Optical and optomechanical ultralightweight C/SiC components

NASA Astrophysics Data System (ADS)

Papenburg, Ulrich; Pfrang, Wilhelm; Kutter, G. S.; Mueller, Claus E.; Kunkel, Bernd P.; Deyerler, Michael; Bauereisen, Stefan

1999-11-01

Optical and optomechanical structures based on silicon carbide (SiC) ceramics are becoming increasingly important for ultra- lightweight optical systems that must work in adverse environments. At IABG and Dornier Satellite Systems (DSS) in Munich, a special form of SiC ceramics carbon fiber reinforced silicon carbide (C/SiCR) has been developed partly under ESA and NASA contracts. C/SiCR is a light-weight, high- strength engineering material that features tunable mechanical and thermal properties. It offers exceptional design freedom due to its reduced brittleness and negligible volume shrinkage during processing in comparison to traditional, powder-based ceramics. Furthermore, its rapid fabrication process produces near-net-shape components using conventional NC machining/milling equipment and, thus, provides substantial schedule, cost, and risk savings. These characteristics allow C/SiCR to overcome many of the problems associated with more traditional optical materials. To date, C/SiCR has been used to produce ultra-lightweight mirrors and reflectors, antennas, optical benches, and monolithic and integrated reference structures for a variety of space and terrestrial applications. This paper describes the material properties, optical system and structural design aspects, the forming and manufacturing process including high-temperature joining technology, precision grinding and cladding techniques, and the performance results of a number of C/SiCR optical components we have built.

Cryogenic Fracture Toughness Evaluation of an Investment Cast Al-Be Alloy for Structural Applications

NASA Technical Reports Server (NTRS)

Gamwell, W. R.; McGill, P. B.

2006-01-01

Aluminum-Beryllium metal matrix composite materials are useful due to their desirable performance characteristics for aerospace applications. Desirable characteristics of this material includes light-weight, dimensional stability, stiffness, good vibration damping characteristics, low coefficient of thermal expansion, and workability, This material is 3.5 times stiffer and 22% lighter than conventional aluminum alloys. electro-optical systems, advanced sensor and guidance components for flight and satellite systems, components for light-weight high-performance aircraft engines, and structural components for helicopters. Aluminum-beryllium materials are now available in the form of near net shape investment castings. In this materials properties characterization study, the cryogenic tensile and fracture properties of an investment casting alloy, Beralcast 363, were determined. Tensile testing was performed at 21 C (70 F), -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F), and fracture (K(sub lc) and da/dN) testing was performed at -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F). Their use is attractive for weight critical structural applications such as advanced

Metal-Matrix/Hollow-Ceramic-Sphere Composites

NASA Technical Reports Server (NTRS)

Baker, Dean M.

2011-01-01

A family of metal/ceramic composite materials has been developed that are relatively inexpensive, lightweight alternatives to structural materials that are typified by beryllium, aluminum, and graphite/epoxy composites. These metal/ceramic composites were originally intended to replace beryllium (which is toxic and expensive) as a structural material for lightweight mirrors for aerospace applications. These materials also have potential utility in automotive and many other terrestrial applications in which there are requirements for lightweight materials that have high strengths and other tailorable properties as described below. The ceramic component of a material in this family consists of hollow ceramic spheres that have been formulated to be lightweight (0.5 g/cm3) and have high crush strength [40.80 ksi (.276.552 MPa)]. The hollow spheres are coated with a metal to enhance a specific performance . such as shielding against radiation (cosmic rays or x rays) or against electromagnetic interference at radio and lower frequencies, or a material to reduce the coefficient of thermal expansion (CTE) of the final composite material, and/or materials to mitigate any mismatch between the spheres and the matrix metal. Because of the high crush strength of the spheres, the initial composite workpiece can be forged or extruded into a high-strength part. The total time taken in processing from the raw ingredients to a finished part is typically 10 to 14 days depending on machining required.

Characterization of Polyimide Foams for Ultra-Lightweight Space Structures

NASA Technical Reports Server (NTRS)

Meador, Michael (Technical Monitor); Hillman, Keithan; Veazie, David R.

2003-01-01

Ultra-lightweight materials have played a significant role in nearly every area of human activity ranging from magnetic tapes and artificial organs to atmospheric balloons and space inflatables. The application range of ultra-lightweight materials in past decades has expanded dramatically due to their unsurpassed efficiency in terms of low weight and high compliance properties. A new generation of ultra-lightweight materials involving advanced polymeric materials, such as TEEK (TM) polyimide foams, is beginning to emerge to produce novel performance from ultra-lightweight systems for space applications. As a result, they require that special conditions be fulfilled to ensure adequate structural performance, shape retention, and thermal stability. It is therefore important and essential to develop methodologies for predicting the complex properties of ultra-lightweight foams. To support NASA programs such as the Reusable Launch Vehicle (RLV), Clark Atlanta University, along with SORDAL, Inc., has initiated projects for commercial process development of polyimide foams for the proposed cryogenic tank integrated structure (see figure 1). Fabrication and characterization of high temperature, advanced aerospace-grade polyimide foams and filled foam sandwich composites for specified lifetimes in NASA space applications, as well as quantifying the lifetime of components, are immensely attractive goals. In order to improve the development, durability, safety, and life cycle performance of ultra-lightweight polymeric foams, test methods for the properties are constant concerns in terms of timeliness, reliability, and cost. A major challenge is to identify the mechanisms of failures (i.e., core failure, interfacial debonding, and crack development) that are reflected in the measured properties. The long-term goal of the this research is to develop the tools and capabilities necessary to successfully engineer ultra-lightweight polymeric foams. The desire is to reduce density at the material and structural levels, while at the same time maintaining or increasing mechanical and other properties.

Mechanical Components from Highly Recoverable, Low Apparent Modulus Materials

NASA Technical Reports Server (NTRS)

Padula, Santo, II (Inventor); Noebe, Ronald D. (Inventor); Stanford, Malcolm K. (Inventor); DellaCorte, Christopher (Inventor)

2015-01-01

A material for use as a mechanical component is formed of a superelastic intermetallic material having a low apparent modulus and a high hardness. The superelastic intermetallic material is conditioned to be dimensionally stable, devoid of any shape memory effect and have a stable superelastic response without irrecoverable deformation while exhibiting strains of at least 3%. The method of conditioning the superelastic intermetallic material is described. Another embodiment relates to lightweight materials known as ordered intermetallics that perform well in sliding wear applications using conventional liquid lubricants and are therefore suitable for resilient, high performance mechanical components such as gears and bearings.

Design and optimization of the CFRP mirror components

NASA Astrophysics Data System (ADS)

Wei, Lei; Zhang, Lei; Gong, Xiaoxue

2017-09-01

As carbon fiber reinforced polymer (CFRP) material has been developed and demonstrated as an effective material in lightweight telescope reflector manufacturing recently, the authors of this article have extended to apply this material on the lightweight space camera mirror design and fabrication. By CFRP composite laminate design and optimization using finite element method (FEM) analysis, a spherical mirror with φ316 mm diameter whose core cell reinforcement is an isogrid configuration is fabricated. Compared with traditional ways of applying ultra-low-expansion glass (ULE) on the CFRP mirror surface, the method of nickel electroplating on the surface effectively reduces the processing cost and difficulty of the CFRP mirror. Through the FEM analysis, the first order resonance frequency of the CFRP mirror components reaches up to 652.3 Hz. Under gravity affection coupling with +5°C temperature rising, the mirror surface shape root-mean-square values (RMS) at the optical axis horizontal state is 5.74 nm, which meets mechanical and optical requirements of the mirror components on space camera.

FY2017 Materials Annual Progress Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wu, Felix; Gibbs, Jerry; Kleinbaum, Sarah

The Materials Technology subprogram supports the Vehicle Technology Office’s mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The Propulsion Materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needs of a variety of high efficiency powertrain types, sizes, fueling concepts, and combustion modes. Advanced Lightweight Materials research enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacingmore » cast iron and traditional steel components with lightweight materials such as high-strength steel, magnesium (Mg), aluminum (Al), and polymer composites can directly reduce a vehicle’s fuel consumption. Materials technology activities focus on the following cost and performance targets: (1) enable a 25 percent weight reduction for light-duty vehicles including body, chassis, and interior as compared to a 2012 baseline at no more than a $5/lb-saved increase in cost; and (2) validate a 25 percent improvement in high temperature (300°C) component strength relative to components made with 2010 baseline cast Al alloys (A319 or A356) for improved efficiency light-duty engines.« less

Combustion synthesis of low exothermic component rich composites

DOEpatents

Halverson, Danny C.; Lum, Beverly Y.; Munir, Zuhair A.

1991-01-01

A self-sustaining combustion synthesis process for producing hard, tough, lightweight, low exothermic potential product (LEPP)/high exothermic potential product (HEPP) composites is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the LEPP and HEPP reactants. For lightweight products the composition must be relatively rich in the LEPP component. LEPP rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component.

Elliptically Framed Tip-Tilt Mirror Optimized for Stellar Tracking

DTIC Science & Technology

2015-01-01

a rotating frame. We used the same materials as the existing tracker; however, light-weighted both the aluminum frame and Zerodur ® mirror . We...as the existing tracker; however, light-weighted both the aluminum frame and Zerodur mirror . We generated a computer-aided design model, converted it...components include an aluminum yoke and ring, glass Zerodur ®4 mirror , piezoelectric (PZT) actuators and stainless steel flexure pivot bearings5. Fig. 1

Alkali-silica reactivity of expanded glass granules in structure of lightweight concrete

NASA Astrophysics Data System (ADS)

Bumanis, G.; Bajare, D.; Locs, J.; Korjakins, A.

2013-12-01

Main component in the lightweight concrete, which provides its properties, is aggregate. A lot of investigations on alkali silica reaction (ASR) between cement and lightweight aggregates have been done with their results published in the academic literature. Whereas expanded glass granules, which is relatively new product in the market of building materials, has not been a frequent research object. Therefore lightweight granules made from waste glass and eight types of cement with different chemical and mineralogical composition were examined in this research. Expanded glass granules used in this research is commercially available material produced by Penostek. Lightweight concrete mixtures were prepared by using commercial chemical additives to improve workability of concrete. The aim of the study is to identify effect of cement composition to the ASR reaction which occurs between expanded glass granules and binder. Expanded glass granules mechanical and physical properties were determined. In addition, properties of fresh and hardened concrete were determined. The ASR test was processed according to RILEM AAR-2 testing recommendation. Tests with scanning electron microscope and microstructural investigations were performed for expanded glass granules and hardened concrete specimens before and after exposing them in alkali solution.

Overview of SBIR Phase II Work on Hollow Graphite Fibers

NASA Technical Reports Server (NTRS)

Stallcup, Michael; Brantley, Lott W. (Technical Monitor)

2001-01-01

Ultra-Lightweight materials are enabling for producing space based optical components and support structures. Heretofore, innovative designs using existing materials has been the approach to produce lighter-weight optical systems. Graphite fiber reinforced composites, because of their light weight, have been a material of frequent choice to produce space based optical components. Hollow graphite fibers would be lighter than standard solid graphite fibers and, thus, would save weight in optical components. The Phase I SBIR program demonstrated it is possible to produce hollow carbon fibers that have strengths up to 4.2 GPa which are equivalent to commercial fibers, and composites made from the hollow fibers had substantially equivalent composite strengths as commercial fiber composites at a 46% weight savings. The Phase II SBIR program will optimize processing and properties of the hollow carbon fiber and scale-up processing to produce sufficient fiber for fabricating a large ultra-lightweight mirror for delivery to NASA. Information presented here includes an overview of the strength of some preliminary hollow fibers, photographs of those fibers, and a short discussion of future plans.

Lightweight composite reflectors for space optics

NASA Astrophysics Data System (ADS)

Williams, Brian E.; McNeal, Shawn R.; Ono, Russell M.

1998-01-01

The primary goal of this work was to advance the state of the art in lightweight, high optical quality reflectors for space- and Earth-based telescopes. This was accomplished through the combination of a precision silicon carbide (SiC) reflector surface and a high specific strength, low-mass SiC structural support. Reducing the mass of components launched into space can lead to substantial cost savings, but an even greater benefit of lightweight reflectors for both space- and Earth-based optics applications is the fact that they require far less complex and less expensive positioning systems. While Ultramet is not the first company to produce SiC by chemical vapor deposition (CVD) for reflector surfaces, it is the first to propose and demonstrate a lightweight, open-cell SiC structural foam that can support a thin layer of the highly desirable polished SiC reflector material. SiC foam provides a substantial structural and mass advantage over conventional honeycomb supports and alternative finned structures. The result is a reflector component that meets or exceeds the optical properties of current high-quality glass, ceramic, and metal reflectors while maintaining a substantially lower areal density.

Polymeric Materials for Aerospace Power and Propulsion-NASA Glenn Overview

NASA Technical Reports Server (NTRS)

Meador, Michael A.

2008-01-01

Use of lightweight materials in aerospace power and propulsion components can lead to significant reductions in vehicle weight and improvements in performance and efficiency. Polymeric materials are well suited for many of these applications, but improvements in processability, durability and performance are required for their successful use in these components. Polymers Research at NASA Glenn is focused on utilizing a combination of traditional polymer science and engineering approaches and nanotechnology to develop new materials with enhanced processability, performance and durability. An overview of these efforts will be presented.

On the lightweighting of automobile engine components : forming sheet metal connecting rod

NASA Astrophysics Data System (ADS)

Date, P. P.; Kasture, R. N.; Kore, A. S.

2017-09-01

Reducing the inertia of the reciprocating engine components can lead to significant savings on fuel. A lighter connecting rod (for the same functionality and performance) with a lower material input would be an advantage to the user (customer) and the manufacturer alike. Light materials will make the connecting rod much more expensive compared to those made from steel. Non-ferrous metals are amenable to cold forging of engine components to achieve lightweighting. Alternately, one can make a hollow connecting rod formed from steel sheet, thereby making it lighter, and with many advantages over the conventionally hot forged product. The present paper describes the process of forming a connecting rod from sheet metal. Cold forming (as opposed to high energy needs, lower tool life and the need for greater number of operations and finishing processes in hot forming) would be expected to reduce the cost of manufacture by cold forming. Work hardening during forming is also expected to enhance the in-service performance of the connecting rod.

Future Nanotube Commercialization Opportunities at the NASA Marshall Space Flight Center and the US Army Aviation and Missile Command

NASA Technical Reports Server (NTRS)

Watson, Michael; Shah, Sandeep; Kaul, Raj; Zhu, Shen; Vandiver, Terry; Zimmerman, Joe E. (Technical Monitor)

2001-01-01

Nanotube technology has broad applicability to programs at both the NASA Marshall Space Flight Center (MSFC) and the US Army Aviation and Missile Command (AMCOM). MSFC has interest in applications of nanotubes as sensors and high strength lightweight materials for propulsion system components, avionic systems, and scientific instruments. MSFC is currently pursuing internal programs to develop nanotube temperature sensors, heat pipes, and metal matrix composites. In support of these application areas MSFC is interested in growth of long nanotubes, growth of nanotubes in the microgravity environment, and nanotubes fabricated from high temperature materials such as Boron Nitride or Silicon Carbide. AMCOM is similarly interested in nanotube applications which take advantage of the nanotube thermal conductance properties, high strength, and lightweight. Applications of interest to AMCOM include rocket motor casing structures, rocket nozzles, and lightweight structure and aeronautic skins.

Next Generation Car — Example of Function Integration at the Light Urban Vehicle (LUV) Vehicle Concept

NASA Astrophysics Data System (ADS)

Kopp, G.; Brückmann, S.; Kriescher, M.; Friedrich, H. E.

In times of climate change vehicle emissions have to be reduced clearly. One possibility is to reduce the mass of the body in white using lightweight sandwich structures. The department `Lightweight and Hybrid Design Methods' of the Institute of Vehicle Concepts develops a vehicle body structure by using sandwiches with aluminum top layers and polyurethane foam as core material. For that the foam and the sandwiches were investigated under different load cases, e.g. pressure loading and in-plane tests. In tests with components the high potential of the sandwich materials were shown. On the dynamic component test facility of the institute, vehicle front structures were tested successfully. The results of all investigations regarding sandwich materials, integration of functions (e.g. crash, thermal) in vehicle structures and the concept LUV are developed under the research program of Next Generation Car of the DLR. We will show the development and results of the LUV.

Directly polished lightweight aluminum mirror

NASA Astrophysics Data System (ADS)

ter Horst, Rik; Tromp, Niels; de Haan, Menno; Navarro, Ramon; Venema, Lars; Pragt, Johan

2017-11-01

During the last ten years, Astron has been a major contractor for the design and manufacturing of astronomical instruments for Space- and Earth based observatories, such as VISIR, MIDI, SPIFFI, X-Shooter and MIRI. Driven by the need to reduce the weight of optically ultra-stiff structures, two promising techniques have been developed in the last years: ASTRON Extreme Lightweighting [1][2] for mechanical structures and an improved Polishing Technique for Aluminum Mirrors. Using one single material for both optical components and mechanical structure simplifies the design of a cryogenic instrument significantly, it is very beneficial during instrument test and verification, and makes the instrument insensitive to temperature changes. Aluminum has been the main material used for cryogenic optical instruments, and optical aluminum mirrors are generally diamond turned. The application of a polishable hard top coating like nickel removes excess stray light caused by the groove pattern, but limits the degree of lightweighting of the mirrors due to the bi-metal effect. By directly polishing the aluminum mirror surface, the recent developments at Astron allow for using a non-exotic material for light weighted yet accurate optical mirrors, with a lower surface roughness ( 1nm RMS), higher surface accuracy and reduced light scattering. This paper presents the techniques, obtained results and a global comparison with alternative lightweight mirror solutions. Recent discussions indicate possible extensions of the extreme light weight technology to alternative materials such as Zerodur or Silicon Carbide.

Fabrication of Lightweight Radiation Shielding Composite Materials by Field Assisted Sintering Technique (FAST)

NASA Technical Reports Server (NTRS)

Prasad, Narasimha; Trivedi, Sudhir; Chen, Henry; Kutcher, Susan; Zhang, Dajie; Singh, Jogender

2017-01-01

Advances in radiation shielding technologies are needed to protect humans and electronic components from all threats of space radiation over long durations. In this paper, we report on the use of the innovative and novel fabrication technology known as Field Assisted Sintering Technology (FAST) to fabricate lightweight material with enhanced radiation shielding strength to safeguard humans and electronics suitable for next generation space exploration missions. The base materials we investigated were aluminum (Al), the current standard material for space hardware, and Ultra-High Molecular Weight Polyethylene (UHMWPE), which has high hydrogen content and resistance to nuclear reaction from neutrons, making it a good shielding material for both gamma radiation and particles. UHMWPE also has high resistance to corrosive chemicals, extremely low moisture sensitivity, very low coefficient of friction, and high resistance to abrasion. We reinforced the base materials by adding high density (ie, high atomic weight) metallic material into the composite. These filler materials included: boron carbide (B4C), tungsten (W), tungsten carbide (WC) and gadolinium (Gd).

