled 2D SiC/SiC panels. The creep models and their key results are discussed assuming state-of-the-art SiC/SiC materials within a simple cylindrical thin-walled tubular structure, which is currently being employed to model creep-related effects for turbine airfoil leading edges subjected to through-thickness thermal stress gradients. Improvements in the creep models are also presented which focus on constituent behavior with more realistic non-linear stress dependencies in order to predict such key creep-related SiC/SiC properties as time-dependent matrix stress, constituent creep and content effects on composite creep rates and rupture times, and stresses on fiber and matrix during and after creep.

Description: In comparison to current state-of-the-art metallic alloys, ceramic matrix composites (CMC) offer a variety of performance advantages, such as higher temperature capability (greater than the approx.2100 F capability for best metallic alloys), lower density (approx.30-50% metal density), and lower thermal expansion. In comparison to other competing high-temperature materials, CMC are also capable of providing significantly better static and dynamic toughness than un-reinforced monolithic ceramics and significantly better environmental resistance than carbon-fiber reinforced composites. Because of these advantages, NASA, the Air Force, and other U.S. government agencies and industries are currently seeking to implement these advanced materials into hot-section components of gas turbine engines for both propulsion and power generation. For applications such as these, CMC are expected to result in many important performance benefits, such as reduced component cooling air requirements, simpler component design, reduced weight, improved fuel efficiency, reduced emissions, higher blade frequencies, reduced blade clearances, and higher thrust. Although much progress has been made recently in the development of CMC constituent materials and fabrication processes, major challenges still remain for implementation of these advanced composite materials into viable engine components. The objective of this presentation is to briefly review some of those challenges that are generally related to the need to develop physics-based computational approaches to allow CMC fabricators and designers to model (1) CMC processes for fiber architecture formation and matrix infiltration, (2) CMC properties of high technical interest such as multidirectional creep, thermal conductivity, matrix cracking stress, damage accumulation, and degradation effects in aggressive environments, and (3) CMC component life times when all of these effects are interacting in a complex stress and service environment. To put these computational issues in perspective, the various modeling needs within these three areas are briefly discussed in terms of their technical importance and their key controlling mechanistic factors as we know them today. Emphasis is placed primarily on the SiC/SiC ceramic composite system because of its higher temperature capability and enhanced development within the CMC industry. A brief summary is then presented concerning on-going property studies aimed at addressing these CMC modeling needs within NASA in terms of their computational approaches and recent important results. Finally an overview perspective is presented on those key areas where further CMC computational studies are needed today to enhance the viability of CMC structural components for high-temperature applications.

Description: Two- and three-dimensional carbon-carbon composites with either resin-derived matrix or CVI matrix were joined to Cu-clad-Mo using active Ag-Cu braze alloys for thermal management applications. The joint microstructure and composition were examined using Field-Emission Scanning Electron Microscopy and Energy-Dispersive Spectroscopy, and the joint hardness was characterized using the Knoop microhardness testing. Observations on the infiltration of the composite with molten braze, dissolution of metal substrate, and solute segregation at the C-C surface have been discussed. The thermal response of the integrated assembly is also briefly discussed.

Description: Turon s methodology for determining optimal analysis parameters for the simulation of progressive delamination is reviewed. Recommended procedures for determining analysis parameters for efficient delamination growth predictions using the Abaqus/Standard cohesive element and relatively coarse meshes are provided for single and mixed-mode loading. The Abaqus cohesive element, COH3D8, and a user-defined cohesive element are used to develop finite element models of the double cantilever beam specimen, the end-notched flexure specimen, and the mixed-mode bending specimen to simulate progressive delamination growth in Mode I, Mode II, and mixed-mode fracture, respectively. The predicted responses are compared with their analytical solutions. The results show that for single-mode fracture, the predicted responses obtained with the Abaqus cohesive element correlate well with the analytical solutions. For mixed-mode fracture, it was found that the response predicted using COH3D8 elements depends on the damage evolution criterion that is used. The energy-based criterion overpredicts the peak loads and load-deflection response. The results predicted using a tabulated form of the BK criterion correlate well with the analytical solution and with the results predicted with the user-written element.

Description: 1987 DuPont manufactured 4560 denier Kevlar/Epoxy Strands were instrumented with nine and three sensors each. Stress tests were performed at 30,45,60,70 and 80% of ultimate strength with dwell times of 10,000 seconds. FBG showed uneven stress levels which is contrary to conventional observation.

Description: During the past few decades, NASA Langley Research Center (LaRC) has supported several large-scale failure and incident investigations and numerous requests for engineering consultations. Although various extenuating circumstances contributed to each of these incidents, in all cases, the failure resulted from accumulation and/or propagation of damage that reduced the load carrying capability of the structure to a level below that which was needed to sustain structural loads. A brief overview of various failure and incident investigations supported by LaRC, including some of the computational and experimental methodologies that have been applied, is presented. An important outcome of many of these failure and incident investigations is the development of an improved understanding of not only the state-of-the-art in experimental and analytical methods but also the state-of-the-art in the design and manufacturing processes that may contribute to such failures. In order to provide insight into such large-scale investigations, a series of lessons learned were captured. Awareness of these lessons learned is highly beneficial to engineers involved in similar investigations. Therefore, it is prudent that the lessons learned are disseminated such that they can be built upon in other investigations and in ensuing research and development activities.

Description: Strain and temperature response of Multiwalled Carbon Nanotube (MWCNT/CNT) yarns on a stainless steel test beam has been studied. The carbon nanotube yarns are spun from a multiwalled carbon nanotube forest grown on a silicon substrate to a 4-ply yarn with a diameter of about 15-20 microns. Four of the 4-ply CNT yarns are arranged in a Wheatstone bridge configuration on the stainless steel test beam using a thin layer of polyurethane resin that insulates and protects the yarns from the test beam. Strain sensitivities of the CNT yarn sensors range from 1.39 to 1.75 mV/V/1000 microstrain at room temperature, and temperature sensitivity of the CNT yarn bridge is 91 microA/degC. Resistance of the yarns range from 215 to 270 ohms for CNT yarn length of approximately 5 mm. Processes used in attaching the CNT yarns on the test beam and experimental procedures used for the measurements are described. Conventional metallic foil strain gages are attached to the test beam to compare with the CNT sensors. The study demonstrates multifunctional capability of the sensor for strain and temperature measurements and shows its applicability where engineering strain is less than 3%.

Description: A multi-level (multi-scale/multi-functional) evaluation is demonstrated by applying it to three different sample problems. These problems include the probabilistic evaluation of a space shuttle main engine blade, an engine rotor and an aircraft wing. The results demonstrate that the blade will fail at the highest probability path, the engine two-stage rotor will fail by fracture at the rim and the aircraft wing will fail at 109 fatigue cycles with a probability of 0.9967.

Description: Forests of multi-walled carbon nanotubes can be twisted and manipulated into continuous fibers or yarns that exhibit many of the characteristics of traditional textiles. Macro-scale analysis and test may provide strength and stiffness predictions for a composite composed of a polymer matrix and low-volume fraction yarns. However, due to the nano-scale of the carbon nanotubes, it is desirable to use atomistic calculations to consider tube-tube interactions and the influence of simulated twist on the effective friction coefficient. This paper reports laboratory test data on the mechanical response of a multi-walled, carbon nanotube yarn/polymer composite from both dynamic and quasi-static tensile tests. Macroscale and nano-scale analysis methods are explored and used to define some of the key structure-property relationships. The measured influence of hot-wet aging on the tensile properties is also reported.