SIC material and technology for space optics

NASA Astrophysics Data System (ADS)

Bougoin, Michel

2017-11-01

Taking benefit from its very high specific stiffness and its exclusive thermal stability, the SiCSPACE material is now used for the fabrication of scientific and commercial lightweight space telescopes. This paper gives a review of the characteristics of this sintered silicon carbide. The BOOSTEC facilities and the technology described here allow to manufacture large structural components or mirrors (up to several meters) at cost effective condition, from a single part to mass production. Several examples of SiC space optical components are presented.

Combustion synthesis of boride and other composites

DOEpatents

Halverson, Danny C.; Lum, Beverly Y.; Munir, Zuhair A.

1989-01-01

A self-sustaining combustion synthesis process for producing hard, tough, lightweight B.sub.4 C/TiB.sub.2 composites is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the B.sub.4 C and TiB.sub.2 reactants. For lightweight products the composition must be relatively rich in the B.sub.4 C component. B.sub.4 C-rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component.

FY2016 Lightweight Materials Annual Progress Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

None, None

The Lightweight Materials research and development (R&D) area within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies under development. Research focuses on addressing critical barriers to commercializing lightweight materials for passenger and commercial vehicles. This report describes the progress made on the research and development projects funded by the Lightweight Materials area.

Cracking evolution behaviors of lightweight materials based on in situ synchrotron X-ray tomography: A review

NASA Astrophysics Data System (ADS)

Luo, Y.; Wu, S. C.; Hu, Y. N.; Fu, Y. N.

2018-03-01

Damage accumulation and failure behaviors are crucial concerns during the design and service of a critical component, leading researchers and engineers to thoroughly identifying the crack evolution. Third-generation synchrotron radiation X-ray computed microtomography can be used to detect the inner damage evolution of a large-density material or component. This paper provides a brief review of studying the crack initiation and propagation inside lightweight materials with advanced synchrotron three-dimensional (3D) X-ray imaging, such as aluminum materials. Various damage modes under both static and dynamic loading are elucidated for pure aluminum, aluminum alloy matrix, aluminum alloy metal matrix composite, and aluminum alloy welded joint. For aluminum alloy matrix, metallurgical defects (porosity, void, inclusion, precipitate, etc.) or artificial defects (notch, scratch, pit, etc.) strongly affect the crack initiation and propagation. For aluminum alloy metal matrix composites, the fracture occurs either from the particle debonding or voids at the particle/matrix interface, and the void evolution is closely related with fatigued cycles. For the hybrid laser welded aluminum alloy, fatigue cracks usually initiate from gas pores located at the surface or sub-surface and gradually propagate to a quarter ellipse or a typical semi-ellipse profile.

Near Term Weight Reduction Potential in a 1977 General Motors B Body Vehicle : final report

DOT National Transportation Integrated Search

1978-05-01

The report presents an analysis of the potential for weight reduction through lightweight material and component substitutions in a 1977 General Motors Corporation B body vehicle. The changes were limited to those that appeared producible in the 1980...

Industrial based volume manufacturing of lightweight aluminium alloy panel components with high-strength and complex-shape for car body and chassis structures

NASA Astrophysics Data System (ADS)

Anyasodor, Gerald; Koroschetz, Christian

2017-09-01

To achieve the high volume manufacture of lightweight passenger cars at economic cost as required in the automotive industry, low density materials and new process route will be needed. While high strength aluminium alloy grades: AA7075 and AA6082 may provide the alternative material solution, hot stamping process used for high-strength and ultrahigh strength steels such as boron steel 22mnb5 can enable the volume manufacture of panel components with high-strength and complex-shape for car body and chassis structures. These aluminium alloy grades can be used to manufacture panel components with possible yield strengths ≥ 500 MPa. Due to the differences in material behaviors, hot stamping process of 22mnb5 cannot be directly applied to high strength aluminium alloy grades. Despite recorded successes in laboratories, researches and niche hot forming processes of high strength aluminium alloy grades, not much have been achieved for adequate and efficient volume manufacturing system applicable in the automotive industry. Due to lack of such system and based on expert knowledge in hot stamping production-line, AP&T presents in this paper a hot stamping processing route for high strength aluminium alloys been suitable for production-line development and volume manufacturing.

Ultra-Low Density Organic-Inorganic Composite Materials Possessing Thermally Insulating and Acoustic Damping Properties

DTIC Science & Technology

1992-05-07

Officer. Dr. Kenneth Wynne d. Brief Description of Project- We are investigating the design and synthesis of strong, ultra-low density xerogel and aerogel ...materials of this type would have applications in a broad range of areas including lightweight engine components, high temperature coatings, aircraft wings...we plan to investigate the formation of ultra-low density composites using supercritical universal drying (SCUD) techniques. SiO2 aerogel materials

Materials characterization of dusts generated by the collapse of the World Trade Center

USGS Publications Warehouse

Meeker, Gregory P.; Sutley, Stephen J.; Brownfield, Isabelle; Lowers, Heather; Bern, Amy M.; Swayze, Gregg A.; Hoefen, Todd M.; Plumlee, Geoffrey S.; Clark, Roger N.; Gent, Carol A.

2009-01-01

The major inorganic components of the dusts generated from the collapse of the World Trade Center buildings on September 11, 2001 were concrete materials, gypsum, and man-made vitreous fibers. These components were likely derived from lightweight Portland cement concrete floors, gypsum wallboard, and spray-on fireproofing and ceiling tiles, respectively. All of the 36 samples collected by the USGS team had these materials as the three major inorganic components of the dust. Components found at minor and trace levels include chrysotile asbestos, lead, crystalline silica, and particles of iron and zinc oxides. Other heavy metals, such as lead, bismuth, copper, molybdenum, chromium, and nickel, were present at much lower levels occurring in a variety of chemical forms. Several of these materials have health implications based on their chemical composition, morphology, and bioaccessibility.

Combustion synthesis of boride and other composites

DOEpatents

Halverson, D.C.; Lum, B.Y.; Munir, Z.A.

1988-07-28

A self-sustaining combustion synthesis process for producing hard, tough, lightweight B/sub 4/C/TiB/sub 2/ composites is described. It is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the B/sub 4/C and TiB/sub 2/ reactants. For lightweight products the composition must be relatively rich in the B/sub 4/C component. B/sub 4/C-rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component. 9 figs., 4 tabs.

Development of advanced fuel cell system

NASA Technical Reports Server (NTRS)

Grevstad, P. E.

1972-01-01

Weight, life and performance characteristics optimization of hydrogen-oxygen fuel cell power systems were considered. A promising gold alloy cathode catalyst was identified and tested in a cell for 5,000 hours. The compatibility characteristics of candidate polymer structural materials were measured after exposure to electrolyte and water vapor for 8,000 hours. Lightweight cell designs were prepared and fabrication techniques to produce them were developed. Testing demonstrated that predicted performance was achieved. Lightweight components for passive product water removal and evaporative cooling of cells were demonstrated. Systems studies identified fuel cell powerplant concepts for meeting the requirements of advanced spacecraft.

Application and Prospects of High-strength Lightweight Materials used in Coal mine

NASA Astrophysics Data System (ADS)

He, Pan

2017-09-01

This paper describes some high-strength lightweight materials used in coal mine, and if their performance can meet the requirements of underground safety for explosion-proof, anti-static, friction sparks mine; and reviewed the species, characteristic, preparation process of high-strength lightweight materials for having inspired lightweight high-strength performance by modifying or changing the synthesis mode used in coal mine equipment.

Upgrading the Center for Lightweighting Automotive Materials and Processing - a GATE Center of Excellence at the University of Michigan-Dearborn

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mallick, P. K.

2012-08-30

The Center for Lightweighting Materials and Processing (CLAMP) was established in September 1998 with a grant from the Department of Energy’s Graduate Automotive Technology Education (GATE) program. The center received the second round of GATE grant in 2005 under the title “Upgrading the Center for Lightweighting Automotive Materials and Processing”. Using the two grants, the Center has successfully created 10 graduate level courses on lightweight automotive materials, integrated them into master’s and PhD programs in Automotive Systems Engineering, and offered them regularly to the graduate students in the program. In addition, the Center has created a web-based lightweight automotive materialsmore » database, conducted research on lightweight automotive materials and organized seminars/symposia on lightweight automotive materials for both academia and industry. The faculty involved with the Center has conducted research on a variety of topics related to design, testing, characterization and processing of lightweight materials for automotive applications and have received numerous research grants from automotive companies and government agencies to support their research. The materials considered included advanced steels, light alloys (aluminum, magnesium and titanium) and fiber reinforced polymer composites. In some of these research projects, CLAMP faculty have collaborated with industry partners and students have used the research facilities at industry locations. The specific objectives of the project during the current funding period (2005 – 2012) were as follows: (1) develop new graduate courses and incorporate them in the automotive systems engineering curriculum (2) improve and update two existing courses on automotive materials and processing (3) upgrade the laboratory facilities used by graduate students to conduct research (4) expand the Lightweight Automotive Materials Database to include additional materials, design case studies and make it more accessible to outside users (5) provide support to graduate students for conducting research on lightweight automotive materials and structures (6) provide industry/university interaction through a graduate certificate program on automotive materials and technology idea exchange through focused seminars and symposia on automotive materials.« less

Comparative Environmental Benefits of Lightweight Design in the Automotive Sector: The Case Study of Recycled Magnesium Against CFRP and Steel

NASA Astrophysics Data System (ADS)

D'Errico, Fabrizio; Ranza, Luigi

A LCA feasibility study was undertaken to determine the environmental impact of an Eco-magnesium process route by recycled chips to manufacture panel for the automotive sector to be compared with comparative scenarios, a non-recycled carbon fiber reinforced polymer (CFRP) and a baseline steel-made component scenario. The objective of this LCA study was to assess the actual benefits of a lightweight solution considering the whole life cycle, including the dirty-phase (i.e. the "cradle-to-exit gate" stage) that impacts differently for the different materials. For this reason the analysis has regarded the net "cradle-to-grave" scenario. Different automotive floor pans were then compared considering the rate of fuel consumption during vehicle operation — i.e. the fuel-mass correlation factor — and the different material substitution factors allowed by the different materials selected.

Optical Spectroscopy of New Materials

NASA Technical Reports Server (NTRS)

White, Susan M.; Arnold, James O. (Technical Monitor)

1993-01-01

Composites are currently used for a rapidly expanding number of applications including aircraft structures, rocket nozzles, thermal protection of spacecraft, high performance ablative surfaces, sports equipment including skis, tennis rackets and bicycles, lightweight automobile components, cutting tools, and optical-grade mirrors. Composites are formed from two or more insoluble materials to produce a material with superior properties to either component. Composites range from dispersion-hardened alloys to advanced fiber-reinforced composites. UV/VIS and FTIR spectroscopy currently is used to evaluate the bonding between the matrix and the fibers, monitor the curing process of a polymer, measure surface contamination, characterize the interphase material, monitor anion transport in polymer phases, characterize the void formation (voids must be minimized because, like cracks in a bulk material, they lead to failure), characterize the surface of the fiber component, and measure the overall optical properties for energy balances.

Mechanically Strong Lightweight Materials for Aerospace Applications (x-aerogels)

NASA Technical Reports Server (NTRS)

Leventis, Nicholas

2005-01-01

The X-Aerogel is a new NASA-developed strong lightweight material made by reacting the mesoporous surfaces of 3-D networks of inorganic nanoparticles with polymeric crosslinkers. Since the relative amount of the crosslinker and the backbone are comparable, X-Aerogels can be viewed either as aerogels modified by templated accumulation of polymer on the skeletal nanoparticles, or as nanoporous polymers made by templated casting of polymeric precursors on a nanostructured framework. The most striking feature of X-Aerogels is that for a nominal 3-fold increase in density (still a ultralightweight material), the mechanical strength can be up to 300 times higher than the strength of the underlying native aerogel. Thus, X-Aerogels combine a multiple of the specific compressive strength of steel, with the thermal conductivity of styrofoam. XAerogels have been demonstrated with several polymers such as polyurethanes/polyureas, epoxies and polyolefins, while crosslinking of approximately 35 different oxide aerogels yields a wide variety of dimensionally stable, porous lightweight materials with interesting structural, magnetic and optical properties. X-Aerogels are evaluated for cryogenic rocket fuel storage tanks and for Advanced EVA suits, where they will play the dual role of the thermal insulator/structural material. Along the same lines, major impact is also expected by the use of X-Aerogels in structural components/thermal protection for small satellites, spacecrafts, planetary vehicles and habitats.

Lightweight Mechanical Metamaterials with Tunable Negative Thermal Expansion

NASA Astrophysics Data System (ADS)

Wang, Qiming; Jackson, Julie A.; Ge, Qi; Hopkins, Jonathan B.; Spadaccini, Christopher M.; Fang, Nicholas X.

2016-10-01

Ice floating on water is a great manifestation of negative thermal expansion (NTE) in nature. The limited examples of natural materials possessing NTE have stimulated research on engineered structures. Previous studies on NTE structures were mostly focused on theoretical design with limited experimental demonstration in two-dimensional planar geometries. In this work, aided with multimaterial projection microstereolithography, we experimentally fabricate lightweight multimaterial lattices that exhibit significant negative thermal expansion in three directions and over a temperature range of 170 degrees. Such NTE is induced by the structural interaction of material components with distinct thermal expansion coefficients. The NTE can be tuned over a large range by varying the thermal expansion coefficient difference between constituent beams and geometrical arrangements. Our experimental results match qualitatively with a simple scaling law and quantitatively with computational models.

S/EV 1992: Solar and Electric Vehicles. Volume 1: Proceedings

NASA Astrophysics Data System (ADS)

These proceedings include the morning plenary sessions and then sessions on each of the following topics: Electric Vehicle (EV) fundamentals, advanced EV's, photovoltaics, policy, and fleets. Many individual topics are considered to include: EV races, environmental benefits, demonstration programs, lightweight composite materials, advanced components, and electric batteries.

Vehicle Lightweighting: Mass Reduction Spectrum Analysis and Process Cost Modeling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mascarin, Anthony; Hannibal, Ted; Raghunathan, Anand

2016-03-01

The U.S. Department of Energy’s Vehicle Technologies Office, Materials area commissioned a study to model and assess manufacturing economics of alternative design and production strategies for a series of lightweight vehicle concepts. In the first two phases of this effort examined combinations of strategies aimed at achieving strategic targets of 40% and a 45% mass reduction relative to a standard North American midsize passenger sedan at an effective cost of $3.42 per pound (lb) saved. These results have been reported in the Idaho National Laboratory report INL/EXT-14-33863 entitled Vehicle Lightweighting: 40% and 45% Weight Savings Analysis: Technical Cost Modeling formore » Vehicle Lightweighting published in March 2015. The data for these strategies were drawn from many sources, including Lotus Engineering Limited and FEV, Inc. lightweighting studies, U.S. Department of Energy-funded Vehma International of America, Inc./Ford Motor Company Multi-Material Lightweight Prototype Vehicle Demonstration Project, the Aluminum Association Transportation Group, many United States Council for Automotive Research’s/United States Automotive Materials Partnership LLC lightweight materials programs, and IBIS Associates, Inc.’s decades of experience in automotive lightweighting and materials substitution analyses.« less

Investigations on Laser Beam Welding of Different Dissimilar Joints of Steel and Aluminum Alloys for Automotive Lightweight Construction

NASA Astrophysics Data System (ADS)

Seffer, Oliver; Pfeifer, Ronny; Springer, André; Kaierle, Stefan

Due to the enormous potential of weight saving, and the consequential reduction of pollutant emissions, the use of hybrid components made of steel and aluminum alloys is increasing steadily, especially concerning automotive lightweight construction. However, thermal joining of steel and aluminum is still being researched, due to a limited solubility of the binary system of iron and aluminum causing the formation of hard and brittle intermetallic phases, which decrease the strength and the formability of the dissimilar seam. The presented results show the investigation of laser beam welding for joining different dissimilar hybrid components of the steel materials HX220LAD+Z100, 22MnB5+AS150 and 1.4301, as well as the aluminum alloy AA6016-T4 as a lap joint. Among other things, the influences of the energy per unit length, the material grade, the sheet thickness t, the weld type (lap weld, fillet weld) and the arrangement of the base materials in a lap joint (aluminum-sided irradiation, steel-sided irradiation) on the achievable strengths are analyzed. The characterization of the dissimilar joints includes tensile shear tests and metallographic analyses, depending on the energy per unit length.

Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

DOE PAGES

Huang, Runze; Riddle, Matthew; Graziano, Diane; ...

2015-05-08

Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM) processes. For these reasons, AM has been adopted by a growing number of aircraft component manufacturers to achieve more lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integratesmore » engineering criteria, life-cycle environmental data, and aircraft fleet stock and fuel use models under different AM adoption scenarios. Estimated fleetwide life-cycle primary energy savings in a rapid adoption scenario reach 70-174 million GJ/year in 2050, with cumulative savings of 1.2-2.8 billion GJ. Associated cumulative emission reduction potentials of CO2e were estimated at 92.8-217.4 million metric tons. About 95% of the savings is attributed to airplane fuel consumption reductions due to lightweighting. In addition, about 4050 tons aluminum, 7600 tons titanium and 8100 tons of nickel alloys could be saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.« less

Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

DOE Office of Scientific and Technical Information (OSTI.GOV)

Huang, Runze; Riddle, Matthew; Graziano, Diane

Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM) processes. For these reasons, AM has been adopted by a growing number of aircraft component manufacturers to achieve more lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integratesmore » engineering criteria, life-cycle environmental data, and aircraft fleet stock and fuel use models under different AM adoption scenarios. Estimated fleetwide life-cycle primary energy savings in a rapid adoption scenario reach 70-174 million GJ/year in 2050, with cumulative savings of 1.2-2.8 billion GJ. Associated cumulative emission reduction potentials of CO2e were estimated at 92.8-217.4 million metric tons. About 95% of the savings is attributed to airplane fuel consumption reductions due to lightweighting. In addition, about 4050 tons aluminum, 7600 tons titanium and 8100 tons of nickel alloys could be saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.« less

Lightweight Phase-Change Material For Solar Power

NASA Technical Reports Server (NTRS)

Stark, Philip

1993-01-01

Lightweight panels containing phase-change materials developed for use as heat-storage elements of compact, lightweight, advanced solar dynamic power system. During high insolation, heat stored in panels via latent heat of fusion of phase-change material; during low insolation, heat withdrawn from panels. Storage elements consist mainly of porous carbon-fiber structures imbued with germanium. Developed for use aboard space station in orbit around Earth, also adapted to lightweight, compact, portable solar-power systems for use on Earth.