Description: Conformable stress and strain sensors are required for monitoring the integrity of airframe structures as well as for sensing the mechanical stimuli in prosthetic arms. For this purpose, we have developed a series of piezoresistive single-wall carbon nanotube (SWCNT)/polymer nanocomposites. The electromechanical coupling of pressure with resistance changes in these nanocomposites is exceptionally greater than that of metallic piezoresistive materials. In fact, the piezoresistive stress coefficient (pi) of a SWCNT/polymer nanocomposite is approximately two orders of magnitude higher than that of a typical metallic piezoresistive. The piezoresistive stress coefficient is a function of the nanotube concentration wherein the maximum value occurs at a concentration just above the percolation threshold concentration (phi approx. 0.05 %). This response appears to originate from a change in intrinsic resistivity under compression/tension. A systematic study of the effect of the modulus of the polymer matrix on piezoresistivity allowed us to make flexible and conformable sensors for biomedical applications. The prototype haptic sensors using these nanocomposites are demonstrated. The piezocapacitive properties of SWCNT/polymer are also characterized by monitoring the capacitance change under pressure.

Description: Intergranular fracture is a dominant mode of failure in ultrafine grained materials. In the present study, the atomistic mechanisms of grain-boundary debonding during intergranular fracture in aluminum are modeled using a coupled molecular dynamics finite element simulation. Using a statistical mechanics approach, a cohesive-zone law in the form of a traction-displacement constitutive relationship, characterizing the load transfer across the plane of a growing edge crack, is extracted from atomistic simulations and then recast in a form suitable for inclusion within a continuum finite element model. The cohesive-zone law derived by the presented technique is free of finite size effects and is statistically representative for describing the interfacial debonding of a grain boundary (GB) interface examined at atomic length scales. By incorporating the cohesive-zone law in cohesive-zone finite elements, the debonding of a GB interface can be simulated in a coupled continuum-atomistic model, in which a crack starts in the continuum environment, smoothly penetrates the continuum-atomistic interface, and continues its propagation in the atomistic environment. This study is a step towards relating atomistically derived decohesion laws to macroscopic predictions of fracture and constructing multiscale models for nanocrystalline and ultrafine grained materials.

Description: Composite materials made with triaxial braid architecture and large tow size carbon fibers are beginning to be used in many applications, including composite aircraft and engine structures. Recent advancements in braiding technology have led to commercially viable manufacturing approaches for making large structures with complex shape. Although the large unit cell size of these materials is an advantage for manufacturing efficiency, the fiber architecture presents some challenges for materials characterization, design, and analysis. In some cases, the static load capability of structures made using these materials has been higher than expected based on material strength properties measured using standard coupon tests. A potential problem with using standard tests methods for these materials is that the unit cell size can be an unacceptably large fraction of the specimen dimensions. More detailed investigation of deformation and failure processes in large unit cell size triaxial braid composites is needed to evaluate the applicability of standard test methods for these materials and to develop alternative testing approaches. In recent years, commercial equipment has become available that enables digital image correlation to be used on a more routine basis for investigation of full field 3D deformation in materials and structures. In this paper, some new techniques that have been developed to investigate local deformation and failure using digital image correlation techniques are presented. The methods were used to measure both local and global strains during standard straight-sided coupon tensile tests on composite materials made with 12 and 24 k yarns and a 0/+60/-60 triaxial braid architecture. Local deformation and failure within fiber bundles was observed, and this local failure had a significant effect on global stiffness and strength. The matrix material had a large effect on local damage initiation for the two matrix materials used in this investigation. Premature failure in regions of the unit cell near the edge of the straight-sided specimens was observed for transverse tensile tests in which the braid axial fibers were perpendicular to the specimen axis and the bias fibers terminated on the cut edges in the specimen gage section. This edge effect is one factor that could contribute to a measured strength that is lower than the actual material strength in a structure without edge effects.

Description: In this study, a sub-scale advanced composite shell design is evaluated to determine its potential for use on a future aircraft fuselage. Two composite shells with the same nominal 8-ply [+/-45/+/-Theta](sub s) layup are evaluated, where Theta indicates a tow-steered ply. To build this shell, a fiber placement machine would be used to steer unidirectional prepreg tows as they are placed around the circumference of a 17-inch diameter right circular cylinder. The fiber orientation angle varies continuously from 10 degrees (with respect to the shell axis of revolution) at the crown, to 45 degrees on the side, and back to 10 degrees on the keel. All 24 tows are placed at each point on every fiber path in one structure designated as the shell with overlaps. The resulting pattern of tow overlaps causes the laminate thickness to vary between 8 and 16 plies. The second shell without tow overlaps uses the capability of the fiber placement machine to cut and add tows at any point along the fiber paths to fabricate a shell with a nearly uniform 8-ply laminate thickness. Issues encountered during the design and analysis of these shells are presented and discussed. Static stiffness and buckling loads of shells with tow-steered layups are compared with the performance of a baseline quasi-isotropic shell using both finite element analyses and classical strength of materials theory.

Description: Shear piezoelectricity was investigated in a series of composites consisting of increased loadings of single-wall carbon nanotubes (SWCNTs) in poly (gamma-benzyl-L-glutamate), or PBLG. The effects of the SWCNTs on this material property in PBLG will be discussed. Their influence on the morphology of the polymer (degree of orientation and crystallinity), and electrical and dielectric properties of the composite will be reported

Description: Fiber optic Bragg gratings were used to measure strain fields during Stress Rupture (SSM) test of Kevlar Composite Over-Wrapped Pressure Vessels (COPV). The sensors were embedded under the over-wrapped attached to the liner released from the Kevlar and attached to the Kevlar released from the liner. Additional sensors (foil gages and fiber bragg gratings) were surface mounted on the COPY liner.

Description: This viewgraph presentation reviews the production of Metal Nanoparticle-decorated carbon Nanotubes. Multi-walled carbon nanotubes (MWCNTs) were efficiently decorated with metal nanoparticles (e.g. Ag, Pt, etc.) using the corresponding metal acetate in a simple mixing process without the need of chemical reagents or further processing. The conversion of acetate compounds to the corresponding metal reached over 90%, forming nanoparticles with average diameters less than 10 nm under certain conditions. The process was readily scalable allowing for the convenient preparation of multi-gram quantities of metal nanoparticle-decorated MWCNTs in a matter of a few minutes. These materials are under evaluation for a variety of electrical and catalytic applications. The preparation and characterization of these materials will be presented. The microscopic views of the processed MWCNTs are shown

Description: Multifunctional structural materials can enable a novel design space for advanced aerospace structures. A promising route to multifunctionality is the use of nanotubes possessing the desired combination of properties to enhance the characteristics of structural polymers. Recent nanotube-polymer nanocomposite studies have revealed that these materials have the potential to provide structural integrity as well as sensing and/or actuation capabilities. Judicious selection or modification of the polymer matrix to promote donor acceptor and/or dispersion interactions can improve adhesion at the interface between the nanotubes and the polymer matrix significantly. The effect of nanotube incorporation on the modulus and toughness of the polymer matrix will be presented. Very small loadings of single wall nanotubes in a polyimide matrix yield an effective sensor material that responds to strain, stress, pressure, and temperature. These materials also exhibit significant actuation in response to applied electric fields. The objective of this work is to demonstrate that physical properties of multifunctional material systems can be tailored for specific applications by controlling nanotube treatment (different types of nanotubes), concentration, and degree of alignment.

Description: Progressive failure material modeling methods used for structural analysis including failure initiation and material degradation are presented. Different failure initiation criteria and material degradation models are described that define progressive failure formulations. These progressive failure formulations are implemented in a user-defined material model for use with a nonlinear finite element analysis tool. The failure initiation criteria include the maximum stress criteria, maximum strain criteria, the Tsai-Wu failure polynomial, and the Hashin criteria. The material degradation model is based on the ply-discounting approach where the local material constitutive coefficients are degraded. Applications and extensions of the progressive failure analysis material model address two-dimensional plate and shell finite elements and three-dimensional solid finite elements. Implementation details are described in the present paper. Parametric studies for laminated composite structures are discussed to illustrate the features of the progressive failure modeling methods that have been implemented and to demonstrate their influence on progressive failure analysis predictions.