Perforating Thin Metal Sheets

NASA Technical Reports Server (NTRS)

Davidson, M. E.

1985-01-01

Sheets only few mils thick bonded together, punched, then debonded. Three-step process yields perforated sheets of metal. (1): Individual sheets bonded together to form laminate. (2): laminate perforated in desired geometric pattern. (3): After baking, laminate separates into individual sheets. Developed for fabricating conductive layer on blankets that collect and remove ions; however, perforated foils have other applications - as conductive surfaces on insulating materials; stiffeners and conductors in plastic laminates; reflectors in antenna dishes; supports for thermal blankets; lightweight grille cover materials; and material for mockup of components.

Innovation of Iron Reinforcing Column of Partical From Frame of Light Steel

NASA Astrophysics Data System (ADS)

Ramadhan, M. R.; Faslih, A.; Umar, M. Z.

2018-05-01

Almost half of houses in Indonesia are using lightweight steel roof truss today. The phenomenon in the field is that lightweight steel roof truss can blend with mortar mixture. Thus this phenomenon is captured for later applied dynamically, creatively, and innovatively with new idioms such as reinforcement for columns. This research aims to investigate the comparison of the way of making and the price of the materials between the column material made of the light steel and the column material made of the iron reinforcement which is the most efficient. Type of research is qualitative with a comparative causal approach. This research is divided into several stages, namely; Literature study, column creation, and validation. This study concluds that the manufacture of column material from reinforcement is more efficient, than the lightweight steel column material. The reinforcement column material is more efficient because of the more effective way of making and the price of the working materials more economical than the lightweight steel column material. Lightweight steel columns can be used for public housing on condition made by experienced craftsmen to make the process faster, and the dimensions of lightweight steel can be scaled down to make it more economical.

Vehicle Lightweighting: 40% and 45% Weight Savings Analysis: Technical Cost Modeling for Vehicle Lightweighting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mascarin, Anthony; Hannibal, Ted; Raghunathan, Anand

2015-04-01

The U.S. Department of Energy’s Vehicle Technologies Office, Materials area commissioned a study to model and assess manufacturing economics of alternative design and production strategies for a series of lightweight vehicle concepts. The strategic targets were a 40% and a 45% mass reduction relative to a standard North American midsize passenger sedan at an effective cost of $3.42 per pound (lb) saved. The baseline vehicle was an average of several available vehicles in this class. Mass and cost breakdowns from several sources were used, including original equipment manufacturers’ (OEMs’) input through U.S. Department of Energy’s Vehicle Technologies Office programs andmore » public presentations, A2Mac1 LLC’s teardown information, Lotus Engineering Limited and FEV, Inc. breakdowns in their respective lightweighting studies, and IBIS Associates, Inc.’s decades of experience in automotive lightweighting and materials substitution analyses. Information on lightweighting strategies in this analysis came from these same sources and the ongoing U.S. Department of Energy-funded Vehma International of America, Inc. /Ford Motor Company Multi-Material Lightweight Prototype Vehicle Demonstration Project, the Aluminum Association Transportation Group, and many United States Council for Automotive Research’s/United States Automotive Materials Partnership LLC lightweight materials programs.« less

Thermal Response Of Composite Insulation

NASA Technical Reports Server (NTRS)

Stewart, David A.; Leiser, Daniel B.; Smith, Marnell; Kolodziej, Paul

1988-01-01

Engineering model gives useful predictions. Pair of reports presents theoretical and experimental analyses of thermal responses of multiple-component, lightweight, porous, ceramic insulators. Particular materials examined destined for use in Space Shuttle thermal protection system, test methods and heat-transfer theory useful to chemical, metallurgical, and ceramic engineers needing to calculate transient thermal responses of refractory composites.

Lightweight custom composite prosthetic components using an additive manufacturing-based molding technique.

PubMed

Leddy, Michael T; Belter, Joseph T; Gemmell, Kevin D; Dollar, Aaron M

2015-01-01

Additive manufacturing techniques are becoming more prominent and cost-effective as 3D printing becomes higher quality and more inexpensive. The idea of 3D printed prosthetics components promises affordable, customizable devices, but these systems currently have major shortcomings in durability and function. In this paper, we propose a fabrication method for custom composite prostheses utilizing additive manufacturing, allowing for customizability, as well the durability of professional prosthetics. The manufacturing process is completed using 3D printed molds in a multi-stage molding system, which creates a custom finger or palm with a lightweight epoxy foam core, a durable composite outer shell, and soft urethane gripping surfaces. The composite material was compared to 3D printed and aluminum materials using a three-point bending test to compare stiffness, as well as gravimetric measurements to compare weight. The composite finger demonstrates the largest stiffness with the lowest weight compared to other tested fingers, as well as having customizability and lower cost, proving to potentially be a substantial benefit to the development of upper-limb prostheses.

DOE Office of Scientific and Technical Information (OSTI.GOV)

None, None

The Lightweight Materials research and development (R&D) area within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies under development. Research focuses on addressing critical barriers to commercializing lightweight materials for passenger and commercial vehicles. This report describes the progress made on the research and development projects funded by the Lightweight Materials area.

Ultralight, scalable nano-architected metamaterials (Conference Presentation)

NASA Astrophysics Data System (ADS)

Zheng, Xiaoyu R.

2017-04-01

It has been a long research and engineering pursuit to create lightweight and mechanically robust and energy efficient materials with interconnected porosity. These cellular materials are desirable for a broad range of applications including structural components, lightweight transportation, heat exchange, catalyst supports, battery electrodes and biomaterials. However, the required outstanding properties have remained elusive on lightweight materials (<10kg/m3), constrained by the inherent coupling of material properties and the lack of suitable processes to generate these artificial materials. For example, graphene aerogels have among the lowest record densities 1kg/m^3, but their strength have been degraded to tens to hundreds of Pascal (<10^-8 of that of carbon nanotubes). The attainment of low density has come with a price -- significant reduction of bulk scale properties. We present the design, manufacturing and defect tolerance study of a new class of ultralight, three-dimensional multi-functional architected materials. These 3D bulk metamaterials (polymer, metal, ceramic and combinations thereof) possess weight density comparable to that of carbon aerogel, but with over 10^4 higher stiffness and strength. By designing and studying their hierarchical architectures, material compositions and feature sizes spanning multiple length-scales, we create a wide range of decoupled material properties such as programmable stiffness, tunable strength and fracture toughness as well as programmable possion ratio. With the possibility of incorporating precise control of topological architectures across length-scale sets as well as prediction and optimization of their defect tolerance, we enter into a paradigm where nanoscale material properties can be harnessed and made accessible in large scale objects, opening a wide range of applications of these materials in energy, health care and flexible electronics.

Lightweight panel study 2012: Perceptions and usage by North American wood products manufacturers

Treesearch

Urs Buehlmann; Matt Bumgardner; Karl D. Forth

2012-01-01

Lightweight panels (panels made of two thin panels on the outside and a lightweight material in the core) can offer enhanced performance, reduced material use, and new design opportunities over traditional types of panels. Opportunities exist for the adoption of lightweight panels by the secondary wood industry in North America, as 62 percent of respondents to a recent...

Optical Property Measurements on the Stardust Sample Return Capsule

NASA Technical Reports Server (NTRS)

Finckenor, Miria

2007-01-01

The Advanced Materials for Exploration (AME) task Materials Analysis of Returned Hardware from Stardust received funding to perform non-destructive analyses of the non-primary science hardware components of the Stardust sample return capsule. These components were (a) the blunt body reentry heatshield, encased in Phenolic Impregnated Carbon Ablator (PICA); (b) the backshell of Super Lightweight Ablator 561 (SLA-561) material handpacked into phenolic Flexcore and coated with CV-1100 silicone; (c) the rope seal used in between the heatshield and backshell; (d) the internal multi-layer insulation (MLI) blankets; and (e) parts of the Kevlar straps left attached to the backshell. These components were analyzed to determine the materials' durability in the space environment. The goals of the task were (a) to determine how the various materials from which the components were built weathered the extreme temperatures and harsh space environment during the capsule's nearly 7-year voyage to and from its rendezvous with Comet Wild 2 and (b) to provide lessons-learned data for designers of future missions.

KSC-08pd2088

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center mate the Hubble vertical platform to the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2098

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center installs a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2097

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center installs a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2089

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center secure the Hubble vertical platform to the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2096

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center installs a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2094

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center install the pallet support struts on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2087

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center move the Hubble vertical platform toward the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope, to which it will be mated. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2085

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope, elevated at left, is ready to be mated to the Hubble vertical platform, at right. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2086

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center move the Hubble vertical platform toward the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope, to which it will be mated. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2095

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center documents the installation of a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

Vehicle lightweighting energy use impacts in U.S. light-duty vehicle fleet

DOE Office of Scientific and Technical Information (OSTI.GOV)

Das, Sujit; Graziano, Diane; Upadhyayula, Venkata K. K.

In this article, we estimate the potential energy benefits of lightweighting the light-duty vehicle fleet from both vehicle manufacturing and use perspectives using plausible lightweight vehicle designs involving several alternative lightweight materials, low- and high-end estimates of vehicle manufacturing energy, conventional and alternative powertrains, and two different market penetration scenarios for alternative powertrain light-duty vehicles at the fleet level. Cumulative life cycle energy savings (through 2050) across the nine material scenarios based on the conventional powertrain in the U.S. vehicle fleet range from -29 to 94 billion GJ, with the greatest savings achieved by multi-material vehicles that select different lightweightmore » materials to meet specific design purposes. Lightweighting alternative-powertrain vehicles could produce significant energy savings in the U.S. vehicle fleet, although their improved powertrain efficiencies lessen the energy savings opportunities for lightweighting. A maximum level of cumulative energy savings of lightweighting the U.S. light-duty vehicle through 2050 is estimated to be 66.1billion GJ under the conventional-vehicle dominated business-as-usual penetration scenario.« less

PMR Extended Shelf Life Technology Given 2000 R and D 100 Award

NASA Technical Reports Server (NTRS)

Meador, Michael A.

2001-01-01

An approach developed at the NASA Glenn Research Center for extending the shelf life of PMR polyimide solutions and prepregs received an R&D 100 Award this year. PMR polyimides, in particular PMR-15, have become attractive materials for a variety of aerospace applications because of their outstanding high-temperature stability and performance. PMR-15 can be used in components with exposures to temperatures as high as 290 C, which leads to substantial reductions in weight, as much as 30 percent over metal components. PMR-15 composites are used widely in aerospace applications ranging from ducts and external components in aircraft engines to an engine access door for the Space Shuttle Main Engine. A major barrier to more widespread use of these materials is high component costs. Recent efforts at Glenn have addressed the various factors that contribute to these costs in an attempt to more fully utilize these lightweight, high-temperature materials.

Superplastic forming of Al-Li alloys for lightweight, low-cost structures

NASA Technical Reports Server (NTRS)

Hales, Stephen J.; Wagner, John A.

1991-01-01

Superplastic forming of advanced aluminum alloys is being evaluated as an approach for fabricating low-cost, light-weight, cryogenic propellant tanks. Built-up structure concepts (with inherent reduced scrap rate) are under investigation to offset the additional raw material expenses incurred by using aluminum lithium alloys. This approach to fabrication offers the potential for significant improvements in both structural efficiency and overall manufacturing costs. Superplasticity is the ability of specially processed material to sustain very large forming strains without failure at elevated temperatures under controlled deformation conditions. It was demonstrated that superplastic forming technology can be used to fabricate complex structural components in a single operation and increase structural efficiency by as much as 60 percent compared to conventional configurations in skin-stiffened structures. Details involved in the application of this technology to commercial grade superplastic aluminum lithium material are presented. Included are identification of optimum forming parameters, development of forming procedures, and assessment of final part quality in terms of cavitation volume and thickness variation.

Influence of Implementation of Composite Materials in Civil Aircraft Industry on reduction of Environmental Pollution and Greenhouse Effect

NASA Astrophysics Data System (ADS)

Beck, A. J.; Hodzic, A.; Soutis, C.; Wilson, C. W.

2011-12-01

Computer-based Life Cycle Analysis (LCA) models were carried out to compare lightweight composites with the traditional aluminium over their useful lifetime. The analysis included raw materials, production, useful life in operation and disposal at the end of the material's useful life. The carbon fibre epoxy resin composite could in some cases reduce the weight of a component by up to 40 % compared to aluminium. As the fuel consumption of an aircraft is strongly influenced by its total weight, the emissions can be significantly reduced by increasing the proportion of composites used in the aircraft structure. Higher emissions, compared to aluminium, produced during composites production meet their 'break even' point after certain number of time units when used in aircraft structures, and continue to save emissions over their long-term operation. The study highlighted the environmental benefits of using lightweight structures in aircraft design, and also showed that utilisation of composites in products without energy saving may lead to increased emissions in the environment.

Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

DOE Office of Scientific and Technical Information (OSTI.GOV)

Huang, Runze; Riddle, Matthew; Graziano, Diane

Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM), and AM has been increasingly adopted by aircraft component manufacturers for lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integrates engineering criteria, life-cycle environmental data, aircraft fleet stockmore » and fuel use models under different AM adoption scenarios. Estimated fleet-wide life-cycle primary energy savings at most reach 70-173 million GJ/year in 2050, with cumulative savings of 1.2–2.8 billion GJ. Associated cumulative GHG emission reductions were estimated at 92.1–215.0 million metric tons. In addition, thousands of tons of aluminum, titanium and nickel alloys could be potentially saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.« less

Hypersonic Composites Resist Extreme Heat and Stress

NASA Technical Reports Server (NTRS)

2007-01-01

Through research contracts with NASA, Materials and Electrochemical Research Corporation (MER), of Tucson, Arizona, contributed a number of technologies to record-breaking hypersonic flights. Through this research, MER developed a coating that successfully passed testing to simulate Mach 10 conditions, as well as provide several additional carbon-carbon (C-C) composite components for the flights. MER created all of the leading edges for the X-43A test vehicles at Dryden-considered the most critical parts of this experimental craft. In addition to being very heat resistant, the coating had to be very lightweight and thin, as the aircraft was designed to very precise specifications and could not afford to have a bulky coating. MER patented its carbon-carbon (C-C) composite process and then formed a spinoff company, Frontier Materials Corporation (FMC), also based in Tucson. FMC is using the patent in conjunction with low-cost PAN (polyacrylonitrile)-based fibers to introduce these materials to the commercial markets. The C-C composites are very lightweight and exceptionally strong and stiff, even at very high temperatures. The composites have been used in industrial heating applications, the automotive and aerospace industries, as well as in glass manufacturing and on semiconductors. Applications also include transfer components for glass manufacturing and structural members for carrier support in semiconductor processing.

Lightweighting Impacts on Fuel Economy, Cost, and Component Losses

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brooker, A. D.; Ward, J.; Wang, L.

2013-01-01

The Future Automotive Systems Technology Simulator (FASTSim) is the U.S. Department of Energy's high-level vehicle powertrain model developed at the National Renewable Energy Laboratory. It uses a time versus speed drive cycle to estimate the powertrain forces required to meet the cycle. It simulates the major vehicle powertrain components and their losses. It includes a cost model based on component sizing and fuel prices. FASTSim simulated different levels of lightweighting for four different powertrains: a conventional gasoline engine vehicle, a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), and a battery electric vehicle (EV). Weight reductions impacted themore » conventional vehicle's efficiency more than the HEV, PHEV and EV. Although lightweighting impacted the advanced vehicles' efficiency less, it reduced component cost and overall costs more. The PHEV and EV are less cost effective than the conventional vehicle and HEV using current battery costs. Assuming the DOE's battery cost target of $100/kWh, however, the PHEV attained similar cost and lightweighting benefits. Generally, lightweighting was cost effective when it costs less than $6/kg of mass eliminated.« less

Research Technology

NASA Image and Video Library

1998-01-01

Engineers at Marshall Space Flight Center (MSFC) in Huntsville, Alabama, are working with industry partners to develop a new generation of more cost-efficient space vehicles. Lightweight fuel tanks and components under development will be the critical elements in tomorrow's reusable launch vehicles and will tremendously curb the costs of getting to space. In this photo, Tom DeLay, a materials processes engineer for MSFC, uses a new graphite epoxy technology to create lightweight cryogenic fuel lines for futuristic reusable launch vehicles. He is wrapping a water-soluble mandrel, or mold, with a graphite fabric coated with an epoxy resin. Once wrapped, the pipe will be vacuum-bagged and autoclave-cured. The disposable mold will be removed to reveal a thin-walled fuel line. In addition to being much lighter and stronger than metal, this material won't expand or contract as much in the extreme temperatures encountered by launch vehicles.

Graded High-Strength Spring-Steels by a Special Inductive Heat T reatment

NASA Astrophysics Data System (ADS)

Tump, A.; Brandt, R.

2016-03-01

A method for effective lightweight design is the use of materials with high specific strength. As materials e.g. titanium are very expensive, steel is still the most important material for manufacturing automotive components. Steel is cost efficient, easy to recycle and its tensile strength easily exceeds 2,000 MPa by means of modern QT-technology (Quenched and Tempered). Therefore, lightweight design is still feasible in spite of the high density of steel. However, a further increase of tensile strength is limited, especially due to an increasing notch sensitivity and exposure to a corrosive environment. One solution is a special QT-process for steel, which creates a hardness gradient from the surface to the core of the material. This type of tailored material possesses a softer layer, which improves material properties such as fracture toughness and notch sensitivity. This leads to a better resistance to stress corrosion cracking and corrosion fatigue. Due to this optimization, a weight reduction is feasible without the use of expensive alloying elements. To understand the damage mechanism a comprehensive testing procedure was performed on homogeneous and gradient steels. Some results regarding the fracture mechanic behavior of such steels will be discussed.

Deviatoric Response of AN Armour-Grade Aluminium Alloy

NASA Astrophysics Data System (ADS)

Appleby-Thomas, G. J.; Hazell, P. J.; Millett, J.; Bourne, N. K.

2009-12-01

Aluminium alloys such as 5083 H32 are established light-weight armour materials. As such, the shock response of these materials is of great importance. The shear strength of a material under shock loading provides an insight into its ballistic performance. In this investigation embedded manganin stress gauges have been employed to measure both the longitudinal and lateral components of stress during plate-impact experiments over a range of impact stresses. In turn, these results were used to determine the shear strength and to investigate the time dependence of lateral stress behind the shock front to give an indication of material response.