Description: Fiber waviness in laminated composite material is introduced during manufacture because of uneven curing, resin shrinkage, or ply buckling caused by bending the composite lay-up into its final shape prior to curing. The resulting waviness has a detrimental effect on mechanical properties, therefore this condition is important to detect and characterize. Ultrasonic characterization methods are difficult to interpret because elastic wave propagation is highly dependent on ply orientation and material stresses. By comparison, the pulsed terahertz response of the composite is shown to provide clear indications of the fiber waviness. Pulsed Terahertz NDE is an electromagnetic inspection method that operates in the frequency range between 300 GHz and 3 THz. Its propagation is influenced by refractive index variations and interfaces. This work applies pulsed Terahertz NDE to the inspection of a thick composite beam with fiber waviness. The sample is a laminated glass composite material approximately 15mm thick with a 90-degree bend. Terahertz response from the planar section, away from the bend, is indicative of a homogeneous material with no major reflections from internal plies, while the multiple reflections at the bend area correspond to the fiber waviness. Results of these measurements are presented for the planar and bend areas.

Description: A stress analysis is performed on a nanolaminate subjected to bending. A composite mechanics computer code that is based on constituent properties and nanoelement formulation is used to evaluate the nanolaminate stresses. The results indicate that the computer code is sufficient for the analysis. The results also show that when a stress concentration is present, the nanolaminate stresses exceed their corresponding matrix-dominated strengths and the nanofiber fracture strength.

Description: Lightweight materials with excellent thermal insulating properties are highly sought after for a variety of aerospace and aeronautic applications. (1) Silica based aerogels with their high surface area and low relative densities are ideal for applications in extreme environments such as insulators for the Mars Rover battery. (2) However, the fragile nature of aerogel monoliths prevents their widespread use in more down to earth applications. We have shown that the fragile aerogel network can be cross-linked with a di-isocyanate via amine decorated surfaces to form a conformal coating. (3) This coating reinforces the neck regions between secondary silica particles and significantly strengthens the aerogels with only a small effect on density or porosity. Scheme 1 depicts the cross-linking reaction with the di-isocyanate and exhibits the stages that result in polymer cross-linked aerogel monoliths.

Description: Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.

Description: The relationships between a resistance curve (R-curve), the corresponding fracture process zone length, the shape of the traction/displacement softening law, and the propagation of fracture are examined in the context of the through-the-thickness fracture of composite laminates. A procedure that accounts for R-curve toughening mechanisms by superposing bilinear cohesive elements is proposed. Simple equations are developed for determining the separation of the critical energy release rates and the strengths that define the independent contributions of each bilinear softening law in the superposition. It is shown that the R-curve measured with a Compact Tension specimen test can be reproduced by superposing two bilinear softening laws. It is also shown that an accurate representation of the R-curve is essential for predicting the initiation and propagation of fracture in composite laminates.

Description: Non-proportional mixed-mode loading is present in many systems and a growing crack can experience any manner of mixed-mode loading. Prediction of the resulting crack path is important when assessing potential failure modes or when performing a failure investigation. Current crack path selection criteria are presented along with data for Inconel 718 under non-proportional mixed-mode loading. Mixed-mode crack growth can transition between path deflection mechanisms with very different orientations. Non-proportional fatigue loadings lack a single parameter for input to current crack path criteria. Crack growth transitions were observed in proportional and non-proportional FCG tests. Different paths displayed distinct fracture surface morphologies. New crack path drivers & transition criteria must be developed.

Description: This paper will describe unique and extensive use of pre-woven and impregnated pi cross-sections in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a) To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This paper will focus on the design and fabrication issues supporting selection of the Lockheed Martin patented Pi pre-form to provide sound composite joints a numerous locations in the structure. This abstract is based on Preliminary Design data. The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date.

Description: Pulse detonation engine (PDE) concepts are receiving increasing attention for future aeronautic propulsion applications, due to their potential thermodynamic cycle efficiency and higher thrust to density ratio that lead to the decrease in fuel consumption. But the resulting high gas temperature and pressure fluctuation distributions at high frequency generated with every detonation are viewed to be detrimental to the combustor liner material. Experimental studies on a typical metal combustion material exposed to a laser simulated pulse heating showed extensive surface cracking. Coating of the combustor materials with low thermal conductivity ceramics is shown to protect the metal substrate, reduce the thermal stresses, and hence increase the durability of the PDE combustor liner material. Furthermore, the temperature fluctuation and depth of penetration is observed to decrease with increasing the detonation frequency. A crack propagation rate in the coating is deduced by monitoring the variation of the coating apparent thermal conductivity with time that can be utilized as a health monitoring technique for the coating system under a rapid fluctuating heat flux.

Description: A family of polymer/carbon films has been developed for use as sensory films in electronic noses for detecting SO2 gas at concentrations as low as 1 part per million (ppm). Most previously reported SO2 sensors cannot detect SO2 at concentrations below tens of ppm; only a few can detect SO2 at 1 ppm. Most of the sensory materials used in those sensors (especially inorganic ones that include solid oxide electrolytes, metal oxides, and cadmium sulfide) must be used under relatively harsh conditions that include operation and regeneration at temperatures greater than 100 C. In contrast, the present films can be used to detect 1 ppm of SO2 at typical opening temperatures between 28 and 32 C and can be regenerated at temperatures between 36 and 40 C. The basic concept of making sensing films from polymer/carbon composites is not new. The novelty of the present family of polymer/carbon composites lies in formulating the polymer components of these composites specifically to optimize their properties for detecting SO2. First-principles quantum-mechanical calculations of the energies of binding of SO2 molecules to various polymer functionalities are used as a guide for selecting polymers and understanding the role of polymer functionalities in sensing. The polymer used in the polymer-carbon composite is a copolymer of styrene derivative units with vinyl pyridine or substituted vinyl pyridine derivative units. To make a substituted vinyl pyridine for use in synthesizing such a polymer, poly(2-vinyl pyridine) that has been dissolved in methanol is reacted with 3-chloropropylamine that has been dissolved in a solution of methanol. The methanol is then removed to obtain the copolymer. Later, the copolymer can be dissolved in an appropriate solvent with a suspension of carbon black to obtain a mixture that can be cast and then dried to obtain a sensory film.

Description: Organic/inorganic polymeric composite materials have been invented with significant reduction in heat-transfer properties. Measured decreases of 20-50 percent in thermal conductivity versus that of the unmodified polymer matrix have been attained. These novel composite materials also maintain mechanical properties of the unmodified polymer matrix. The present embodiments are applicable, but not limited to: racing applications, aerospace applications, textile industry, electronic applications, military hardware improvements, and even food service industries. One specific application of the polymeric composition is for use in tanks, pipes, valves, structural supports, and components for hot or cold fluid process systems where heat flow through materials is problematic and not desired. With respect to thermal conductivity and physical properties, these materials are superior alternatives to prior composite materials. These materials may prove useful as substitutes for metals in some cryogenic applications. A material of this type can be made from a blend of thermoplastics, elastomers, and appropriate additives and processed on normal polymer processing equipment. The resulting processed organic/inorganic composite can be made into fibers, molded, or otherwise processed into useable articles.

Description: A theory for predicting mechanical, thermal, electrical, and other properties of unidirectional-nanofiber/matrix composite materials is based on the prior theory of micromechanics of composite materials. In the development of the present theory, the prior theory of micromechanics was extended, through progressive substructuring, to the level of detail of a nanoscale slice of a nanofiber. All the governing equations were then formulated at this level. The substructuring and the equations have been programmed in the ICAN/JAVA computer code, which was reported in "ICAN/JAVA: Integrated Composite Analyzer Recoded in Java" (LEW-17247), NASA Tech Briefs, Vol. 26, No. 12 (December 2002), page 36. In a demonstration, the theory as embodied in the computer code was applied to a graphite-nanofiber/epoxy laminate and used to predict 25 properties. Most of the properties were found to be distributed along the through-the-thickness direction. Matrix-dependent properties were found to have bimodal through-the-thickness distributions with discontinuous changes from mode to mode.

Description: This innovation blends the merits of multifoil insulation (MFI) with aerogel-based insulation to develop a highly versatile, ultra-low thermally conductive material called hybrid multifoil aerogel thermal insulation (HyMATI). The density of the opacified aerogel is 240 mg/cm3 and has thermal conductivity in the 20 mW/mK range in high vacuum and 25 mW/mK in 1 atmosphere of gas (such as argon) up to 800 C. It is stable up to 1,000 C. This is equal to commercially available high-temperature thermal insulation. The thermal conductivity of the aerogel is 36 percent lower compared to several commercially available insulations when tested in 1 atmosphere of argon gas up to 800 C.

Description: In-plane tensile stress-strain, tensile creep, and after-creep retained tensile properties of melt-infiltrated SiC-SiC composites reinforced with different fiber types were evaluated with an emphasis on obtaining simple or first-order microstructural design guidelines for these in-plane mechanical properties. Using the mini-matrix approach to model stress-strain behavior and the results of this study, three basic general design criteria for stress and strain limits are formulated, namely a design stress limit, a design total strain limit, and an after-creep design retained strength limit. It is shown that these criteria can be useful for designing components for high temperature applications.

Description: The electric resistance of woven SiC fiber reinforced SiC matrix composites were measured under tensile loading conditions. The results show that the electrical resistance is closely related to damage and that real-time information about the damage state can be obtained through monitoring of the resistance. Such self-sensing capability provides the possibility of on-board/in-situ damage detection and accurate life prediction for high-temperature ceramic matrix composites. Woven silicon carbide fiber-reinforced silicon carbide (SiC/SiC) ceramic matrix composites (CMC) possess unique properties such as high thermal conductivity, excellent creep resistance, improved toughness, and good environmental stability (oxidation resistance), making them particularly suitable for hot structure applications. In specific, CMCs could be applied to hot section components of gas turbines [1], aerojet engines [2], thermal protection systems [3], and hot control surfaces [4]. The benefits of implementing these materials include reduced cooling air requirements, lower weight, simpler component design, longer service life, and higher thrust [5]. It has been identified in NASA High Speed Research (HSR) program that the SiC/SiC CMC has the most promise for high temperature, high oxidation applications [6]. One of the critical issues in the successful application of CMCs is on-board or insitu assessment of the damage state and an accurate prediction of the remaining service life of a particular component. This is of great concern, since most CMC components envisioned for aerospace applications will be exposed to harsh environments and play a key role in the vehicle s safety. On-line health monitoring can enable prediction of remaining life; thus resulting in improved safety and reliability of structural components. Monitoring can also allow for appropriate corrections to be made in real time, therefore leading to the prevention of catastrophic failures. Most conventional nondestructive evaluation (NDE) techniques such as ultrasonic C-scan, x-ray, thermography, and eddy current are limited since they require structural components of complex geometry to be taken out of service for a substantial length of time for post-damage inspection and assessment. Furthermore, the typical NDE techniques are useful for identifying large interlaminar flaws, but insensitive to CMC materials flaws developed perpendicular to the surface under tensile creep conditions. There are techniques such as piezoelectric sensor [7,8], and optical fiber [9,10] that could be used for on-line health monitoring of CMC structures. However, these systems involve attaching an external sensor or putting special fibers in CMC composites, which would be problematic at high temperature applications.

Description: This report summarizes the ballistic impact testing that was conducted to provide validation data for the development of numerical models of blade out events in fabric containment systems. The ballistic impact response of two different fiber materials - Kevlar 49 (E.I. DuPont Nemours and Company) and Zylon AS (Toyobo Co., Ltd.) was studied by firing metal projectiles into dry woven fabric specimens using a gas gun. The shape, mass, orientation and velocity of the projectile were varied and recorded. In most cases the tests were designed such that the projectile would perforate the specimen, allowing measurement of the energy absorbed by the fabric. The results for both Zylon and Kevlar presented here represent a useful set of data for the purposes of establishing and validating numerical models for predicting the response of fabrics under conditions simulating those of a jet engine blade release situations. In addition some useful empirical observations were made regarding the effects of projectile orientation and the relative performance of the different materials.

Description: The present work is concerned with modeling the non-linear response of fiber reinforced polymer laminates. Recent experimental data suggests that the non-linearity is not only caused by matrix cracking but also by matrix plasticity due to shear stresses. To capture the effects of those two mechanisms, a model combining a plasticity formulation with continuum damage has been developed to simulate the non-linear response of laminates under plane stress states. The model is used to compare the predicted behavior of various laminate lay-ups to experimental data from the literature by looking at the degradation of axial modulus and Poisson s ratio of the laminates. The influence of residual curing stresses and in-situ effect on the predicted response is also investigated. It is shown that predictions of the combined damage/plasticity model, in general, correlate well with the experimental data. The test data shows that there are two different mechanisms that can have opposite effects on the degradation of the laminate Poisson s ratio which is captured correctly by the damage/plasticity model. Residual curing stresses are found to have a minor influence on the predicted response for the cases considered here. Some open questions remain regarding the prediction of damage onset.

Description: Various solid polymers, polymer-based composites, and closed-cell polymer foam are being characterized to determine their mechanical properties, using low-load test methods. The residual mechanical properties of these materials after environmental exposure or extreme usage conditions determines their value in aerospace structural applications. In this experimental study, four separate polymers were evaluated to measure their individual mechanical responses after thermal aging and moisture exposure by dynamic mechanical analysis. A ceramic gap filler, used in the gaps between the tiles on the Space Shuttle, was also tested, using dynamic mechanical analysis to determine material property limits during flight. Closed-cell polymer foam, used for the Space Shuttle External Tank insulation, was tested under low load levels to evaluate how the foam's mechanical properties are affected by various loading and unloading scenarios.

Description: The present invention involves the interaction of radiation with functionalized carbon nanotubes that have been incorporated into various host materials, particularly polymeric ones. The present invention is directed to chemistries, methods, and apparatuses which exploit this type of radiation interaction, and to the materials which result from such interactions. The present invention is also directed toward the time dependent behavior of functionalized carbon nanotubes in such composite systems.

Description: A family of aerogel-matrix composite materials having thermal-stability and mechanical- integrity properties better than those of neat aerogels has been developed. Aerogels are known to be excellent thermal- and acoustic-insulation materials because of their molecular-scale porosity, but heretofore, the use of aerogels has been inhibited by two factors: (1) Their brittleness makes processing and handling difficult. (2) They shrink during production and shrink more when heated to high temperatures during use. The shrinkage and the consequent cracking make it difficult to use them to encapsulate objects in thermal-insulation materials. The underlying concept of aerogel-matrix composites is not new; the novelty of the present family of materials lies in formulations and processes that result in superior properties, which include (1) much less shrinkage during a supercritical-drying process employed in producing a typical aerogel, (2) much less shrinkage during exposure to high temperatures, and (3) as a result of the reduction in shrinkage, much less or even no cracking.

Description: Temperature and magnetic field dependent magnetization measurements were performed on polyimide nanocomposite samples, synthesized with various weight percentages of single wall carbon nanotubes. It was found that the magnetization of the composite, normalized to the mass of nanotube material in the sample, decreased with increasing weight percentage of nanotubes. It is possible that the interfacial coupling between the carbon nanotube (CNT) fillers and the polyimide matrix promotes the diamagnetic response from CNTs and reduces the total magnetization of the composite. The coercivity of the samples, believed to originate from the residual magnetic catalyst particles, was enhanced and had a stronger temperature dependence as a result of the composite synthesis. These changes in magnetic properties can form the basis of a new approach to investigate the interfacial properties in the CNT nanocomposites through magnetic property measurements.

Description: The present invention is generally directed to nanocomposite thermoelectric materials that exhibit enhanced thermoelectric properties. The nanocomposite materials include two or more components, with at least one of the components forming nano-sized structures within the composite material. The components are chosen such that thermal conductivity of the composite is decreased without substantially diminishing the composite's electrical conductivity. Suitable component materials exhibit similar electronic band structures. For example, a band-edge gap between at least one of a conduction band or a valence band of one component material and a corresponding band of the other component material at interfaces between the components can be less than about 5k.sub.BT, wherein k.sub.B is the Boltzman constant and T is an average temperature of said nanocomposite composition.