Artificial Muscle Kits for the Classroom

NASA Technical Reports Server (NTRS)

2004-01-01

Commonly referred to as "artificial muscles," electroactive polymer (EAP) materials are lightweight strips of highly flexible plastic that bend or stretch when subjected to electric voltage. EAP materials may prove to be a substitution for conventional actuation components such as motors and gears. Since the materials behave similarly to biological muscles, this emerging technology has the potential to develop improved prosthetics and biologically-inspired robots, and may even one day replace damaged human muscles. The practical application of artificial muscles provides a challenge, however, since the material requires improved effectiveness and durability before it can fulfill its potential.

The Evaluation of Vehicle Mass Reduction and Material ...

EPA Pesticide Factsheets

Developments in the realm of lightweight materials for automotive use continue to be announced by the industry and by academia. This session will provide new and updated information on new generation of materials. Additionally, this session will focus on the key topics involved in Life-Cycle-Analysis of light-weight materials including practices and developments in material recyclability. This presentation will review key findings from recent LCAs for vehicle mass reduction. Presentation for panel session on advanced materials/lightweighting for light duty vehicles at the Society of Automotive Engineers (SAE) Government/Industry Meeting, Washington, DC (January 25, 2017)

Reducing supply chain energy use in next-generation vehicle lightweighting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hanes, Rebecca J.; Das, Sujit; Carpenter, Alberta

Vehicle lightweighting reduces the amount of fuel consumed in a vehicle's use phase, but depending on what lightweight materials replace the conventional materials, and in what amounts, the manufacturing energy may increase or decrease. For carbon fiber reinforced polymer (CFRP), a next-generation lightweighting material, the increase in vehicle manufacturing energy is greater than the fuel savings, resulting in a net increase in energy consumption over a vehicle's manufacturing and use relative to a standard non-lightweighted car. [1] This work explores ways to reduce the supply chain energy of CFRP lightweighted vehicles through alternative production technologies and energy efficiency improvements. Themore » objective is to determine if CFRP can offer energy savings comparable to or greater than aluminum, a conventional lightweighting material. Results of this analysis can be used to inform additional research and development efforts in CFRP production and future directions in lightweight vehicle production. The CFRP supply chain is modeled using the Material Flows through Industry (MFI) scenario modeling tool, which calculates 'mine to materials' energy consumption, material inventories and greenhouse gas emissions for industrial supply chains. In this analysis, the MFI tool is used to model the supply chains of two lightweighted vehicles, an aluminum intensive vehicle (AIV) and a carbon fiber intensive vehicle (CFV), under several manufacturing scenarios. Vehicle specifications are given in [1]. Scenarios investigated cover alternative carbon fiber (CF) feedstocks and energy efficiency improvements at various points in the vehicle supply chains. The alternative CF feedstocks are polyacrylonitrile, lignin and petroleum-derived mesophase pitch. Scenarios in which the energy efficiency of CF and CFRP production increases are explored using sector efficiency potential values, which quantify the reduction in energy consumption achievable when process equipment is upgraded to the most efficient available. Preliminary analyses indicate that producing CF from lignin instead of polyacrylonitrile, the most commonly used feedstock, reduces energy consumption in the CFRP supply chain by 7.5%, and that implementing energy efficient process equipment produces an additional 8% reduction. Final results will show if these potential reductions are sufficient to make the CFV energy savings comparable with AIV energy savings. [1] Das, S., Graziano, D., Upadhyayula, V. K., Masanet, E., Riddle, M., & Cresko, J. (2016). Vehicle lightweighting energy use impacts in US light-duty vehicle fleet. Sustainable Materials and Technologies, 8, 5-13.« less

State-of-the-Art Review of Low-Cost Collector Technologies

DTIC Science & Technology

1981-06-01

Mobility Low-Cost Parabolic Trough Survivability Light-Weight Thin-Film Reliability Heliostats Polymers Military 20. ABSTRACT (Contine an revers. deo It... heliostats and parabolic dish collectors. In addition several criteria were evaluated with respect to low-cost collector technologies These included...has produced collectors which incorporate sophisticated materials, = Heliostat heavy components, expensive seals and compli- o- (Point Focus) cated

Thermo-mechanical performance of precision C/SiC mounts

NASA Astrophysics Data System (ADS)

Goodman, William A.; Mueller, Claus E.; Jacoby, Marc T.; Wells, Jim D.

2001-12-01

For complex shaped, lightweight, high precision opto- mechanical structures that must operate in adverse environments and over wide ranges of temperature, we consider IABG's optical grade silicon carbide composite ceramic (C/SiC) as the material of choice. C/SiC employs conventional NC machining/milling equipment to rapidly fabricate near-net shape parts, providing substantial schedule, cost, and risk savings for high precision components. Unlike powder based SiC ceramics, C/SiC does not experience significant shrinkage during processing, nor does it suffer from incomplete densification. If required, e.g. for large-size components, a fully-monolithic ceramic joining technique can be applied. Generally, the thermal and mechanical properties of C/SiC are tunable in certain ranges by modifying certain process steps. This paper focuses on the thermo-mechanical performance of new, high precision mounts designed by Schafer Corporation and manufactured by IABG. The mounts were manufactured using standard optical grade C/SiC (formulation internally called A-3). The A-3 formulation has a near-perfect CTE match with silicon, making it the ideal material to athermally support Schafer produced Silicon Lightweight Mirrors (SLMs) that will operate in a cryogenic environment. Corresponding thermo- mechanical testing and analysis is presented in this manuscript.

Lightweight Composite Materials for Heavy Duty Vehicles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pruez, Jacky; Shoukry, Samir; Williams, Gergis

The main objective of this project is to develop, analyze and validate data, methodologies and tools that support widespread applications of automotive lightweighting technologies. Two underlying principles are guiding the research efforts towards this objective: • Seamless integration between the lightweight materials selected for certain vehicle systems, cost-effective methods for their design and manufacturing, and practical means to enhance their durability while reducing their Life-Cycle-Costs (LCC). • Smooth migration of the experience and findings accumulated so far at WVU in the areas of designing with lightweight materials, innovative joining concepts and durability predictions, from applications to the area of weightmore » savings for heavy vehicle systems and hydrogen storage tanks, to lightweighting applications of selected systems or assemblies in light–duty vehicles.« less

Measurements of the frame acoustic properties of porous and granular materials

NASA Astrophysics Data System (ADS)

Park, Junhong

2005-12-01

For porous and granular materials, the dynamic characteristics of the solid component (frame) are important design factors that significantly affect the material's acoustic properties. The primary goal of this study was to present an experimental method for measuring the vibration characteristics of this frame. The experimental setup was designed to induce controlled vibration of the solid component while minimizing the influence from coupling between vibrations of the fluid and the solid component. The Biot theory was used to verify this assumption, taking the two dilatational wave propagations and interactions into account. The experimental method was applied to measure the dynamic properties of glass spheres, lightweight microspheres, acoustic foams, and fiberglass. A continuous variation of the frame vibration characteristics with frequency similar to that of typical viscoelastic materials was measured. The vibration amplitude had minimal effects on the dynamic characteristics of the porous material compared to those of the granular material. For the granular material, materials comprised of larger particles and those under larger vibration amplitudes exhibited lower frame wave speeds and larger decay rates.

Advanced technology for extended endurance alkaline fuel cells

NASA Technical Reports Server (NTRS)

Sheibley, D. W.; Martin, R. A.

1987-01-01

Advanced components have been developed for alkaline fuel cells with a view to the satisfaction of NASA Space Station design requirements for extended endurance. The components include a platinum-on-carbon catalyst anode, a potassium titanate-bonded electrolyte matrix, a lightweight graphite electrolyte reservoir plate, a gold-plated nickel-perforated foil electrode substrate, a polyphenylene sulfide cell edge frame material, and a nonmagnesium cooler concept. When incorporated into the alkaline fuel cell unit, these components are expected to yield regenerative operation in a low earth orbit Space Station with a design life greater than 5 years.

Analysis of the possibilities of using dielectric foam in the construction of composite high voltage post-insulators

NASA Astrophysics Data System (ADS)

Mączka, T.; Paściak, G.; Jarski, A.; Piątek, M.

2016-02-01

This paper presents the construction and basic performance parameters of the innovative tubular construction of high voltage composite insulator filled with the lightweight foamed electroinsulating material. The possibility of using of the commercially available expanding foams for preparing the lightweight foamed dielectric materials was analysed. The expanding foams of silicone RTV and compositions based on epoxy resin and LSR silicone were taken into account. The lightweight foamed dielectric materials were prepared according to the own foaming technology. In this work the experimental results on the use of the selected foams for the preparing of the lightweight filling materials to the tubular structure of composite insulator of 110 kV are presented.

Effect of acoustic resonance phenomenon on fluid flow with light dust

NASA Astrophysics Data System (ADS)

Hamakawa, Hiromitsu; Arshad, Azim B. M.; Ohta, Mitsuo

2011-10-01

In the present paper, the attention is focused on the characteristics of lightweight materials collection in the duct using acoustic resonance phenomena. The acoustic resonance was excited by using a controlled speaker at the middle of a test duct. We measured the sound pressure level, frequency response characteristics, acoustic damping ratio, mode shape, and lightweight materials response to acoustic resonance excited by a speaker. As a result, the acoustic damping ratio decreased as the mode number of acoustic resonance increased. The tissue strips and the lightweight materials were collected at the node of acoustic pressure when the acoustic resonance was excited. It was made clear that it is possible to control lightweight materials using acoustic resonance excited by a speaker.

Mechanical and Physical Properties of Hydrophobized Lightweight Aggregate Concrete with Sewage Sludge.

PubMed

Suchorab, Zbigniew; Barnat-Hunek, Danuta; Franus, Małgorzata; Łagód, Grzegorz

2016-04-27

This article is focused on lightweight aggregate-concrete modified by municipal sewage sludge and lightweight aggregate-concrete obtained from light aggregates. The article presents laboratory examinations of material physical parameters. Water absorptivity of the examined material was decreased by the admixture of water emulsion of reactive polysiloxanes. Water transport properties were determined using Time Domain Reflectometry, an indirect technique for moisture detection in porous media. Together with basic physical parameters, the heat conductivity coefficient λ was determined for both types of lightweight aggregate-concrete. Analysis of moisture and heat properties of the examined materials confirmed the usefulness of light aggregates supplemented with sewage sludge for prospective production.

Materials and structures

NASA Astrophysics Data System (ADS)

Saito, Theodore T.; Langenbeck, Sharon L.; Al-Jamily, Ghanim; Arnold, Joe; Barbee, Troy; Coulter, Dan; Dolgin, Ben; Fichter, Buck; George, Patricia; Gorenstein, Paul

1992-08-01

Materials and structures technology covers a wide range of technical areas. Some of the most pertinent issues for the Astrotech 21 missions include dimensionally stable structural materials, advanced composites, dielectric coatings, optical metallic coatings for low scattered light applications, low scattered light surfaces, deployable and inflatable structures (including optical), support structures in 0-g and 1-g environments, cryogenic optics, optical blacks, contamination hardened surfaces, radiation hardened glasses and crystals, mono-metallic telescopes and instruments, and materials characterization. Some specific examples include low coefficients of thermal expansion (CTE) structures (0.01 ppm/K), lightweight thermally stable mirror materials, thermally stable optical assemblies, high reliability/accuracy (1 micron) deployable structures, and characterization of nanometer level behavior of materials/structures for interferometry concepts. Large filled-aperture concepts will require materials with CTE's of 10(exp 9) at 80 K, anti-contamination coatings, deployable and erectable structures, composite materials with CTE's less than 0.01 ppm/K and thermal hysteresis, 0.001 ppm/K. Gravitational detection systems such as LAGOS will require rigid/deployable structures, dimensionally stable components, lightweight materials with low conductivity, and high stability optics. The Materials and Structures panel addressed these issues and the relevance of the Astrotech 21 mission requirements by dividing materials and structures technology into five categories. These categories, the necessary development, and applicable mission/program development phasing are summarized. For each of these areas, technology assessments were made and development plans were defined.

Fresnel Concentrators for Space Solar Power and Solar Thermal Propulsion

NASA Technical Reports Server (NTRS)

Bradford, Rodney; Parks, Robert W.; Craig, Harry B. (Technical Monitor)

2001-01-01

Large deployable Fresnel concentrators are applicable to solar thermal propulsion and multiple space solar power generation concepts. These concentrators can be used with thermophotovoltaic, solar thermionic, and solar dynamic conversion systems. Thin polyimide Fresnel lenses and reflectors can provide tailored flux distribution and concentration ratios matched to receiver requirements. Thin, preformed polyimide film structure components assembled into support structures for Fresnel concentrators provide the capability to produce large inflation-deployed concentrator assemblies. The polyimide film is resistant to the space environment and allows large lightweight assemblies to be fabricated that can be compactly stowed for launch. This work addressed design and fabrication of lightweight polyimide film Fresnel concentrators, alternate materials evaluation, and data management functions for space solar power concepts, architectures, and supporting technology development.

On development of an inexpensive, lightweight thermal micrometeroid garment for space suits

NASA Technical Reports Server (NTRS)

1975-01-01

A lightweight and inexpensive coverlayer developed for space suits is described. Material selection, procurement, and testing, pattern design, and prototype fabrication are discussed. By using the minimum required cross section necessary for earth orbital mission, by utilizing the lightest weight materials possible, and by decreasing the use of weight costly taping a lightweight and economical thermal micrometeroid garment was developed. Simplification of manufacturing techniques and use of off-the-shelf materials helped to reduce costs.

Total Life Cycle-Based Materials Selection for Polymer Metal Hybrid Body-in-White Automotive Components

NASA Astrophysics Data System (ADS)

Grujicic, M.; Sellappan, V.; He, T.; Seyr, Norbert; Obieglo, Andreas; Erdmann, Marc; Holzleitner, Jochen

2009-03-01

Over the last dozen of years, polymer metal hybrid (PMH) technologies have established themselves as viable alternatives for use in light-weight automotive body-in-white bolt-on as well as load-bearing (structural) components. Within the PMH technologies, sheet-metal stamped/formed and thermoplastic injection molding subcomponents are integrated into a singular component/module. Due to attending synergetic effects, the performance of the PMH component typically exceeds that attainable by an alternative single-material technologies. In the present work, a total life cycle (TLC) approach to the selection of metallic and thermoplastic materials (as well as the selection of structural adhesives, where appropriate) is considered. The TLC material selection approach considers the consequences and ramifications of material selection at each major stage of the vehicle manufacturing process chain (press shop, injection molding shop, body shop, paint shop, and assembly), as well as relation to the vehicle performance, durability and the end-of-the-life-of-the-vehicle considerations. The approach is next applied to the case of injection overmolding technology to identify the optimal grade of short glass-fiber reinforced nylon when used in a prototypical PMH load-bearing automotive body-in-white component.

Composite armored vehicle advanced technology demonstator

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ostberg, D.T.; Dunfee, R.S.; Thomas, G.E.

1996-12-31

Composite structures are a key technology needed to develop future lightweight combat vehicles that are both deployable and survivable. The Composite Armored Vehicle Advanced Technology Demonstrator Program that started in fiscal year 1994 will continue through 1998 to verily that composite structures are a viable solution for ground combat vehicles. Testing thus far includes material characterization, structural component tests and full scale quarter section tests. Material and manufacturing considerations, tests, results and changes, and the status of the program will be described. The structural component tests have been completed successfully, and quarter section testing is in progress. Upon completion ofmore » the critical design review, the vehicle demonstrator will be Fabricated and undergo government testing.« less

NASA Subsonic Rotary Wing Project - Structures and Materials Discipline

NASA Technical Reports Server (NTRS)

Halbig, Michael C.; Johnson, Susan M.

2008-01-01

The Structures & Materials Discipline within the NASA Subsonic Rotary Wing Project is focused on developing rotorcraft technologies. The technologies being developed are within the task areas of: 5.1.1 Life Prediction Methods for Engine Structures & Components 5.1.2 Erosion Resistant Coatings for Improved Turbine Blade Life 5.2.1 Crashworthiness 5.2.2 Methods for Prediction of Fatigue Damage & Self Healing 5.3.1 Propulsion High Temperature Materials 5.3.2 Lightweight Structures and Noise Integration The presentation will discuss rotorcraft specific technical challenges and needs as well as details of the work being conducted in the six task areas.

Materials for geothermal production

NASA Astrophysics Data System (ADS)

Kukacka, L. E.

Advances in the development of new materials continue to be made in the geothermal materials project. Many successes have already been accrued and the results used commercially. In FY-91, work was focused on reducing well drilling, fluid transport and energy conversion costs. Specific activities performed included lightweight CO2 resistant well cements, thermally conductive and scale resistant protective liner systems, chemical systems for lost circulation control, corrosion mitigation in process components at The Geysers, and elastomer-metal bonding systems. Efforts to transfer the technologies developed in these efforts to other energy-related sectors of the economy continued, and considerable success was achieved.

Analysis of stress concentration at holes in components made of 2195 aluminum-lithium

NASA Astrophysics Data System (ADS)

Ahmed, R.

1995-05-01

Because the 2195 aluminum-lithium of the super lightweight external tank (SLWT ET) has a lower toughness than the 2219 aluminum used in previous ET's, careful attention must be paid to stress concentration in the SLWT ET. This report details the initial analysis performed by NASA to determine the material properties required to ensure structural integrity in these critical areas.

Mechanical and Physical Properties of Hydrophobized Lightweight Aggregate Concrete with Sewage Sludge

PubMed Central

Suchorab, Zbigniew; Barnat-Hunek, Danuta; Franus, Małgorzata; Łagód, Grzegorz

2016-01-01

This article is focused on lightweight aggregate-concrete modified by municipal sewage sludge and lightweight aggregate-concrete obtained from light aggregates. The article presents laboratory examinations of material physical parameters. Water absorptivity of the examined material was decreased by the admixture of water emulsion of reactive polysiloxanes. Water transport properties were determined using Time Domain Reflectometry, an indirect technique for moisture detection in porous media. Together with basic physical parameters, the heat conductivity coefficient λ was determined for both types of lightweight aggregate-concrete. Analysis of moisture and heat properties of the examined materials confirmed the usefulness of light aggregates supplemented with sewage sludge for prospective production. PMID:28773442

Self Healing Fibre-reinforced Polymer Composites: an Overview

NASA Astrophysics Data System (ADS)

Bond, Ian P.; Trask, Richard S.; Williams, Hugo R.; Williams, Gareth J.