Description: A modicum of progress has been made in an effort to exploit single-walled carbon nanotubes as fibers in epoxy-matrix/fiber composite materials. Two main obstacles to such use of carbon nanotubes are the following: (1) bare nanotubes are not soluble in epoxy resins and so they tend to agglomerate instead of becoming dispersed as desired; and (2) because of lack of affinity between nanotubes and epoxy matrices, there is insufficient transfer of mechanical loads between the nanotubes and the matrices. Part of the effort reported here was oriented toward (1) functionalization of single-walled carbon nanotubes with methyl methacrylate (MMA) to increase their dispersability in epoxy resins and increase transfer of mechanical loads and (2) ultrasonic dispersion of the functionalized nanotubes in tetrahydrofuran, which was used as an auxiliary solvent to aid in dispersing the functionalized nanotubes into a epoxy resin. In another part of this effort, poly(styrene sulfonic acid) was used as the dispersant and water as the auxiliary solvent. In one experiment, the strength of composite of epoxy with MMA-functionalized-nanotubes was found to be 29 percent greater than that of a similar composite of epoxy with the same proportion of untreated nanotubes.

Description: Ceramic thermal and environmental barrier coatings (T/EBCs) that contain multiple layers of alternating chemical composition have been developed as improved means of protecting underlying components of gas-turbine and other heat engines against both corrosive combustion gases and high temperatures.

Description: Carbon-carbon composites with either pitch+CVI matrix or resin-derived matrix were joined to copper-clad molybdenum using two active braze alloys, Cusil-ABA (1.75% Ti) and Ticusil (4.5% Ti). The brazed joints revealed good interfacial bonding, preferential precipitation of Ti at the composite/braze interface, and a tendency toward de-lamination in resin-derived C-C composite due to its low inter-laminar shear strength. Extensive braze penetration of the inter-fiber channels in the pitch+CVI C-C composites was observed. The relatively low brazing temperatures (〈950 C) precluded melting of the clad layer and restricted the redistribution of alloying elements but led to metallurgically sound composite joints. The Knoop microhardness (HK) distribution across the joint interfaces revealed sharp gradients at the Cu-clad-Mo/braze interface and higher hardness in Ticusil (approx.85-250 HK) than in Cusil-ABA (approx.50-150 HK). These C-C/Cu-clad-Mo joints with relatively low thermal resistance may be promising for thermal management applications.

Description: Damage and fracture of composites subjected to monotonically increasing static, tension-tension cyclic, pressurization, and flexural cyclic loading are evaluated via a recently developed composite mechanics code that allows the user to focus on composite response at infinitely small scales. Constituent material properties, stress and strain limits are scaled up to the laminate level to evaluate the overall damage and durability. Results show the number of cycles to failure at different temperatures. A procedure is outlined for use of computational simulation data in the assessment of damage tolerance, determination of sensitive parameters affecting fracture, and interpretation of results with insight for design decisions.

Description: A simple analysis method has been developed for predicting the residual compressive strength of impact-damaged sandwich panels. The method is tailored for honeycomb core-based sandwich specimens that exhibit an indentation growth failure mode under axial compressive loading, which is driven largely by the crushing behavior of the core material. The analysis method is in the form of a finite element model, where the impact-damaged facesheet is represented using shell elements and the core material is represented using spring elements, aligned in the thickness direction of the core. The nonlinear crush response of the core material used in the analysis is based on data from flatwise compression tests. A comparison with a previous analysis method and some experimental data shows good agreement with results from this new approach.

Description: An electroactive sensing or actuating material comprises a composite made from a polymer with polarizable moieties and an effective amount of carbon nanotubes incorporated in the polymer for a predetermined electromechanical operation of the composite when such composite is affected by an external stimulus. In another embodiment, the composite comprises a third component of micro-sized to nano-sized particles of an electroactive ceramic that is also incorporated in the polymer matrix. The method for making the three-phase composite comprises either incorporating the carbon nanotubes in the polymer matrix before incorporation of the particles of ceramic or mixing the carbon nanotubes and particles of ceramic together in a solution before incorporation in the polymer matrix.

Description: This study investigated the effects of core-shell rubber (CSR) nanoparticles on the mechanical properties and fracture toughness of an epoxy resin at ambient and liquid nitrogen (LN2) temperatures. Varying amounts of Kane Ace MX130 toughening agent were added to a commercially available EPON 862/Epikure W epoxy resin. Elastic modulus was calculated using quasi-static tensile data. Fracture toughness was evaluated by the resulting breaking energy measured in Charpy impact tests conducted on an instrumented drop tower. The size and distribution of the CSR nanoparticles were characterized using Transmission Electron Microscopy (TEM) and Small Angle X-ray Scattering (SAXS). Scanning Electron Microscopy (SEM) was used to study the fracture surface morphology. The addition of the CSR nanoparticles increased the breaking energy with negligible change in elastic modulus and ultimate tensile stress (UTS). At ambient temperature the breaking energy increased with increasing additions of the CSR nanoparticles, while at LN2 temperatures, it reached a maximum at 5 wt% CSR concentration. KEY WORDS: liquid nitrogen (LN2) properties, fracture toughness, core-shell rubber (CSR).

Description: An experimental and numerical investigation into the static and dynamic responses of shape memory alloy hybrid composite (SMAHC) beams is performed to provide quantitative validation of a recently commercialized numerical analysis/design tool for SMAHC structures. The SMAHC beam specimens consist of a composite matrix with embedded pre-strained SMA actuators, which act against the mechanical boundaries of the structure when thermally activated to adaptively stiffen the structure. Numerical results are produced from the numerical model as implemented into the commercial finite element code ABAQUS. A rigorous experimental investigation is undertaken to acquire high fidelity measurements including infrared thermography and projection moire interferometry for full-field temperature and displacement measurements, respectively. High fidelity numerical results are also obtained from the numerical model and include measured parameters, such as geometric imperfection and thermal load. Excellent agreement is achieved between the predicted and measured results of the static and dynamic thermomechanical response, thereby providing quantitative validation of the numerical tool.

Description: The market for electrically conductive polymers is rapidly growing, and an emerging pathway for attaining these materials is via polymer-carbon nanotube (CNT) nanocomposites, because of the superior properties of CNTs. Due to their excellent electrical properties and anisotropic magnetic susceptibility, we expect CNTs could be easily aligned to maximize their effectiveness in imparting electrical conductivity to the polymer matrix. Single-walled carbon nanotubes (SWNT) were dispersed in a polyethylene terephthalate (PET) matrix by solution blending then cast onto a glass substrate to create thin, flexible films. Various SWNT loading concentrations were implemented (0.5, 1.0, and 3.0 wt.%) to study the effect of additive density. The processing method was repeated to produce films in the presence of magnetic fields (3 and 9.4 Tesla). The SWNTs showed a high susceptibility to the magnetic field and were effectively aligned in the PET matrix. The alignment was characterized with Raman spectroscopy. Impedance spectroscopy was utilized to study the electrical behavior of the films. Concentration and dispersion seemed to play very important roles in improving electrical conductivity, while alignment played a secondary and less significant role. The most interesting result proved to be the effect of a magnetic field during processing. It appears that a magnetic field may improve dispersion of unmodified SWNTs, which seems to be more important than alignment. It was concluded that SWNTs offer a good option as conductive, nucleating filler for electroconductive polymer applications, and the utilization of a magnetic field may prove to be a novel method for CNT dispersion that could lead to improved nanocomposite materials.

Description: Compliant electrodes to replace conventional metal electrodes have been required for many actuators to relieve the constraint on the electroactive layer. Many conducting polymers have been proposed for the alternative electrodes, but they still have a problem of poor thermal stability. This article reports a novel all-organic actuator with single wall carbon nanotube (SWCNT) films as the alternative electrode. The SWCNT film was obtained by filtering a SWCNT solution through an anodized alumina membrane. The conductivity of the SWCNT film was about 280 S/cm. The performance of the SWCNT film electrode was characterized by measuring the dielectric properties of NASA Langley Research Center - Electroactive Polymer (LaRC-EAP) sandwiched by the SWCNT electrodes over a broad range of temperature (from 25 C to 280 C) and frequency (from 1 KHz to 1 MHz). The all-organic actuator with the SWCNT electrodes showed a larger electric field-induced strain than that with metal electrodes, under identical measurement conditions.

Description: Low color, flexible, space-durable polyimide films with inherent and robust electrical conductivity to dissipate electrostatic charge (ESC) have been under investigation as part of a materials development activity for future NASA space missions. The use of single-walled carbon nanotubes (SWCNTs) is one means to achieving this goal. Even though the concentration of SWCNTs needed to achieve ESC dissipation is typically low, it is dependent upon purity, size, dispersion, and functionalization. In this study, SWCNTs prepared by the electric arc discharge method were used to synthesize nanocomposites using the LaRC(TradeMark) CP2 backbone as the matrix. Pristine and functionalized SWCNTs were mixed with an alkoxysilane terminated amide acid of LaRC(TradeMark) CP2 and the soluble imide form of the polymer and the resultant nanocomposites evaluated for mechanical, thermal, and electrical properties. Due to the preparative conditions for the pristine and functionalized SWCNTs, the average aspect ratio for both was comparable. This permitted the assessment of SWCNT functionalization with respect to various interactions (e.g. van der Waals, hydrogen bonding, covalent bond formation, etc.) with the matrix and the macroscopic effects upon nanocomposite properties. The results of this study are described herein.

Description: A probabilistic method is used to evaluate the structural reliability and risk of select metallic and composite structures. The method is a multiscale, multifunctional and it is based on the most elemental level. A multi-factor interaction model is used to describe the material properties which are subsequently evaluated probabilistically. The metallic structure is a two rotor aircraft engine, while the composite structures consist of laminated plies (multiscale) and the properties of each ply are the multifunctional representation. The structural component is modeled by finite element. The solution method for structural responses is obtained by an updated simulation scheme. The results show that the risk for the two rotor engine is about 0.0001 and the composite built-up structure is also 0.0001.

Description: Material-environment interactions are analyzed at microscopic scale to explain the lower than expected density observed by post-flight analysis of the char layer on the Stardust shield. Mass transfer, ablation (oxidation), and surface recession of fibrous material is simulated in 3D using a Monte-Carlo simulation tool. Ablation is found to occur either at the surface or in volume depending on Knudsen and Thiele number values. This study supports the idea of volume ablation followed by possible carbon fiber spallation that may explain post-flight analyses.

Description: This slide presentation reviews the development of MSFC-RQMT-3479 for requirements for fracture control of composites to be used in the Constellation program. This effort is part of the development of a revision of NASA-STD-5019(A), which will include MSFC-RQMT-3479. Examples of the requirement criteria and implementation are given.

Description: Closed cell polyurethane and, particularly, polyisocyanurate foams are a large family of flexible and rigid products the result of a reactive two part process wherein a urethane based polyol is combined with a foaming or "blowing" agent to create a cellular solid at room temperature. The ratio of reactive components, the constituency of the base materials, temperature, humidity, molding, pouring, spraying and many other processing techniques vary greatly. However, there is no known process for incorporating reinforcing fibers small enough to be integrally dispersed within the cell walls resulting in superior final products. The key differentiating aspect from the current state of art resides in the many processing technologies to be fully developed from the novel concept of milled nano pulp aramid fibers and their enabling entanglement capability fully enclosed within the cell walls of these closed cell urethane foams. The authors present the results of research and development of reinforced foam processing, equipment development, strength characteristics and the evolution of its many applications.

Description: High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Description: Ceramic matrix composites are suitable for high temperature structural applications such as turbine airfoils and hypersonic thermal protection systems. The employment of these materials in such applications is limited by the ability to process components reliable and to accurately monitor and predict damage evolution that leads to failure under stressed-oxidation conditions. Current nondestructive methods such as ultrasound, x-ray, and thermal imaging are limited in their ability to quantify small scale, transverse, in-plane, matrix cracks developed over long-time creep and fatigue conditions. Electrical resistance of SiC/SiC composites is one technique that shows special promise towards this end. Since both the matrix and the fibers are conductive, changes in matrix or fiber properties should relate to changes in electrical conductivity along the length of a specimen or part. Initial efforts to quantify the electrical resistance of different fiber and different matrix SiC/SiC composites will be presented. Also, the effect of matrix cracking on electrical resistivity for several composite systems will be presented. The implications towards electrical resistance as a technique applied to composite processing, damage detection, and life-modeling will be discussed.

Description: Carbon/carbon composites with CVI and resin-derived matrices, and C/SiC composites reinforced with T-300 carbon fibers in a CVI SiC matrix were joined to Cu-clad Mo using two Ag-Cu braze alloys, Cusil-ABA (1.75% Ti) and Ticusil (4.5% Ti). The brazed joints revealed good interfacial bonding, preferential precipitation of Ti at the composite/braze interface, and a tendency toward delamination in resin-derived C/C composite. Extensive braze penetration of the inter-fiber channels in the CVI C/C composites was observed. The Knoop microhardness (HK) distribution across the C/C joints indicated sharp gradients at the interface, and a higher hardness in Ticusil than in Cusil-ABA. For the C/SiC composite to Cu-clad-Mo joints, the effect of composite surface preparation revealed that ground samples did not crack whereas unground samples cracked. Calculated strain energy in brazed joints in both systems is comparable to the strain energy in a number of other ceramic/metal systems. Theoretical predictions of the effective thermal resistance suggest that such joined systems may be promising for thermal management applications.

Description: Woven SiC/SiC composites represent a broad family of composites with a broad range of properties which are of interest for many energy-based and aero-based applications. Two important features of SiC/SiC composites which one must consider are the reinforcing fibers themselves and the fiber-architecture they are formed into. The range of choices for these two features can result in a wide range of elastic, mechanical, thermal, and electrical properties. In this presentation, it will be demonstrated how the effect of fiber-type and fiber architecture effects the important property of "matrix cracking stress" for slurry-cast melt-infiltrated SiC matrix composites, which is often considered to be a critical design parameter for this system of composites.

Description: Recent advances in improving efficiency of thermoelectric materials are linked to nanotechnology. Thermodynamically driven spinodal decomposition was utilized to synthesize bulk nanocomposites. TiO2/SnO2 system exhibits a large spinodal region, ranging from 15 to 85 mole % TiO2. The phase separated microstructures are stable up to 1400 C. Semiconducting TiO2/SnO2 powders were synthesized by solid state reaction between TiO2 and SnO2. High density samples were fabricated by pressureless sintering. Self assemble nanocomposites were achieved by annealing at 1000 to 1350 C. X-ray diffraction reveal phase separation of (Ti(x)Sn(1-x))O2 type phases. The TiO2/SnO2 nanocomposites exhibit n-type behavior; a power factor of 70 W/mK2 at 1000 C has been achieved with penta-valent doping. Seebeck, thermal conductivity, electrical resistivity and microstructure will be discussed in relation to composition and doping.

Description: In previous work, the ballistic impact resistance of triaxial braided carbon/epoxy composites made with large flat tows (12k and 24k) was examined by impacting 2 X2 X0.125" composite panels with gelatin projectiles. Several high strength, intermediate modulus carbon fibers were used in combination with both untoughened and toughened matrix materials. A wide range of penetration thresholds were measured for the various fiber/matrix combinations. However, there was no clear relationship between the penetration threshold and the properties of the constituents. During some of these experiments high speed cameras were used to view the failure process, and full-field strain measurements were made to determine the strain at the onset of failure. However, these experiments provided only limited insight into the microscopic failure processes responsible for the wide range of impact resistance observed. In order to investigate potential microscopic failure processes in more detail, quasi-static tests were performed in tension, compression, and shear. Full-field strain measurement techniques were used to identify local regions of high strain resulting from microscopic failures. Microscopic failure events near the specimen surface, such as splitting of fiber bundles in surface plies, were easily identified. Subsurface damage, such as fiber fracture or fiber bundle splitting, could be identified by its effect on in-plane surface strains. Subsurface delamination could be detected as an out-of-plane deflection at the surface. Using this data, failure criteria could be established at the fiber tow level for use in analysis. An analytical formulation was developed to allow the microscopic failure criteria to be used in place of macroscopic properties as input to simulations performed using the commercial explicit finite element code, LS-DYNA. The test methods developed to investigate microscopic failure will be presented along with methods for determining local failure criteria that can be used in analysis. Results of simulations performed using LS-DYNA will be presented to illustrate the capabilities and limitations for simulating failure during quasi-static deformation and during ballistic impact of large unit cell size triaxial braid composites.