Lightweight, high-strength, high-stiffness fibre-reinforced polymer composite materials are leading contenders as component materials to improve the efficiency and sustainability of many forms of transport. For example, their widespread use is critical to the success of advanced engineering applications, such as the Boeing 787 and Airbus A380. Such materials typically comprise complex architectures of fine fibrous reinforcement e.g. carbon or glass, dispersed within a bulk polymer matrix, e.g. epoxy. This can provide exceptionally strong, stiff, and lightweight materials which are inherently anisotropic, as the fibres are usually arranged at a multitude of predetermined angles within discrete stacked 2D layers. The direction orthogonal to the 2D layers is usually without reinforcement to avoid compromising in-plane performance, which results in a vulnerability to damage in the polymer matrix caused by out-of-plane loading, i.e. impact. Their inability to plastically deform leaves only energy absorption via damage creation. This damage often manifests itself internally within the material as intra-ply matrix cracks and inter-ply delaminations, and can thus be difficult to detect visually. Since relatively minor damage can lead to a significant reduction in strength, stiffness and stability, there has been some reticence by designers for their use in safety critical applications, and the adoption of a `no growth' approach (i.e. damage propagation from a defect constitutes failure) is now the mindset of the composites industry. This has led to excessively heavy components, shackling of innovative design, and a need for frequent inspection during service (Richardson 1996; Abrate 1998).

Materials for Space: It's Challenging!

NASA Technical Reports Server (NTRS)

Johnson, Sylvia M.

2016-01-01

Space environments place tremendous demands on materials that must perform with exceptional reliability to realize the goals of human or robotic space exploration missions. Materials are subjected to extremes of temperature, pressure, radiation and mechanical loads during all phases of use, including takeoff and ascent, exposure to space or entry into an atmosphere, and operation in a planetary atmosphere. Space materials must be robust and enable the formation of lightweight structures or components that perform the required functions; materials that perform multiple functions are of particular interest. This talk will review the unique challenges for materials in space and some of the specific material capabilities that will be needed for future exploration missions. A description of needs and trends in thermal protection materials and systems will complete the talk.

Evaluation of lightweight material concepts for aircraft turbine engine rotor failure protection

DOT National Transportation Integrated Search

1997-07-01

Results of the evaluation of lightweight materials for aircraft turbine engine rotor failure protection are presented in this report. The program consisted of two phases. Phase 1 was an evaluation of a group of composite materials which could possibl...

Aluminum-titanium hydride-boron carbide composite provides lightweight neutron shield material

NASA Technical Reports Server (NTRS)

Poindexter, A. M.

1967-01-01

Inexpensive lightweight neutron shield material has high strength and ductility and withstands high internal heat generation rates without excessive thermal stress. This composite material combines structural and thermal properties of aluminum, neutron moderating properties of titanium hydride, and neutron absorbing characteristics of boron carbide.

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

The Lightweight Materials research and development (R&D) area within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies under development. Research focuses on addressing critical barriers to commercializing lightweight materials for passenger and commercial vehicles.

Lightweight, fire-retardant, crashworthy aircraft seat cushioning

NASA Technical Reports Server (NTRS)

Haslim, Leonard A.; Mcdonough, Paul T.

1991-01-01

A two page discussion of non-aerospace seating applications and the design of NASA's safety seat cushioning (SSC) is presented. The SSC was designed for both safety and comfort in order to replace polyurethane cushioning which is flammable and produces lethal fumes upon combustion. The SSC is composed of advanced fabric reinforced composites and is lightweight, fire-retardent, and crashworthy. The seat design consists of central elliptical tubular spring supports made of fire-resistant and fatigue-durable composites surrounded by a fire-blocking sheath. The cushioning is made crashworthy by incorporating energy-absorbing, viscoelastic layers between the nested, elliptical-hoop springs. The design is intended to provide comfortable seating that meets aircraft-loading requirements without using the conventional polyurethane materials. The designs of an aircraft seat and structural components of the SSC are also presented.

Design and fabrication of silver-hydrogen cells

NASA Technical Reports Server (NTRS)

Klein, M. G.

1975-01-01

The design and fabrication of silver-hydrogen secondary cells capable of delivering higher energy densities than comparable nickel-cadmium and nickel-hydrogen cells and relatively high cycle life is presented. An experimental task utilizing single electrode pairs for the optimization of the individual electrode components, the preparation of a design for lightweight 20Ahr cells, and the fabrication of four 20Ahr cells in heavy wall test housing containing electrode stacks of the lightweight design are described. The design approach is based on the use of a single cylindrical self-contained cell with a stacked disc sequence of electrodes. The electrode stack design is based on the use of NASA- Astropower Separator Material, PPF fuel cell anodes, an intercell electrolyte reservoir concept and sintered silver electrodes. Results of performance tests are given.

Robot Manipulator Technologies for Planetary Exploration

NASA Technical Reports Server (NTRS)

Das, H.; Bao, X.; Bar-Cohen, Y.; Bonitz, R.; Lindemann, R.; Maimone, M.; Nesnas, I.; Voorhees, C.

1999-01-01

NASA exploration missions to Mars, initiated by the Mars Pathfinder mission in July 1997, will continue over the next decade. The missions require challenging innovations in robot design and improvements in autonomy to meet ambitious objectives under tight budget and time constraints. The authors are developing design tools, component technologies and capabilities to address these needs for manipulation with robots for planetary exploration. The specific developments are: 1) a software analysis tool to reduce robot design iteration cycles and optimize on design solutions, 2) new piezoelectric ultrasonic motors (USM) for light-weight and high torque actuation in planetary environments, 3) use of advanced materials and structures for strong and light-weight robot arms and 4) intelligent camera-image coordinated autonomous control of robot arms for instrument placement and sample acquisition from a rover vehicle.

Development of Critical Technologies for the COSMO/SkyMed Hyperspectral Camera

DTIC Science & Technology

2000-10-01

Carbide (SiC) material (SiC or lightweighted Zerodur mirrors , carbon fiber technology. structures). - development of electronics blocks at high - High...investigation was Kcarried out to get the highest lightening factors on the Zerodur mirror substrates. Several samples of the TMA Fig. 5 - Prototypes of...implementation of state-of-the-art - manufacturing of very light mirrors with special manufacturing techniques for light components emphasis on Silicon

Lightweight aggregate abrasion study.

DOT National Transportation Integrated Search

1963-02-01

The rapid increase in the use of lightweight aggregates in structural concrete has created a number of problems for the Materials Engineer in evaluating this type aggregate. Exhaustive studies are being made of a number of properties of lightweight a...

United States Automotive Materials Partnership LLC (USAMP)

DOE Office of Scientific and Technical Information (OSTI.GOV)

United States Automotive Materials Partnership

2011-01-31

The United States Automotive Materials Partnership LLC (USAMP) was formed in 1993 as a partnership between Chrysler Corporation, Ford Motor Company, and General Motors Corporation. Since then the U.S. Department of Energy (DOE) has supported its activities with funding and technical support. The mission of the USAMP is to conduct vehicle-oriented research and development in materials and materials processing to improve the competitiveness of the U.S. Auto Industry. Its specific goals are: (1) To conduct joint research to further the development of lightweight materials for improved automotive fuel economy; and (2) To work with the Federal government to explore opportunitiesmore » for cooperative programs with the national laboratories, Federal agencies such as the DOE and universities. As a major component of the DOE's Office of FreedomCAR and Vehicle Technologies Program (FCVT) collaboration with the USAMP, the Automotive Lightweighting Materials (ALM) program focuses on the development and validation of advanced materials and manufacturing technologies to significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost. The FCVT was announced in FY 2002 and implemented in FY 2003, as a successor of the Partnership for a New Generation of Vehicles (PNGV), largely addressed under the first Cooperative Agreement. This second USAMP Cooperative Agreement with the DOE has expanded a unique and valuable framework for collaboratively directing industry and government research efforts toward the development of technologies capable of solving important societal problems related to automobile transportation. USAMP efforts are conducted by the domestic automobile manufacturers, in collaboration with materials and manufacturing suppliers, national laboratories, universities, and other technology or trade organizations. These interactions provide a direct route for implementing newly developed materials and technologies, and have resulted in significant technical successes to date, as discussed in the individual project summary final reports. Over 70 materials-focused projects have been established by USAMP, in collaboration with participating suppliers, academic/non-profit organizations and national laboratories, and executed through its original three divisions: the Automotive Composites Consortium (ACC), the Automotive Metals Division (AMD), and Auto/Steel Partnership (A/SP). Two new divisions were formed by USAMP in 2006 to drive research emphasis on integration of structures incorporating dissimilar lightweighting materials, and on enabling technology for nondestructive evaluation of structures and joints. These new USAMP divisions are: Multi-Material Vehicle Research and Development Initiative (MMV), and the Non-Destructive Evaluation Steering Committee (NDE). In cooperation with USAMP and the FreedomCAR Materials Technical Team, a consensus process has been established to facilitate the development of projects to help move leveraged research to targeted development projects that eventually migrate to the original equipment manufacturers (OEMs) as application engineering projects. Research projects are assigned to one of three phases: concept feasibility, technical feasibility, and demonstration feasibility. Projects are guided through ongoing monitoring and USAMP offsite reviews, so as to meet the requirements of each phase before they are allowed to move on to the next phase. As progress is made on these projects, the benefits of lightweight construction and enabling technologies will be transferred to the supply base and implemented in production vehicles. The single greatest barrier to automotive use of lightweight materials is their high cost; therefore, priority is given to activities aimed at reducing costs through development of new materials, forming technologies, and manufacturing processes. The emphasis of the research projects reported in this document was largely on applied research and evaluation of mass savings opportunities through the aggressive application of lightweight materials, advanced computational methods, and the demonstration of production capable manufacturing processes intended for high-volume applications, all directed towards the FreedomCAR Program goals. Priority lightweighting materials include advanced high-strength steels (AHSS), aluminum, magnesium, titanium, and composites such as metal-matrix materials, and glass- and carbon-fiber-reinforced thermosets and thermoplastics. Besides developing valuable new design and material property information, several projects have extensively used computer-based product modeling and simulation technologies to optimize designs and materials usage while addressing the cost-performance issues. The purpose of this Summary Final Closeout Report is to document the successes, degree of progress, technology dissemination efforts, and lessons learned.« less

FY 2012 Lightweight Materials Annual Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Warren, David C.

2013-04-15

The FY 2012 Annual Progress Report for Lightweight Materials provides a detailed description of the activities and technical accomplishments which focuses on the development and validation of advanced materials and manufacturing technologies to significantly reduce light and heavy duty vehicle weight without compromising other attributes such as safety, performance, recyclability, and cost.

Laser hybrid joining of plastic and metal components for lightweight components

NASA Astrophysics Data System (ADS)

Rauschenberger, J.; Cenigaonaindia, A.; Keseberg, J.; Vogler, D.; Gubler, U.; Liébana, F.

2015-03-01

Plastic-metal hybrids are replacing all-metal structures in the automotive, aerospace and other industries at an accelerated rate. The trend towards lightweight construction increasingly demands the usage of polymer components in drive trains, car bodies, gaskets and other applications. However, laser joining of polymers to metals presents significantly greater challenges compared with standard welding processes. We present recent advances in laser hybrid joining processes. Firstly, several metal pre-structuring methods, including selective laser melting (SLM) are characterized and their ability to provide undercut structures in the metal assessed. Secondly, process parameter ranges for hybrid joining of a number of metals (steel, stainless steel, etc.) and polymers (MABS, PA6.6-GF35, PC, PP) are given. Both transmission and direct laser joining processes are presented. Optical heads and clamping devices specifically tailored to the hybrid joining process are introduced. Extensive lap-shear test results are shown that demonstrate that joint strengths exceeding the base material strength (cohesive failure) can be reached with metal-polymer joining. Weathering test series prove that such joints are able to withstand environmental influences typical in targeted fields of application. The obtained results pave the way toward implementing metalpolymer joints in manufacturing processes.

New technologies for the actuation and controls of large aperture lightweight quality mirrors

NASA Technical Reports Server (NTRS)

Lih, S. S.; Yang, E. H.; Gullapalli, S. N.; Flood, R.

2003-01-01

This paper presents a set of candidate components: MEMS based large stroke (>100 microns) ultra lightweight (0.01 gm) discrete inch worm actuator technology, and a distributed actuator technology, in the context of a novel lightweight active flexure-hinged substrate concept that uses the nanolaminate face sheet.

Innovative and Highly Productive Joining Technologies for Multi-Material Lightweight Car Body Structures

NASA Astrophysics Data System (ADS)

Meschut, G.; Janzen, V.; Olfermann, T.

2014-05-01

Driven by increasing costs for energy and raw material and especially by the European CO2-emission laws, automotive industry faces the challenge to develop more lightweight and at the same time still rigid and crash-stable car bodies, that are affordable for large-scale production. The implementation of weight-reduced constructions depends not only on the availability of lightweight materials and related forming technologies, but also on cost-efficient and reliable joining technologies suitable for multi-material design. This article discusses the challenges and requirements for these technologies, based on the example of joining aluminium with press-hardened boron steels, what is considered as a very important material combination for affordable future lightweight mobility. Besides a presentation of recent developments for extending the process limits of conventional mechanical joining methods, new promising technologies such as resistance element welding are introduced. In addition, the performance, advantages, and disadvantages of the presented technologies are compared and discussed.

Influencing Factors and Workpiece's Microstructure in Laser-Assisted Milling of Titanium

NASA Astrophysics Data System (ADS)

Wiedenmann, R.; Liebl, S.; Zaeh, M. F.

Today's lightweight components have to withstand increasing mechanical and thermal loads. Therefore, advanced materials substitute conventional materials like steel or aluminum alloys. Using these high-performance materials the associated costs become prohibitively high. This paper presents the newest fundamental investigations on the hybrid process 'laser-assisted milling' which is an innovative technique to process such materials. The focus is on the validation of a numerical database for a CAD/CAM process control unit which is calculated by using simulation. Prior to that, the influencing factors on a laser-assisted milling process are systematically investigated using Design of Experiments (DoE) to identify the main influencing parameters coming from the laser and the milling operation.

Multistage Passive Cooler for Spaceborne Instruments

NASA Technical Reports Server (NTRS)

Rodriquez, Jose I.

2007-01-01

A document describes a three-stage passive radiative cooler for a cryogenic spectrometer to be launched into a low orbit around the Moon. This cooler is relatively lightweight and compact, and its basic design is scalable and otherwise adaptable to other applications in which there are requirements for cooling instrumentation in orbit about planets. The cooler includes multiple lightweight flat radiator blades alternating with cylindrical parabolic infrared reflectors. The radiator blades are oriented at an angle chosen to prevent infrared loading from the Moon limb at the intended orbital altitude and attitude. The reflectors are shaped and oriented to position their foci outside the radiator surfaces. There are six radiator-blade/reflector pairs - two pairs for each stage of cooling. The radiator blades and reflectors are coated on their front and back surfaces with materials having various infrared emissivities, infrared reflectivities, and solar reflectivities so as to maximize infrared radiation to cold outer space and minimize inadvertent solar heating. The radiator blades and reflectors are held in place by a lightweight support structure, the components of which are designed to satisfy a complex combination of thermal and mechanical requirements.

Vibration, acoustic, and shock design and test criteria for components on the Solid Rocket Boosters (SRB), Lightweight External Tank (LWT), and Space Shuttle Main Engines (SSME)

NASA Technical Reports Server (NTRS)

1984-01-01

The vibration, acoustics, and shock design and test criteria for components and subassemblies on the space shuttle solid rocket booster (SRB), lightweight tank (LWT), and main engines (SSME) are presented. Specifications for transportation, handling, and acceptance testing are also provided.

A lightweight solar array study

NASA Technical Reports Server (NTRS)

Josephs, R. H.

1977-01-01

A sample module was assembled to model a portion of a flexible extendable solar array, a type that promises to become the next generation of solar array design. The resulting study of this module is intended to provide technical support to the array designer for lightweight component selection, specifications, and tests. Selected from available lightweight components were 127-micron-thick wrap-around contacted solar cells, 34- micron-thick sputtered glass covers, and as a substrate a 13-micron-thick polyimide film clad with a copper printed circuit. Each component displayed weaknesses. The thin solar cells had excessive breakage losses. Sputtered glass cover adhesion was poor, and the covered cell was weaker than the cell uncovered. Thermal stresses caused some cell delamination from the model solar array substrate.

FY2013 Lightweight Materials R&D Annual Progress Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

none,

2014-02-01

As part of the U.S. Department of Energy’s (DOE’s) Vehicle Technologies Program (VTO), the Lightweight Materials (LM) activity focuses on the development and validation of advanced materials and manufacturing technologies to significantly reduce light and heavy duty vehicle weight without compromising other attributes such as safety, performance, recyclability, and cost.

Additive-free thick graphene film as an anode material for flexible lithium-ion batteries

NASA Astrophysics Data System (ADS)

Rana, Kuldeep; Kim, Seong Dae; Ahn, Jong-Hyun

2015-04-01

This work demonstrates a simple route to develop mechanically flexible electrodes for Li-ion batteries (LIBs) that are usable as lightweight effective conducting networks for both cathodes and anodes. Removing electrochemically dead elements, such as binders, conducting agents and metallic current collectors, from the battery components will allow remarkable progress in this area. To investigate the feasibility of using thick, additive-free graphene films as anodes for flexible LIBs, we have synthesized and tested thick, additive-free, freestanding graphene films as anodes, first in a coin cell and further in a flexible full cell. As an anode material in a half cell, it showed a discharge capacity of about 350 mA h g-1 and maintained nearly this capacity over 50 cycles at various current rates. This film was also tested as an anode material in a full cell with a LiCoO2 cathode and showed good electrochemical performance. Because the graphene-based flexible film showed good performance in half- and full coin cells, we used this film as a flexible anode for flexible LIBs. No conducting agent or binder was used in the anode side, which helped in realizing the flexible LIBs. Using this, we demonstrate a thin, lightweight and flexible lithium ion battery with good electrochemical performance in both its flat and bent states.This work demonstrates a simple route to develop mechanically flexible electrodes for Li-ion batteries (LIBs) that are usable as lightweight effective conducting networks for both cathodes and anodes. Removing electrochemically dead elements, such as binders, conducting agents and metallic current collectors, from the battery components will allow remarkable progress in this area. To investigate the feasibility of using thick, additive-free graphene films as anodes for flexible LIBs, we have synthesized and tested thick, additive-free, freestanding graphene films as anodes, first in a coin cell and further in a flexible full cell. As an anode material in a half cell, it showed a discharge capacity of about 350 mA h g-1 and maintained nearly this capacity over 50 cycles at various current rates. This film was also tested as an anode material in a full cell with a LiCoO2 cathode and showed good electrochemical performance. Because the graphene-based flexible film showed good performance in half- and full coin cells, we used this film as a flexible anode for flexible LIBs. No conducting agent or binder was used in the anode side, which helped in realizing the flexible LIBs. Using this, we demonstrate a thin, lightweight and flexible lithium ion battery with good electrochemical performance in both its flat and bent states. Electronic supplementary information (ESI) available. See DOI: 10.1039/c4nr06082b

Polymer-based composites for aerospace: An overview of IMAST results

NASA Astrophysics Data System (ADS)

Milella, Eva; Cammarano, Aniello

2016-05-01

This paper gives an overview of technological results, achieved by IMAST, the Technological Cluster on Engineering of Polymeric Composite Materials and Structures, in the completed Research Projects in the aerospace field. In this sector, the Cluster developed different solutions: lightweight multifunctional fiber-reinforced polymer composites for aeronautic structures, advanced manufacturing processes (for the optimization of energy consumption and waste reduction) and multifunctional components (e.g., thermal, electrical, acoustic and fire resistance).

Filling material for a buried cavity in a collapse area using light-weighted foam and active feldspar

NASA Astrophysics Data System (ADS)

Cho, Jin Woo; Lee, Ju-hyoung; Kim, Sung-Wook; Choi, Eun-Kyeong

2017-04-01

Concrete which is generally used as filling material for a buried cavity has very high strength but significantly high self-load is considered its disadvantage. If it is used as filling material, the second collapse due to additional load, causing irreversible damage. If light-weighted foam and active feldspar are used to solve this problem, the second collapse can be prevented by reducing of self-load of filling material. In this study, the specimen was produced by mixing light-weighted foam, active feldspar and cement, and changes in the density, unconfined compressive strength and hydraulic conductivity were analyzed. Using the light-weighted foam could enable the adjustment of density of specimen between 0.5 g/cm3 and 1.7 g/cm3, and if the mixing ratio of the light-weighted foam increases, the specimen has more pores and smaller range of cross-sectional area. It is confirmed that it has direct correlation with the density, and if the specimen has more pores, the density of the specimen is lowered. The density of the specimen influences the unconfined compressive strength and the hydraulic conductivity, and it was also confirmed that the unconfined compressive strength could be adjusted between 0.6 MPa and 8 MPa and the hydraulic conductivity could be adjusted between 10-9cm/sec and 10-3cm/sec. These results indicated that we can adjust unconfined compressive strength and hydraulic conductivity of filling materials by changing the mixing amount of lightweight-weighted foam according to the requirements of the field condition. Keywords: filling material, buried cavity, light-weighted foam, feldspar Acknowledgement This research was supported by a Grant from a Strategic Research Project (Horizontal Drilling and Stabilization Technologies for Urban Search and Rescue (US&R) Operation) funded by the Korea Institute of Civil Engineering and Building Technology.

Laser-assisted manufacturing of super-insulation materials

NASA Astrophysics Data System (ADS)

Wang, Zhen; Zhang, Tao; Park, Byung Kyu; Lee, Woo Il; Hwang, David

2017-02-01

Being lightweight materials with good mechanical and thermal properties, hollow glass micro-particles (HGMPs) have been widely studied for multiple applications. In this study, it is shown that by using reduced binder fraction diluted in solvent, enables minimal contacts among the HGMPs assisted by a natural capillary trend, as confirmed by optical and electron microscope imaging. Such material architecture fabricated in a composite level proves to have enhanced thermal insulation performance through quantitative thermal conductivity measurement. Mechanical strength has also been evaluated in terms of particle-binder bonding by tensile test via in-situ microscope inspection. Effect of laser treatment was examined for further improvement of thermal and mechanical properties by selective binder removal and efficient redistribution of remaining binder components. The fabricated composite materials have potential applications to building insulation materials for their scalable manufacturing nature, improved thermal insulation performance and reasonable mechanical strength. Further studies are needed to understand mechanical and thermal properties of the resulting composites, and key fabrication mechanisms involved with laser treatment of complex multi-component and multi-phase systems.

Semisolid forming of S48C steel grade

NASA Astrophysics Data System (ADS)

Plata, Gorka; Lozares, Jokin; Azpilgain, Zigor; Hurtado, Iñaki; Loizaga, Iñigo; Idoyaga, Zuriñe

2017-10-01

Steel production and component manufacturing industries have to face the challenge of globalization, trying to overcome the economic pressure to remain competitive. Moreover, the lightweighting trend of the latter years implies an even higher challenge to maintain the steel use. Therefore, advanced manufacturing processes will be the cornerstone. In this field, Semisolid forming (SSF) has demonstrated the capability of obtaining complex geometries and saving raw material and energy. Despite it is complicated the SSF of sound components, in Mondragon Unibertsitatea it has been successfully demonstrated the capability of producing strong enough automotive components with 42CrMo4 steel grade. In this work, we demonstrate the capability of SSF S48C steel grade with great mechanical properties.

Materials Needs for Future In-Space Propulsion Systems

NASA Technical Reports Server (NTRS)

Johnson, Les

2006-01-01

NASA's In-Space Propulsion Technology Project is developing the next generation of in-space propulsion systems in support of robotic exploration missions throughout the solar system. The propulsion technologies being developed are non-traditional and have stressing materials performance requirements. Earth-storable bipropellant performance is constrained by temperature limitations of the columbium used in the chamber. Iridium/rhenium (Ir/Re) is now available and has been implemented in initial versions of Earth- Storable rockets with specific impulses about 10 seconds higher than columbium rocket chambers. New chamber fabrication methods that improve process and performance of Ir/Re and other promising material systems are needed. The solar sail is a propellantless propulsion system that gains momentum by reflecting sunlight. The sails need to be very large in area (from 10000 sq m up to 62500 sq m) yet be very lightweight in order to achieve adequate accelerations for realistic mission times. Lightweight materials that can be manufactured in thicknesses of less than 1 micron and that are not harmed by the space environment are desired. Blunt Body Aerocapture uses aerodynamic drag to slow an approaching spacecraft and insert it into a science orbit around any planet or moon with an atmosphere. The spacecraft is enclosed by a rigid aeroshell that protects it from the entry heating and aerodynamic environment. Lightweight, high-temperature structural systems, adhesives, insulators, and ablatives are key components for improving aeroshell efficiencies at heating rates of 1000-2000 W/sq cm and beyond. Inflatable decelerators in the forms of ballutes and inflatable aeroshells will use flexible polymeric thin film materials, high temperature fabrics, and structural adhesives. The inflatable systems will be tightly packaged during cruise and will be inflated prior to entry interface at the destination. Materials must maintain strength and flexibility while packaged at cold temperatures (-100 C) for up to 10 years and then withstand the high temperatures (500 C) encountered during aerocapture.

Materials for a new generation of vehicles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Grobstein, T.

1995-12-31

The Partnership for a New Generation of Vehicles (PNGV) is a national initiative with three goals: first, to significantly improve national competitiveness in manufacturing; second, to implement commercially viable innovations from ongoing research on conventional vehicles, and third, to develop a vehicle to achieve up to three times the fuel efficiency of today`s comparable vehicle (i.e., the 1994 Chrysler Concorde, Ford Taurus, and Chevrolet Lumina). Note this vehicle will have the equivalent customer purchase price of today`s vehicles adjusted for economics, while meeting the customers` needs for quality, performance, and utility. Eight federal agencies are currently contributing to these goals,more » as well as the three principal US automobile manufacturers, numerous automotive component suppliers, research laboratories, and universities. Materials research and development is a significant effort within PNGV. The goals in this area include development of lightweight, recyclable materials for structural applications, high strength, long-life, high temperature materials for engine components, improved materials for alternative propulsion and energy storage systems, and cost-effective process technologies and component fabrication methods. Application of advanced materials to automobiles will involve consideration of diverse factors, including weight savings, affordability, recyclability, crashworthiness, repairability, and manufacturability.« less

Lightweight Thermoformed Structural Components and Optics

NASA Technical Reports Server (NTRS)

Zeiders, Glenn W.; Bradford, Larry J.

2004-01-01

A technique that involves the use of thermoformed plastics has been developed to enable the design and fabrication of ultra-lightweight structural components and mirrors for use in outer space. The technique could also be used to produce items for special terrestrial uses in which minimization of weight is a primary design consideration. Although the inherent strengths of thermoplastics are clearly inferior to those of metals and composite materials, thermoplastics offer a distinct advantage in that they can be shaped, at elevated temperatures, to replicate surfaces (e.g., prescribed mirror surfaces) precisely. Furthermore, multiple elements can be bonded into structures of homogeneous design that display minimal thermal deformation aside from simple expansion. The design aspect of the present technique is based on the principle that the deflection of a plate that has internal structure depends far more on the overall thickness than on the internal details; thus, a very stiff, light structure can be made from thin plastic that is heatformed to produce a sufficiently high moment of inertia. General examples of such structures include I beams and eggcrates.

Lightweight Radiator System for a Spacecraft

NASA Technical Reports Server (NTRS)

Copeland, Robert J.; Mason, Georgia; Weislogel, Mark M.

2005-01-01

Three documents describe various aspects of a proposed lightweight, deployable radiator system for dissipating excess heat from the life-support system of a habitable spacecraft. The first document focuses on a radiator tube that would include a thin metal liner surrounded and supported by a thicker carbon-fiber-reinforced composite tubular structure that, in turn, would be formed as part of a unitary composite radiator-fin structure consisting mostly of a sheet of reticulated vitreous carbon laminated between carbon-fiber-reinforced face sheets. The thermal and mechanical properties, including the anisotropies, of the component materials are taken into account in the design. The second document describes thermo-structural bumpers, in the form of exterior multiple-ply carbon-fiber sheets enclosing hollows on opposite sides of a radiator fin, which would protect the radiator tube against impinging micrometeors and orbital debris. The third document describes a radiator system that would include multiple panels containing the aforementioned components, among others. The system would also include mechanisms for deploying the panels from compact stowage. Deployment would not involve breaking and remaking of fluid connections to the radiator panels.

Development of Lightweight CubeSat with Multi-Functional Structural Battery Systems

NASA Technical Reports Server (NTRS)

Karkkainen, Ryan L.; Hunter, Roger C.; Baker, Christopher

2017-01-01

This collaborative multi-disciplinary effort aims to develop a lightweight, 1-unit (1U) CubeSat (10x10x10 cm) which utilizes improved and fully integrated structural battery materials for mission life extension, larger payload capability, and significantly reduced mass.The electrolytic carbon fiber material serves the multifunctional capacitive energy system as both a lightweight, load bearing structure and an electrochemical battery system. This implementation will improve traditional multifunctional energy storage concepts with a highly effective energy storage capability.

Damage prognosis of adhesively-bonded joints in laminated composite structural components of unmanned aerial vehicles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Farrar, Charles R; Gobbato, Maurizio; Conte, Joel

2009-01-01

The extensive use of lightweight advanced composite materials in unmanned aerial vehicles (UAVs) drastically increases the sensitivity to both fatigue- and impact-induced damage of their critical structural components (e.g., wings and tail stabilizers) during service life. The spar-to-skin adhesive joints are considered one of the most fatigue sensitive subcomponents of a lightweight UAV composite wing with damage progressively evolving from the wing root. This paper presents a comprehensive probabilistic methodology for predicting the remaining service life of adhesively-bonded joints in laminated composite structural components of UAVs. Non-destructive evaluation techniques and Bayesian inference are used to (i) assess the current statemore » of damage of the system and, (ii) update the probability distribution of the damage extent at various locations. A probabilistic model for future loads and a mechanics-based damage model are then used to stochastically propagate damage through the joint. Combined local (e.g., exceedance of a critical damage size) and global (e.g.. flutter instability) failure criteria are finally used to compute the probability of component failure at future times. The applicability and the partial validation of the proposed methodology are then briefly discussed by analyzing the debonding propagation, along a pre-defined adhesive interface, in a simply supported laminated composite beam with solid rectangular cross section, subjected to a concentrated load applied at mid-span. A specially developed Eliler-Bernoulli beam finite element with interlaminar slip along the damageable interface is used in combination with a cohesive zone model to study the fatigue-induced degradation in the adhesive material. The preliminary numerical results presented are promising for the future validation of the methodology.« less

Acoustic emission monitoring of crack propagation in additively manufactured and conventional titanium components

DOE Office of Scientific and Technical Information (OSTI.GOV)

Strantza, Maria; Van Hemelrijck, Danny; Guillaume, Patrick

We report that additive manufacturing (AM) is a novel and innovative production technology that can produce complex and lightweight engineering products. In AM components, as in all engineering materials, fatigue is considered as one of the principle causes of unexpected failure. In order to detect, localise and characterise cracks in various material components and metals, acoustic emission (AE) is used as a non-destructive monitoring technique. One of the main advantages of AE is that it can be also used for dynamic damage characterisation and specifically for crack propagation monitoring. In this research, we use AE to monitor the fatigue crackmore » growth behaviour of Ti6Al4V components under four-point bending. The samples were produced by means of AM as well as conventional material. Notched and unnotched specimens were investigated with respect to the crack severity and crack detection using AE. The main AE signal parameters –such as cumulative events, hits, duration, average frequency and rise time– were evaluated and indicate sensitivity to damage propagation in order to lead to a warning against the final fracture occurrence. Finally, this is the first time that AE is applied in AM components under fatigue.« less

Acoustic emission monitoring of crack propagation in additively manufactured and conventional titanium components

DOE PAGES

Strantza, Maria; Van Hemelrijck, Danny; Guillaume, Patrick; ...

2017-05-31

We report that additive manufacturing (AM) is a novel and innovative production technology that can produce complex and lightweight engineering products. In AM components, as in all engineering materials, fatigue is considered as one of the principle causes of unexpected failure. In order to detect, localise and characterise cracks in various material components and metals, acoustic emission (AE) is used as a non-destructive monitoring technique. One of the main advantages of AE is that it can be also used for dynamic damage characterisation and specifically for crack propagation monitoring. In this research, we use AE to monitor the fatigue crackmore » growth behaviour of Ti6Al4V components under four-point bending. The samples were produced by means of AM as well as conventional material. Notched and unnotched specimens were investigated with respect to the crack severity and crack detection using AE. The main AE signal parameters –such as cumulative events, hits, duration, average frequency and rise time– were evaluated and indicate sensitivity to damage propagation in order to lead to a warning against the final fracture occurrence. Finally, this is the first time that AE is applied in AM components under fatigue.« less

Power Electronics Packaging Reliability | Transportation Research | NREL

Science.gov Websites

interface materials, are a key enabling technology for compact, lightweight, low-cost, and reliable power , reliability, and cost. High-temperature bonded interface materials are an important facilitating technology for compact, lightweight, low-cost, reliable power electronics packaging that fully utilizes the

Microstructural Characteristics of High Rate Plastic Deformation in Elektron (trademark) WE43 Magnesium Alloy

DTIC Science & Technology

2012-04-01

extremely lightweight metal , weighing 30% less than aluminum, and 70% less than steel, it also has the highest strength-to-weight ratio among any of the...commonly used non- ferrous and ferrous metallic materials [2]. As magnesium is used more often in structural components, there is an increasing...mechanism of deformation in metals has been shown to be shear localization [6] [7]. The shear localization seen in high strain rate deformation is

Using shredded waste tires as a lightweight fill material for road subgrades : summary report

DOT National Transportation Integrated Search

1994-04-01

Waste tires have been a disposal problem in the past and are continuing to accumulate throughout the U.S. today. Using shredded waste tires as a lightweight fill material for road construction has proven to be a beneficial use of this waste product. ...

Using shredded waste tires as a lightweight fill material for road subgrades. Summary report

DOT National Transportation Integrated Search

1994-04-01

Waste tires have been a disposal problem in the past and are continuing to accumulate throughout the U.S. today. Using shredded waste tires as a lightweight fill material for road construction has proven to be a beneficial use of this waste product. ...

Program Evaluation - Automotive Lightweighting Materials Program Research and Development Projects Assessment of Benefits - Case Studies No. 2

DOE Office of Scientific and Technical Information (OSTI.GOV)

Das, S.

This report is the second of a series of studies to evaluate research and development (R&D) projects funded by the Automotive Lightweighting Materials (ALM) Program of the Office of Advanced Automotive Technologies (OAAT) of the U.S. Department of Energy (DOE). The objectives of the program evaluation are to assess short-run outputs and long-run outcomes that may be attributable to the ALM R&D projects. The ALM program focuses on the development and validation of advanced technologies that significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost. Funded projects range from fundamentalmore » materials science research to applied research in production environments. Collaborators on these projects include national laboratories, universities, and private sector firms, such as leading automobile manufacturers and their suppliers. Three ALM R&D projects were chosen for this evaluation: Design and Product Optimization for Cast Light Metals, Durability of Lightweight Composite Structures, and Rapid Tooling for Functional Prototyping of Metal Mold Processes. These projects were chosen because they have already been completed. The first project resulted in development of a comprehensive cast light metal property database, an automotive application design guide, computerized predictive models, process monitoring sensors, and quality assurance methods. The second project, the durability of lightweight composite structures, produced durability-based design criteria documents, predictive models for creep deformation, and minimum test requirements and suggested test methods for establishing durability properties and characteristics of random glass-fiber composites for automotive structural composites. The durability project supported Focal Project II, a validation activity that demonstrates ALM program goals and reduces the lead time for bringing new technology into the marketplace. Focal projects concentrate on specific classes of materials and nonproprietary components and are done jointly by DOE and the Automotive Composites Consortium of U.S. Council for Automotive Research (USCAR). The third project developed a rapid tooling process that reduces tooling time, originally some 48-52 weeks, to less than 12 weeks by means of rapid generation of die-casting die inserts and development of generic holding blocks, suitable for use with large casting applications. This project was conducted by the United States Automotive Materials Partnership, another USCAR consortium.« less

A methodology for choosing candidate materials for the fabrication of planetary space suit structures

NASA Technical Reports Server (NTRS)

Jacobs, Gilda

1990-01-01

A study of space suit structures and materials is under way at NASA Ames Research Center, Moffett Field, CA. The study was initiated by the need for a generation of lightweight space suits to be used in future planetary Exploration Missions. This paper provides a brief description of the Lunar and Mars environments and reviews what has been done in the past in the design and development of fabric, metal, and composite suit components in order to establish criteria for comparison of promising candidate materials and space suit structures. Environmental factors and mission scenarios will present challenging material and structural requirements; thus, a program is planned to outline the methodology used to identify materials and processes for producing candidate space suit structures which meet those requirements.