Description: Reinforced carbon/carbon (RCC) is used to protect the wing leading edge and nose cap of the Space Shuttle Orbiter on re-entry. It is composed of a lay-up of carbon/carbon fabric protected by a SiC conversion coating. Due to the thermal expansion mismatch of the carbon/carbon and the SiC, the SiC cracks on cool-down from the processing temperature. The cracks act as pathways for oxidation of the carbon/carbon. A model for the diffusion controlled oxidation of carbon/carbon through machined slots and cracks is developed and compared to laboratory experiments. A symmetric cylindrical oxidation cavity develops under the slots, confirming diffusion control. Comparison of cross sectional dimensions as a function of oxidation time shows good agreement with the model. A second set of oxidation experiments was done with samples with only the natural craze cracks, using weight loss as an index of oxidation. The agreement of these rates with the model is quite reasonab

Description: Three types of hot-pressed zirconium diboride (ZrB2)-based ultra-high-temperature ceramic composites (UHTCC), ZrB2-SiC (ZS), ZrB2-SiC-C (ZSC), and ZrB2-SCS9-SiC (ZSS), were joined to Cu-clad-Mo using two Ag-Cu brazes (Cusil-ABA and Ticusil, T(sub L) approx.1073-1173 K) and two Pd-base brazes (Palco and Palni, T(sub L) approx.1493-1513 K). Scanning Electron Microscopy (SEM) coupled with energy-dispersive spectroscopy (EDS) revealed greater chemical interaction in joints made using Pd-base brazes than in joints made using Ag-Cu based active brazes. The degree of densification achieved in hot pressed composites influenced the Knoop hardness of the UHTCC and the hardness distribution across the braze interlayer. The braze region in Pd-base system displayed higher hardness in joints made using fully-dense ZS composites than in joints made using partially-dense ZSS composites and the carbon-containing ZSC composites. Calculations indicate a small negative elastic strain energy and an increase in the UHTCC's fracture stress up to a critical clad layer thickness . Above this critical thickness, strain energy in the UHTCC is positive, and it increases with increasing clad layer thickness. Empirical projections show a reduction in the effective thermal resistance of the joints and highlight the potential benefits of joining the UHTCC to Cu-clad-Mo.

Description: Impact performance of 2D woven SiC/SiC composites coated with 225 and 525 microns thick environmental barrier coating (EBC) was investigated. The composites were fabricated by melt infiltration and the EBC was deposited by plasma spray. Impact tests were conducted at room temperature and at 1316 C in air using 1.59 mm diameter steel-balls at projectile velocities ranging from 110 to 375 m/s . Both microscopy and non-destructive evaluation (NDE) methods were used to determine the extent of damage in the substrate and coating with increasing projectile velocity. The impacted specimens were tensile tested at room temperature to determine their residual mechanical properties. At projectile velocities less than 125 m/s , no detectable internal damage was noticed in the MI SiC/SiC composites coated with 525 microns EBC. With increase in projectile velocity beyond this value, spallation of EBC layers, delamination of fiber plies, and fiber fracture were detected. At a fixed projectile velocity, the composites coated with 525 microns EBC showed less damage than those coated with 225 microns EBC. Both types of coated composites retained a large fraction of the baseline properties of the as-fabricated composites and exhibited non-brittle failure after impact testing. Furnace exposure of impacted specimens in a moisture environment at 1316 C for 500 h indicated that the through-the-thickness cracks in the coating and delamination cracks in the substrate generated after impact testing acted as conduits for internal oxidation.

Description: To reduce weight and increase the mobility, comfort, and performance of future spacesuits, flexible, thermally conductive fabrics and plastic tubes are needed for the Liquid Cooling and Ventilation Garment. Such improvements would allow astronauts to operate more efficiently and safely for extended extravehicular activities. As an approach to raise the thermal conductivity (TC) of an ethylene vinyl acetate copolymer (Elvax 260), it was compounded with three types of carbon based nanofillers: multi-walled carbon nanotubes (MWCNTs), vapor grown carbon nanofibers (CNFs), and expanded graphite (EG). In addition, other nanofillers including metallized CNFs, nickel nanostrands, boron nitride, and powdered aluminum were also compounded with Elvax 260 in the melt at various loading levels. In an attempt to improve compatibility between Elvax 260 and the nanofillers, MWCNTs and EG were modified by surface coating and through noncovalent and covalent attachment of organic molecules containing alkyl groups. Ribbons of the nanocomposites were extruded to form samples in which the nanofillers were aligned in the direction of flow. Samples were also fabricated by compression molding to yield nanocomposites in which the nanofillers were randomly oriented. Mechanical properties of the aligned samples were determined by tensile testing while the degree of dispersion and alignment of nanoparticles were investigated using high-resolution scanning electron microscopy. TC measurements were performed using a laser flash (Nanoflash ) technique. TC of the samples was measured in the direction of, and perpendicular to, the alignment direction. Additionally, tubing was also extruded from select nanocomposite compositions and the TC and mechanical flexibility measured.

Description: The oxidation of SiC-protected carbon/carbon through machined slots and naturally occurring craze cracks in the SiC was studied. The slot and crack geometries were characterized, and the subsurface oxidation of the carbon/carbon substrate at temperatures of 1000 to 1300 C in air was assessed using weight change, x-ray computed tomography, and optical microscopy of sections. Rate constants were derived from these measurements and compared with a two-step diffusion control model of carbon oxidation. Oxidation kinetic measurements on both the specimens with machined slots and with naturally occurring craze cracks showed good agreement with the model.

Description: An analysis of the heat transfer in a tool for producing neat resin disks was conducted to determine how to bring about a better agreement between the tool temperature and the applied temperature profile. Using the commercial code FLUENT to investigate the relative effects of heat conduction into the tool and heat loss from the tool by convection, it was shown that convective heat transfer appears more important than conduction in controlling the tool performance. Decreasing the height of the tool was predicted to decrease the heat losses by convection. Redesign of the tool based on this analysis resulted in the tool experiencing the applied temperature profile.

Description: This paper will present an overview of efforts to investigate the application of Raman spectroscopy for the characterization of Kevlar materials. Raman spectroscopy is a laser technique that is sensitive to molecular interactions in materials such as Kevlar, graphite and carbon used in composite materials. The overall goal of this research reported here is to evaluate Raman spectroscopy as a potential nondestructive evaluation (NDE) tool for the detection of stress rupture in Kevlar composite over-wrapped pressure vessels (COPVs). Characterization of the Raman spectra of Kevlar yarn and strands will be presented and compared with analytical models provided in the literature. Results of testing to investigate the effects of creep and high-temperature aging on the Raman spectra will be presented.