Lightweight Combat Vehicle S&T Initiatives

DTIC Science & Technology

2015-08-01

1 U.S. ARMY TANK AUTOMOTIVE RESEARCH, DEVELOPMENT AND ENGINEERING CENTER Lightweight Combat Vehicle S &T Initiatives Dr. Richard Gerth Ground Systems...00-00-2015 to 00-00-2015 4. TITLE AND SUBTITLE Lightweight Combat Vehicle S &T Initiatives Global Automotive Lightweight Materials 2015 - August...18-20 2015 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR( S ) Richard Gerth 5d. PROJECT NUMBER 5e. TASK NUMBER 5f

Lewis Researcher in the Materials and Stresses Building

NASA Image and Video Library

1952-12-21

A materials researcher at the NACA’s Lewis Flight Propulsion Laboratory examines a surface crack detection apparatus in the Materials and Stresses Building during December 1952. Materials research was an important aspect of propulsion technology. Advanced engine systems relied upon alloys, and later composites, that were strong, lightweight, and impervious to high temperatures. Jet engines which became increasingly popular in the late 1940s, produced much higher temperatures than piston engines. These higher temperatures stressed engine components, particularly turbines. Although Lewis materials research began during World War II, the Materials and Thermodynamics Division was not created until 1949. Its primary laboratories were located in the Materials and Stresses Building. The group sought to create new, improved materials and to improve engine design through increased understanding of materials. The Lewis materials researchers of the 1950s made contributions to nickel-aluminum alloys, cermet blades, metal matrix composites, oxide dispersion strengthened superalloys, and universal slopes.

Early detection of materials degradation

NASA Astrophysics Data System (ADS)

Meyendorf, Norbert

2017-02-01

Lightweight components for transportation and aerospace applications are designed for an estimated lifecycle, taking expected mechanical and environmental loads into account. The main reason for catastrophic failure of components within the expected lifecycle are material inhomogeneities, like pores and inclusions as origin for fatigue cracks, that have not been detected by NDE. However, material degradation by designed or unexpected loading conditions or environmental impacts can accelerate the crack initiation or growth. Conventional NDE methods are usually able to detect cracks that are formed at the end of the degradation process, but methods for early detection of fatigue, creep, and corrosion are still a matter of research. For conventional materials ultrasonic, electromagnetic, or thermographic methods have been demonstrated as promising. Other approaches are focused to surface damage by using optical methods or characterization of the residual surface stresses that can significantly affect the creation of fatigue cracks. For conventional metallic materials, material models for nucleation and propagation of damage have been successfully applied for several years. Material microstructure/property relations are well established and the effect of loading conditions on the component life can be simulated. For advanced materials, for example carbon matrix composites or ceramic matrix composites, the processes of nucleation and propagation of damage is still not fully understood. For these materials NDE methods can not only be used for the periodic inspections, but can significantly contribute to the material scientific knowledge to understand and model the behavior of composite materials.

Higher-Order Theory: Structural/MicroAnalysis Code (HOTSMAC) Developed

NASA Technical Reports Server (NTRS)

Arnold, Steven M.

2002-01-01

The full utilization of advanced materials (be they composite or functionally graded materials) in lightweight aerospace components requires the availability of accurate analysis, design, and life-prediction tools that enable the assessment of component and material performance and reliability. Recently, a new commercially available software product called HOTSMAC (Higher-Order Theory--Structural/MicroAnalysis Code) was jointly developed by Collier Research Corporation, Engineered Materials Concepts LLC, and the NASA Glenn Research Center under funding provided by Glenn's Commercial Technology Office. The analytical framework for HOTSMAC is based on almost a decade of research into the coupled micromacrostructural analysis of heterogeneous materials. Consequently, HOTSMAC offers a comprehensive approach for analyzing/designing the response of components with various microstructural details, including certain advantages not always available in standard displacement-based finite element analysis techniques. The capabilities of HOTSMAC include combined thermal and mechanical analysis, time-independent and time-dependent material behavior, and internal boundary cells (e.g., those that can be used to represent internal cooling passages, see the preceding figure) to name a few. In HOTSMAC problems, materials can be randomly distributed and/or functionally graded (as shown in the figure, wherein the inclusions are distributed linearly), or broken down by strata, such as in the case of thermal barrier coatings or composite laminates.

Evaluation of the Effects of Crushed and Expanded Waste Glass Aggregates on the Material Properties of Lightweight Concrete Using Image-Based Approaches

PubMed Central

Abd Elrahman, Mohamed; Sikora, Pawel; Rucinska, Teresa; Horszczaruk, Elzbieta

2017-01-01

Recently, the recycling of waste glass has become a worldwide issue in the reduction of waste and energy consumption. Waste glass can be utilized in construction materials, and understanding its effects on material properties is crucial in developing advanced materials. In this study, recycled crushed and expanded glasses are used as lightweight aggregates for concrete, and their relation to the material characteristics and properties is investigated using several approaches. Lightweight concrete specimens containing only crushed and expanded waste glass as fine aggregates are produced, and their pore and structural characteristics are examined using image-based methods, such as scanning electron microscopy (SEM), X-ray computed tomography (CT), and automated image analysis (RapidAir). The thermal properties of the materials are measured using both Hot Disk and ISOMET devices to enhance measurement accuracy. Mechanical properties are also evaluated, and the correlation between material characteristics and properties is evaluated. As a control group, a concrete specimen with natural fine sand is prepared, and its characteristics are compared with those of the specimens containing crushed and expanded waste glass aggregates. The obtained results support the usability of crushed and expanded waste glass aggregates as alternative lightweight aggregates. PMID:29186854

Evaluation of the Effects of Crushed and Expanded Waste Glass Aggregates on the Material Properties of Lightweight Concrete Using Image-Based Approaches.

PubMed

Chung, Sang-Yeop; Abd Elrahman, Mohamed; Sikora, Pawel; Rucinska, Teresa; Horszczaruk, Elzbieta; Stephan, Dietmar

2017-11-25

Recently, the recycling of waste glass has become a worldwide issue in the reduction of waste and energy consumption. Waste glass can be utilized in construction materials, and understanding its effects on material properties is crucial in developing advanced materials. In this study, recycled crushed and expanded glasses are used as lightweight aggregates for concrete, and their relation to the material characteristics and properties is investigated using several approaches. Lightweight concrete specimens containing only crushed and expanded waste glass as fine aggregates are produced, and their pore and structural characteristics are examined using image-based methods, such as scanning electron microscopy (SEM), X-ray computed tomography (CT), and automated image analysis (RapidAir). The thermal properties of the materials are measured using both Hot Disk and ISOMET devices to enhance measurement accuracy. Mechanical properties are also evaluated, and the correlation between material characteristics and properties is evaluated. As a control group, a concrete specimen with natural fine sand is prepared, and its characteristics are compared with those of the specimens containing crushed and expanded waste glass aggregates. The obtained results support the usability of crushed and expanded waste glass aggregates as alternative lightweight aggregates.

Replicated Composite Optics Development

NASA Technical Reports Server (NTRS)

Engelhaupt, Darell

1997-01-01

Advanced optical systems for applications such as grazing incidence Wolter I x-ray mirror assemblies require extraordinary mirror surfaces in ten-ns of fine surface finish and figure. The impeccable mirror surface is on the inside of the rotational mirror form. One practical method of producing devices with these requirements is to first fabricate an exterior surface for the optical device then replicate that surface to have the inverse component with lightweight characteristics. The replicate optic is not better than the master or mandrel from which it is made. This task is a continuance of previous studies to identify methods and materials for forming these extremely low roughness optical components.

Graphite composite truss welding and cap section forming subsystems. Volume 2: Program results

NASA Technical Reports Server (NTRS)

1980-01-01

The technology required to develop a beam builder which automatically fabricates long, continuous, lightweight, triangular truss members in space from graphite/thermoplastics composite materials is described. Objectives are: (1) continue the development of forming and welding methods for graphite/thermoplastic (GR/TP) composite material; (2) continue GR/TP materials technology development; and (3) fabricate and structurally test a lightweight truss segment.

Optimization of SMA layers in composite structures to enhance damping

NASA Astrophysics Data System (ADS)

Haghdoust, P.; Cinquemani, S.; Lecis, N.; Bassani, P.

2016-04-01

The performance of lightweight structures can be severely affected by vibration. New design concepts leading to lightweight, slender structural components can increase the vulnerability of the components to failure due to excessive vibration. The intelligent approach to address the problem would be the use of materials which are more capable in dissipating the energy due to their high value of loss factor. Among the different materials available to achieve damping, much attention has been attached to the use of shape memory alloys (SMAs) because of their unique microstructure, leading to good damping capacity. This work describes the design and optimization of a hybrid layered composite structure for the passive suppression of flexural vibrations in slender and light structures. Embedding the SMA layers in composite structure allows to combine different properties: the lightness of the base composite (e.g. fiber glass), the mechanical strength of the insert of metallic material and the relevant damping properties of SMA, in the martensitic phase. In particular, we put our attention on embedding the CuZnAl in the form of thin sheet in a layered composite made by glass fiber reinforced epoxy. By appropriately positioning of the SMA sheets so that they are subjected to the maximum curvature, the damping of the hybrid system can be considerably enhanced. Accordingly analytical method for evaluating the energy dissipation of the thin sheets with different shapes and patterns is developed and is followed by a shape optimization based on genetic algorithm. Eventually different configurations of the hybrid beam structure with different patterns of SMA layer are proposed and compared in the term of damping capacity.

Next-Generation MKIII Lightweight HUT/Hatch Assembly

NASA Technical Reports Server (NTRS)

McCarthy, Mike; Toscano, Ralph

2013-01-01

The MK III (H-1) carbon-graphite/ epoxy Hard Upper Torso (HUT)/Hatch assembly was designed, fabricated, and tested in the early 1990s. The spacesuit represented an 8.3 psi (˜58 kPa) technology demonstrator model of a zero prebreathe suit. The basic torso shell, brief, and hip areas of the suit were composed of a carbon-graphite/epoxy composite lay-up. In its current configuration, the suit weighs approximately 120 lb (˜54 kg). However, since future planetary suits will be designed to operate at 0.26 bar (˜26 kPa), it was felt that the suit's re-designed weight could be reduced to 79 lb (˜35 kg) with the incorporation of lightweight structural materials. Many robust, lightweight structures based on the technologies of advanced honeycomb materials, revolutionary new composite laminates, metal matrix composites, and recent breakthroughs in fullerene fillers and nanotechnology lend themselves well to applications requiring materials that are both light and strong. The major problem involves the reduction in weight of the HUT/ Hatch assembly for use in lunar and/or planetary applications, while at the same time maintaining a robust structural design. The technical objective is to research, design, and develop manufacturing methods that support fa b rica - tion of a lightweight HUT/Hatch assembly using advanced material and geometric redesign as necessary. Additionally, the lightweight HUT/Hatch assembly will interface directly with current MK III hardware. Using the new operating pressure and current MK III (H-1) interfaces as a starting block, it is planned to maximize HUT/Hatch assembly weight reduction through material selection and geometric redesign. A hard upper torso shell structure with rear-entry closure and corresponding hatch will be fabricated. The lightweight HUT/Hatch assembly will retrofit and interface with existing MK III (H-1) hardware elements, providing NASA with immediate "plug-andplay" capability. NASA crewmembers will have a lightweight, robust, life-support system that will minimize fatigue during extraterrestrial surface sojourns. Its unique feature is the utilization of a new and innovative family of materials used by the aerospace industry, which at the time of this reporting has not been used for the proposed application.

Compact and lightweight support platform with electromagnetic disturbance elimination for interferometer on reversed field pinch Keda Torus eXperiment

NASA Astrophysics Data System (ADS)

Mao, Wenzhe; Yuan, Peng; Zheng, Jian; Ding, Weixing; Li, Hong; Lan, Tao; Liu, Adi; Liu, Wandong; Xie, Jinlin

2016-11-01

A compact and lightweight support platform has been used as a holder for the interferometer system on the Keda Torus eXperiment (KTX), which is a reversed field pinch device. The vibration caused by the interaction between the time-varying magnetic field and the induced current driven in the metal optical components has been measured and, following comparison with the mechanical vibration of the KTX device and the refraction effect of the ambient turbulent air flow, has been identified as the primary vibration source in this case. To eliminate this electromagnetic disturbance, nonmetallic epoxy resin has been selected as the material for the support platform and the commercially available metal optical mounts are replaced. Following these optimization steps and mechanical reinforcements, the stability of the interferometer platform has improved significantly. The phase shift caused by the vibration has been reduced to the level of background noise.

Making Ceramic Components For Advanced Aircraft Engines

NASA Technical Reports Server (NTRS)

Franklin, J. E.; Ezis, A.

1994-01-01

Lightweight, oxidation-resistant silicon nitride components containing intricate internal cooling and hydraulic passages and capable of withstanding high operating temperatures made by ceramic-platelet technology. Used to fabricate silicon nitride test articles of two types: components of methane-cooled regenerator for air turbo ramjet engine and components of bipropellant injector for rocket engine. Procedures for development of more complex and intricate components established. Technology has commercial utility in automotive, aircraft, and environmental industries for manufacture of high-temperature components for use in regeneration of fuels, treatment of emissions, high-temperature combustion devices, and application in which other high-temperature and/or lightweight components needed. Potential use in fabrication of combustors and high-temperature acoustic panels for suppression of noise in future high-speed aircraft.

Mechanically Strong, Polymer Cross-linked Aerogels (X-Aerogels)

NASA Technical Reports Server (NTRS)

Leventis, Nicholas

2006-01-01

Aerogels comprise a class of low-density, high porous solid objects consisting of dimensionally quasi-stable self-supported three-dimensional assemblies of nanoparticles. Aerogels are pursued because of properties above and beyond those of the individual nanoparticles, including low thermal conductivity, low dielectric constant and high acoustic impedance. Possible applications include thermal and vibration insulation, dielectrics for fast electronics, and hosting of functional guests for a wide variety of optical, chemical and electronic applications. Aerogels, however, are extremely fragile materials, hence they have found only limited application in some very specialized environments, for example as Cerenkov radiation detectors in certain types of nuclear reactors, aboard spacecraft as collectors of hypervelocity particles (refer to NASA's Stardust program) and as thermal insulators on planetary vehicles on Mars (refer to Sojourner Rover in 1997 and Spirit and Opportunity in 2004). Along these lines, the X-Aerogel is a new NASA-developed strong lightweight material that has resolved the fragility problem of traditional (native) aerogels. X-Aerogels are made by applying a conformal polymer coating on the surfaces of the skeletal nanoparticles of native aerogels (see Scanning Electron Micrographs). Since the relative amounts of the polymeric crosslinker and the backbone are comparable, X-Aerogels can be viewed either as aerogels modified by the templated accumulation of polymer on the skeletal nanoparticles, or as nanoporous polymers made by remplated casting of polymer on a nanostructured framework. The most striking feature of X-Aerogels is that for a nominal 3-fold increase in density (still a ultralighweight material), the mechanical strength can be up to 300 times higher than the strength of the underlying native aerogel. Thus, X-Aerogels combine a multiple of the specific compressive strength of steel, with the the thermal conductivity of styrofoam. X-Aerogels have been demonstrated with several polymers such as polyurethanes/polyureas, epoxies and polyolefins, while crosslinking of approximately 35 different oxide aerogels yields a range of dimensionally stable, porous lightweight materials with unique combinations of structural, magnetic and optical properties. The main theme in materials development for space exploration is multifunction. For example, use of one material for thermal insulation/structural component will free weight for useful payload. In that regard, X-aerogels are evaluated at NASA for cryogenic fuel storage tanks and for spacesuits. Along the same lines, major impact fro X-Aerogels is also expected in commercial applications for thermal/acoustic insulation, in catalytic reformers and converters, in filtration membranes and membranes for fuel cells, as platforms for optical, electrical and magnetic sensors, and as lightweight structural component for aircraft and satellites.

Development of lightweight graphite/polyimide honeycomb. Phase 1: Materials selection

NASA Technical Reports Server (NTRS)

Poesch, J. G.

1971-01-01

The materials selected for the production of extremely lightweight honeycomb sandwich panels are discussed. The resin selected for the first core and face sheet fabrication was Monsanto RS6234 polyimide. The fiber selected for core manufacture was Hercules HT-S, and for face sheets, Hercules HM-S; these selections are discussed.

Performance of lightweight nickel electrodes

NASA Technical Reports Server (NTRS)

Britton, Doris L.

1988-01-01

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen (Ni-H2) batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art (SOA) sintered nickel electrodes. In the present approach, lightweight materials or plaques are used as conductive supports for the nickel hydroxide active material. These plaques (fiber and felt, nickel plated plastic and graphite) are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C 1.37C, 2.0C and 2.74C. The electrodes that pass the initial tests are life cycle tested in a low Earth orbit regime at 80 percent depth of discharge. Different formulations of nickel fiber materials obtained from several manufacturers are currently being tested as possible candidates for nickel electrodes. One particular lightweight fiber mat electrode has accumulated over 3000 cycles to date, with stable capacity and voltage. Life and performance data of this electrode were investigated and presented. Good dimensional stability and active material adherence have been demonstrated in electrodes made from this lightweight plaque.

Optimization of the gypsum-based materials by the sequential simplex method

NASA Astrophysics Data System (ADS)

Doleželová, Magdalena; Vimmrová, Alena

2017-11-01

The application of the sequential simplex optimization method for the design of gypsum based materials is described. The principles of simplex method are explained and several examples of the method usage for the optimization of lightweight gypsum and ternary gypsum based materials are given. By this method lightweight gypsum based materials with desired properties and ternary gypsum based material with higher strength (16 MPa) were successfully developed. Simplex method is a useful tool for optimizing of gypsum based materials, but the objective of the optimization has to be formulated appropriately.

Recent Advances in Near-Net-Shape Fabrication of Al-Li Alloy 2195 for Launch Vehicles

NASA Technical Reports Server (NTRS)

Wagner, John; Domack, Marcia; Hoffman, Eric

2007-01-01

Recent applications in launch vehicles use 2195 processed to Super Lightweight Tank specifications. Potential benefits exist by tailoring heat treatment and other processing parameters to the application. Assess the potential benefits and advocate application of Al-Li near-net-shape technologies for other launch vehicle structural components. Work with manufacturing and material producers to optimize Al-Li ingot shape and size for enhanced near-net-shape processing. Examine time dependent properties of 2195 critical for reusable applications.

Rational construction of a 3D hierarchical NiCo2O4/PANI/MF composite foam as a high-performance electrode for asymmetric supercapacitors.