Description: Multi-layer insulation, MLI, is a material used on rocket bodies and satellites mainly for thermal insulation. MLI can be comprised of a variety of materials, layer numbers, and dimensions based on its purpose. A common composition of MLI consists of outer facing copper-colored Kapton with an aluminized backing for the top and bottom layers and the middle consisting of alternating layers of DARCON or Nomex netting with aluminized Mylar. If this material became separated from the spacecraft or rocket body its orbit would vary greatly in eccentricity due to its high area to mass (A/m) and susceptibility to solar radiation pressure perturbations. Recently a debris population was found with high A/m, which could be MLI. Laboratory photometric measurements of one intact piece and three different layers of MLI is presented in an effort to predict the characteristics of a MLI light curve and aid in identifying the source of the new population. For this paper, the layers used will be consistent with the common MLI mentioned in the above paragraph. Using a robotic arm, the piece was rotated from 0-360 degrees in one degree increments along the object s longest axis. Laboratory photometric data was recorded with a CCD camera using various filters (Johnson B, Johnson V and Bessell R). The measurements were taken at an 18 degree (light-object-camera) phase angle. As expected, the MLI pieces showed characteristics similar to a bimodal magnitude plot of a flat plate, but with more photometric features, dependant upon the layer of MLI. Time exposures varied from piece to piece such that the amount of pixels saturated would be minimal. In addition to photometric laboratory measurements, laboratory spectral measurements are shown for the same MLI samples. Spectral data will be combined to match the wavelength region of photometric data so a measure of truth can be established for the photometric measurements. Spectral data shows a strong absorption feature near 4800 angstroms, which is due to the copper color of Kapton. If the debris is MLI and the outer layer of copper coloring of Kapton is present, evidence would be seen spectrally by the specific absorption feature as well as using R-B (red-blue) light curves. Using laboratory photometric measurements and the results from spectral laboratory measurements, an optical property database is provided for an object with a high A/m. The benefits of this database for remote optical measurements of orbital debris are shown by illustrating the optical properties expected for a high A/m object, specifically common satellite and rocket body MLI.

Description: New requirements for thermal insulation include robust Multilayer insulation (MU) systems that work for a range of environments from high vacuum to no vacuum. Improved MLI systems must be simple to install and maintain while meeting the life-cycle cost and thermal performance objectives. Performance of actual MLI systems has been previously shown to be much worse than ideal MLI. Spacecraft that must contain cryogens for both lunar service (high vacuum) and ground launch operations (no vacuum) are planned. Future cryogenic spacecraft for the soft vacuum environment of Mars are also envisioned. Industry products using robust MLI can benefit from improved cost-efficiency and system safety. Novel materials have been developed to operate as excellent thermal insulators at vacuum levels that are much less stringent than the absolute high vacuum requirement of current MLI systems. One such robust system, Layered Composite Insulation (LCI), has been developed by the Cryogenics Test Laboratory at NASA Kennedy Space Center. The experimental testing and development of LCI is the focus of this paper. LCI thermal performance under cryogenic conditions is shown to be six times better than MLI at soft vacuum and similar to MLI at high vacuum. The experimental apparent thermal conductivity (k-value) and heat flux data for LCI systems are compared with other MLI systems.

Description: The research testing and demonstration of new bulk-fill materials for cryogenic thermal insulation systems was performed by the Cryogenics Test Laboratory at NASA Kennedy Space Center. Thermal conductivity testing under actual-use cryogenic conditions is a key to understanding the total system performance encompassing engineering, economics, and materials factors. A number of bulk fill insulation materials, including aerogel beads, glass bubbles, and perlite powder, were tested using a new cylindrical cryostat. Boundary temperatures for the liquid nitrogen boil-off method were 293 K and 78 K. Tests were performed as a function of cold vacuum pressure from high vacuum to no vacuum conditions. Results are compared with other complementary test methods in the range of 300 K to 20 K. Various testing techniques are shown to be required to obtain a complete understanding of the operating performance of a material and to provide data for answers to design engineering questions.

Description: No abstract available

Description: The detection of corrosion beneath Space Shuttle Orbiter thermal protective system is traditionally accomplished by removing the Reusable Surface Insulation tiles and performing a visual inspection of the aluminum substrate and corrosion protection system. This process is time consuming and has the potential to damage high cost tiles. To evaluate non-intrusive NDE methods, a Proof of Concept (PoC) experiment was designed and test panels were manufactured. The objective of the test plan was three-fold: establish the ability to detect corrosion hidden from view by tiles; determine the key factor affecting detectability; roughly quantify the detection threshold. The plan consisted of artificially inducing dimensionally controlled corrosion spots in two panels and rebonding tile over the spots to model the thermal protective system of the orbiter. The corrosion spot diameter ranged from 0.100" to 0.600" inches and the depth ranged from 0.003" to 0.020". One panel consisted of a complete factorial array of corrosion spots with and without tile coverage. The second panel consisted of randomized factorial points replicated and hidden by tile. Conventional methods such as ultrasonics, infrared, eddy current and microwave methods have shortcomings. Ultrasonics and IR cannot sufficiently penetrate the tiles, while eddy current and microwaves have inadequate resolution. As such, the panels were interrogated using Backscatter Radiography and Terahertz Imaging. The terahertz system successfully detected artificially induced corrosion spots under orbiter tile and functional testing is in-work in preparation for implementation.

Description: An approach to assessing the delamination propagation capabilities in commercial finite element codes is presented and demonstrated for one code. For this investigation, the Double Cantilever Beam (DCB) specimen and the Single Leg Bending (SLB) specimen were chosen for full three-dimensional finite element simulations. First, benchmark results were created for both specimens. Second, starting from an initially straight front, the delamination was allowed to propagate. Good agreement between the load-displacement relationship obtained from the propagation analysis results and the benchmark results could be achieved by selecting the appropriate input parameters. Selecting the appropriate input parameters, however, was not straightforward and often required an iterative procedure. Qualitatively, the delamination front computed for the DCB specimen did not take the shape of a curved front as expected. However, the analysis of the SLB specimen yielded a curved front as may be expected from the distribution of the energy release rate and the failure index across the width of the specimen. Overall, the results are encouraging but further assessment on a structural level is required.

Description: Florida is home to NASA's Launch Operations Center. Since its establishment in July 1962, the spaceport has served as the departure gate for every American manned mission and hundreds of advanced scientific spacecraft under the Launch Services Program. The center was renamed the John F. Kennedy Space Center in late 1963 to honor the president who put America on the path to the moon. Today, NASA is on the edge of a bold new chaIlenge: the ConsteIlation Program. ConsteIlation is a NASA program to create a new generation of spacecraft for human spaceflight, consisting primarily of the Ares I and Ares V launch vehicles, the Orion crew capsule, the Earth Departure stage and the Lunar access module. These spacecraft will be capable of performing a variety of missions, from Space Station resupply to lunar landings. The ambitious new endeavor caIls for NASA to return human explorers to the moon and then venture even farther, to Mars and beyond. As the nation's premier spaceport, Kennedy Space Center (KSC) will playa critical role in this new chapter in exploration, particularly in the conversion of the launch facilities to accommodate the new launch vehicles. To prepare for this endeavor, the launch site and facilities for the next generation of crew and cargo vehicles must be redesigned, assembled and tested. One critical factor that is being carefuIly considered during the renovation is protecting the new facilities and structures from corrosion and deterioration.

Description: TUFROC (Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite) has been developed as a new thermal protection system (TPS) material for wing leading edge and nose cap applications. The composite withstands temperatures up to 1,970 K, and consists of a toughened, high-temperature surface cap and a low-thermal-conductivity base, and is applicable to both sharp and blunt leading edge vehicles. This extends the possible application of fibrous insulation to the wing leading edge and/or nose cap on a hypersonic vehicle. The lightweight system comprises a treated carbonaceous cap composed of ROCCI (Refractory Oxidation-resistant Ceramic Carbon Insulation), which provides dimensional stability to the outer mold line, while the fibrous base material provides maximum thermal insulation for the vehicle structure.

Description: Spray chemical vapor deposition (spray CVD) processes of a special type have been investigated for use in making CuInS2 absorber layers of thin-film solar photovoltaic cells from either of two subclasses of precursor compounds: [(PBu3) 2Cu(SEt)2In(SEt)2] or [(PPh3)2Cu(SEt)2 In(SEt)2]. The CuInS2 films produced in the experiments have been characterized by x-ray diffraction, scanning electron microscopy, energy-dispersive spectroscopy, and four-point-probe electrical tests.