PubMed

Cui, Fen; Huang, Yunpeng; Xu, Le; Zhao, Yan; Lian, Jiabiao; Bao, Jian; Li, Huaming

2018-04-19

A 3D hierarchical NiCo2O4/PANI/MF composite foam with a macroporous 3D skeleton, a conductive PANI coating and highly electrochemically active NiCo2O4 nanosheets is synthesized as a lightweight and low-cost electrode material. Due to the collaborative contribution of all the components, the prepared composite foam exhibits excellent capacitive performances when incorporated into an asymmetric supercapacitor.

Materials Needs for Future In-space Propulsion Systems

NASA Technical Reports Server (NTRS)

Johnson, Charles Les

2008-01-01

NASA is developing the next generation of in-space propulsion systems in support of robotic exploration missions throughout the solar system. The propulsion technologies being developed are non-traditional and have stressing materials performance requirements. (Chemical Propulsion) Earth-storable chemical bipropellant performance is constrained by temperature limitations of the columbium used in the chamber. Iridium/rhenium (Ir/Re) is now available and has been implemented in initial versions of Earth-Storable rockets with specific impulses (Isp) about 10 seconds higher than columbium rocket chambers. New chamber fabrication methods that improve process and performance of Ir/Re and other promising material systems are needed. (Solar Sail Propulsion) The solar sail is a propellantless propulsion system that gains momentum by reflecting sunlight. The sails need to be very large in area (from 10000 m2 up to 62500 m2) yet be very lightweight in order to achieve adequate accelerations for realistic mission times. Lightweight materials that can be manufactured in thicknesses of less than 1 micron and that are not harmed by the space environment are desired. (Aerocapture) Blunt Body Aerocapture uses aerodynamic drag to slow an approaching spacecraft and insert it into a science orbit around any planet or moon with an atmosphere. The spacecraft is enclosed by a rigid aeroshell that protects it from the entry heating and aerodynamic environment. Lightweight, high-temperature structural systems, adhesives, insulators, and ablatives are key components for improving aeroshell efficiencies at heating rates of 1000-2000 W/cu cm and beyond. Inflatable decelerators in the forms of ballutes and inflatable aeroshells will use flexible polymeric thin film materials, high temperature fabrics, and structural adhesives. The inflatable systems will be tightly packaged during cruise and will be inflated prior to entry interface at the destination. Materials must maintain strength and flexibility while packaged at cold temperatures (_100oC) for up to 10 years and then withstand the high temperatures (500oC) encountered during aerocapture. The presentation will describe the status of each propulsion technology and summarize the materials needed for their implementation.

Comfortable, lightweight safety helmet holds radio transmitter, receiver

NASA Technical Reports Server (NTRS)

Atlas, N. D.

1964-01-01

For two-way radio communication where safety gear is required, a lightweight helmet with few protrusions has been designed. The electronics components and power supply are mounted between the inner and outer shells, and resilient padding is used for the lining.

Modeling, simulation and optimization approaches for design of lightweight car body structures

NASA Astrophysics Data System (ADS)

Kiani, Morteza

Simulation-based design optimization and finite element method are used in this research to investigate weight reduction of car body structures made of metallic and composite materials under different design criteria. Besides crashworthiness in full frontal, offset frontal, and side impact scenarios, vibration frequencies, static stiffness, and joint rigidity are also considered. Energy absorption at the component level is used to study the effectiveness of carbon fiber reinforced polymer (CFRP) composite material with consideration of different failure criteria. A global-local design strategy is introduced and applied to multi-objective optimization of car body structures with CFRP components. Multiple example problems involving the analysis of full-vehicle crash and body-in-white models are used to examine the effect of material substitution and the choice of design criteria on weight reduction. The results of this study show that car body structures that are optimized for crashworthiness alone may not meet the vibration criterion. Moreover, optimized car body structures with CFRP components can be lighter with superior crashworthiness than the baseline and optimized metallic structures.

Shock Response of Lightweight Adobe Masonry

NASA Astrophysics Data System (ADS)

Sauer, C.; Bagusat, F.; Heine, A.; Riedel, W.

2018-06-01

The behavior of a low density and low-strength building material under shock loading is investigated. The considered material is lightweight adobe masonry characterized by a density of 1.2 g/cm3 and a quasi-static uniaxial compressive strength of 2.8 MPa. Planar-plate-impact (PPI) tests with velocities in between 295 and 950 m/s are performed in order to obtain Hugoniot data and to derive parameters for an equation of state (EOS) that captures the occurring phenomenology of porous compaction and subsequent unloading. The resulting EOS description is validated by comparing the experimental free surface velocity time curves with those obtained by numerical simulations of the performed PPI tests. The non-linear compression behavior, including the pore compaction mechanism, constitutes a main ingredient for modelling the response of adobe to blast and high-velocity impact loading. We hence present a modeling approach for lightweight adobe which can be applied to such high rate loading scenarios in future studies. In general, this work shows that PPI tests on lightweight and low-strength geological materials can be used to extract Hugoniot data despite significant material inhomogeneity. Furthermore, we demonstrate that a homogenous material model is able to numerically describe such a material under shock compression and release with a reasonable accuracy.

Shock Response of Lightweight Adobe Masonry

NASA Astrophysics Data System (ADS)

Sauer, C.; Bagusat, F.; Heine, A.; Riedel, W.

2018-04-01

The behavior of a low density and low-strength building material under shock loading is investigated. The considered material is lightweight adobe masonry characterized by a density of 1.2 g/cm3 and a quasi-static uniaxial compressive strength of 2.8 MPa. Planar-plate-impact (PPI) tests with velocities in between 295 and 950 m/s are performed in order to obtain Hugoniot data and to derive parameters for an equation of state (EOS) that captures the occurring phenomenology of porous compaction and subsequent unloading. The resulting EOS description is validated by comparing the experimental free surface velocity time curves with those obtained by numerical simulations of the performed PPI tests. The non-linear compression behavior, including the pore compaction mechanism, constitutes a main ingredient for modelling the response of adobe to blast and high-velocity impact loading. We hence present a modeling approach for lightweight adobe which can be applied to such high rate loading scenarios in future studies. In general, this work shows that PPI tests on lightweight and low-strength geological materials can be used to extract Hugoniot data despite significant material inhomogeneity. Furthermore, we demonstrate that a homogenous material model is able to numerically describe such a material under shock compression and release with a reasonable accuracy.

Bonded repair of composite aircraft structures: A review of scientific challenges and opportunities

NASA Astrophysics Data System (ADS)

Katnam, K. B.; Da Silva, L. F. M.; Young, T. M.

2013-08-01

Advanced composite materials have gained popularity in high-performance structural designs such as aerospace applications that require lightweight components with superior mechanical properties in order to perform in demanding service conditions as well as provide energy efficiency. However, one of the major challenges that the aerospace industry faces with advanced composites - because of their inherent complex damage behaviour - is structural repair. Composite materials are primarily damaged by mechanical loads and/or environmental conditions. If material damage is not extensive, structural repair is the only feasible solution as replacing the entire component is not cost-effective in many cases. Bonded composite repairs (e.g. scarf patches) are generally preferred as they provide enhanced stress transfer mechanisms, joint efficiencies and aerodynamic performance. With an increased usage of advanced composites in primary and secondary aerospace structural components, it is thus essential to have robust, reliable and repeatable structural bonded repair procedures to restore damaged composite components. But structural bonded repairs, especially with primary structures, pose several scientific challenges with the current existing repair technologies. In this regard, the area of structural bonded repair of composites is broadly reviewed - starting from damage assessment to automation - to identify current scientific challenges and future opportunities.

Silicon Carbide Technologies for Lightweighted Aerospace Mirrors

NASA Astrophysics Data System (ADS)

Matson, L.; Chen, M.; Deblonk, B.; Palusinski, I.

The use of monolithic glass and beryllium to produce lightweighted aerospace mirror systems has reached its limits due to the long lead times, high processing costs, environmental effects and launch load/weight requirements. New material solutions and manufacturing processes are required to meet DoD's directed energy weapons, reconnaissance/surveillance, and secured communications needs. Over the past several years the Air Force, MDA, and NASA has focused their efforts on the fabrication, lightweighting, and scale-up of numerous silicon carbide (SiC) based materials. It is anticipated that SiC can be utilized for most applications from cryogenic to high temperatures. This talk will focus on describing the SOA for these (near term) SiC technology solutions for making mirror structural substrates, figuring and finishing technologies being investigated to reduce cost time and cost, and non-destructive evaluation methods being investigated to help eliminate risk. Mirror structural substrates made out of advanced engineered materials (far term solutions) such as composites, foams, and microsphere arrays for ultra lightweighting will also be briefly discussed.

Lightweight ZERODUR mirror blanks: recent advances supporting faster, cheaper, and better spaceborne optical telescope assemblies

NASA Astrophysics Data System (ADS)

Hull, Tony; Westerhoff, Thomas

2014-10-01

While there is no single material solution ideal for all missions, recent advances by SCHOTT in fabricating lightweight mirror blanks makes ZERODUR® a highly viable solution for many spaceborne telescopes. ZERODUR® is a well-characterized very low-expansion material. Monolithic mirrors are made without bonding or fusing out of highly homogeneous and isotropic blanks currently available in sizes up to 4m plus. We will summarize results recently given in a series of papers on the characteristics of these lightweight mirror blanks in sizes from 0.3m up, and describe the method of blank fabrication, with its compatibility to contemporary optical fabrication techniques that control of all optical spatial frequencies. ZERODUR® has a 35 year heritage in space on numerous missions, including the secondary mirror of Hubble, and all the Chandra mirrors. With the lightweighting we will discuss, ZERODUR® is now a high performing, affordable and rapidly produced mirror substrate suitable for lightweight imaging telescopes.

Lightweight concrete with enhanced neutron shielding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brindza, Paul Daniel; Metzger, Bert Clayton

A lightweight concrete containing polyethylene terephthalate in an amount of 20% by total volume. The concrete is enriched with hydrogen and is therefore highly effective at thermalizing neutrons. The concrete can be used independently or as a component of an advanced neutron radiation shielding system.

Optimized adhesives for strong, lightweight, damage-resistant, nanocomposite materials: new insights from natural materials

NASA Astrophysics Data System (ADS)

Hansma, P. K.; Turner, P. J.; Ruoff, R. S.

2007-01-01

From our investigations of natural composite materials such as abalone shell and bone we have learned the following. (1) Nature is frugal with resources: it uses just a few per cent glue, by weight, to glue together composite materials. (2) Nature does not avoid voids. (3) Nature makes optimized glues with sacrificial bonds and hidden length. We discuss how optimized adhesives combined with high specific stiffness/strength structures such as carbon nanotubes or graphene sheets could yield remarkably strong, lightweight, and damage-resistant materials.

High-Glass-Transition-Temperature Polyimides Developed for Reusable Launch Vehicle Applications

NASA Technical Reports Server (NTRS)

Chuang, Kathy; Ardent, Cory P.

2002-01-01

Polyimide composites have been traditionally used for high-temperature applications in aircraft engines at temperatures up to 550 F (288 C) for thousands of hours. However, as NASA shifts its focus toward the development of advanced reusable launch vehicles, there is an urgent need for lightweight polymer composites that can sustain 600 to 800 F (315 to 427 C) for short excursions (hundreds of hours). To meet critical vehicle weight targets, it is essential that one use lightweight, high-temperature polymer matrix composites in propulsion components such as turbopump housings, ducts, engine supports, and struts. Composite materials in reusable launch vehicle components will heat quickly during launch and reentry. Conventional composites, consisting of layers of fabric or fiber-reinforced lamina, would either blister or encounter catastrophic delamination under high heating rates above 300 C. This blistering and delamination are the result of a sudden volume expansion within the composite due to the release of absorbed moisture and gases generated by the degradation of the polymer matrix. Researchers at the NASA Glenn Research Center and the Boeing Company (Long Beach, CA) recently demonstrated a successful approach for preventing this delamination--the use of three-dimensional stitched composites fabricated by resin infusion.

The effects of strain and stress state in hot forming of mg AZ31 sheet

NASA Astrophysics Data System (ADS)

Sherek, Paul A.; Carpenter, Alexander J.; Hector, Louis G.; Krajewski, Paul E.; Carter, Jon T.; Lasceski, Joshua; Taleff, Eric M.

Wrought magnesium alloys, such as AZ31 sheet, are of considerable interest for light-weighting of vehicle structural components. The poor room-temperature ductility of AZ31 sheet has been a hindrance to forming the complex part shapes necessary for practical applications. However, the outstanding formability of AZ31 sheet at elevated temperature provides an opportunity to overcome that problem. Complex demonstration components have already been produced at 450°C using gas-pressure forming. Accurate simulations of such hot, gas-pressure forming will be required for the design and optimization exercises necessary if this technology is to be implemented commercially. We report on experiments and simulations used to construct the accurate material constitutive models necessary for finite-element-method simulations. In particular, the effects of strain and stress state on plastic deformation of AZ31 sheet at 450°C are considered in material constitutive model development. Material models are validated against data from simple forming experiments.

USE OF COMPOSITE MATERIALS AS A COMPONENT OF TUSK FRACTURE MANAGEMENT IN AN ASIAN ELEPHANT (ELEPHAS MAXIMUS) AND AN AFRICAN ELEPHANT (LOXODONTA AFRICANA).

PubMed

Sim, Richard R; Stringer, Elizabeth; Donovan, Dennis; Chappell, Rachael; Flora, Pat; Hall, Jon; Pillay, Selvum; Willis, Benjamin G; McCain, Stephanie

2017-09-01

Tusk fractures in Asian (Elephas maximus) and African elephants (Loxodonta africana) can result in damage to the distal end or to longitudinal cracks, potentially progressing to pulpitis. With pulp exposure, endodontic therapy is the treatment of choice, but conservative therapy has sufficed for some elephants. This manuscript describes the use of composite materials as a component of tusk fracture management. A 7-yr-old male Asian elephant fractured the distal end of both tusks with pulp exposure in one. Capping of each tusk with a Kevlar/fiberglass composite prevented further damage, and a modification allowed care of the exposed pulp tissue. A 34-yr-old male African elephant with a longitudinal crack received a carbon fiber/fiberglass composite circumferential wrap to potentially stabilize the crack. Compression of the crack was achieved, but follow-up was truncated due to bacterial pulpitis. Both cases show that composite material allows for lightweight, durable management of tusk fractures with continued radiographic monitoring.

The scope of additive manufacturing in cryogenics, component design, and applications

NASA Astrophysics Data System (ADS)

Stautner, W.; Vanapalli, S.; Weiss, K.-P.; Chen, R.; Amm, K.; Budesheim, E.; Ricci, J.

2017-12-01

Additive manufacturing techniques using composites or metals are rapidly gaining momentum in cryogenic applications. Small or large, complex structural components are now no longer limited to mere design studies but can now move into the production stream thanks to new machines on the market that allow for light-weight, cost optimized designs with short turnaround times. The potential for cost reductions from bulk materials machined to tight tolerances has become obvious. Furthermore, additive manufacturing opens doors and design space for cryogenic components that to date did not exist or were not possible in the past, using bulk materials along with elaborate and expensive machining processes, e.g. micromachining. The cryogenic engineer now faces the challenge to design toward those new additive manufacturing capabilities. Additionally, re-thinking designs toward cost optimization and fast implementation also requires detailed knowledge of mechanical and thermal properties at cryogenic temperatures. In the following we compile the information available to date and show a possible roadmap for additive manufacturing applications of parts and components typically used in cryogenic engineering designs.

ChemDoodle Web Components: HTML5 toolkit for chemical graphics, interfaces, and informatics.

PubMed

Burger, Melanie C

2015-01-01

ChemDoodle Web Components (abbreviated CWC, iChemLabs, LLC) is a light-weight (~340 KB) JavaScript/HTML5 toolkit for chemical graphics, structure editing, interfaces, and informatics based on the proprietary ChemDoodle desktop software. The library uses and WebGL technologies and other HTML5 features to provide solutions for creating chemistry-related applications for the web on desktop and mobile platforms. CWC can serve a broad range of scientific disciplines including crystallography, materials science, organic and inorganic chemistry, biochemistry and chemical biology. CWC is freely available for in-house use and is open source (GPL v3) for all other uses.Graphical abstractAdd interactive 2D and 3D chemical sketchers, graphics, and spectra to websites and apps with ChemDoodle Web Components.

Lightweight alumina refractory aggregate. Final report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Swansiger, T.G.; Pearson, A.

1996-07-16

Objective was to develop a lightweight, high alumina refractory aggregate for use in various high performance insulating (low thermal conductivity) refractory applications (e.g., in the aluminium, glass, cement, and iron and steel industries). A new aggregate process was developed through bench and pilot-scale experiments involving extrusion of a blend of calcined and activated alumina powders and organic extrusion aids and binders. The aggregate, with a bulk density approaching 2.5 g/cc, exhibited reduced thermal conductivity and adequate fired strength compared to dense tabular aggregate. Refractory manufacturers were moderately enthusiastic over the results. Alcoa prepared an economic analysis for producing lightweight aggregate,more » based on a retrofit of this process into existing Alcoa production facilities. However, a new, competing lightweight aggregate material was developed by another company; this material (Plasmal{trademark})had a significantly more favorable cost base than the Alcoa/DOE material, due to cheap raw materials and fewer processing steps. In late 1995, Alcoa became a distributor of Plasmal. Alcoa estimated that {ge}75% of the market originally envisioned for the Alcoa/DOE aggregate would be taken by Plasmal. Hence, it was decided to terminate the contract without the full- scale demonstration.« less

Foamed lightweight materials made from mixed scrap metal waste powder and sewage sludge ash.

PubMed

Wang, Kuen-Sheng; Chiou, Ing-Jia

2004-10-01

The porous properties and pozzolanic effects of sewage sludge ash (SSA) make it possible to produce lightweight materials. This study explored the effects of different metallic foaming agents, made from waste aluminium products, on the foaming behaviours and engineering characteristics, as well as the microstructure of sewage sludge ash foamed lightweight materials. The results indicated that aluminium powder and mixed scrap metal waste powder possessed similar chemical compositions. After proper pre-treatment, waste aluminium products proved to be ideal substitutes for metallic foaming agents. Increasing the amount of mixed scrap metal waste by 10-15% compared with aluminium powder would produce a similar foaming ratio and compressive strength. The reaction of the metallic foaming agents mainly produced pores larger than 10 microm, different from the hydration reaction of cement that produced pores smaller than 1 microm mostly. To meet the requirements of the lightweight materials characteristics and the compressive strength, the amount of SSA could be up to 60-80% of the total solids. An adequate amount of aluminium powder is 0.5-0.9% of the total solids. Increasing the fineness of the mixed scrap metal waste powder could effectively reduce the amount required and improve the foaming ratio.

Life-cycle energy and greenhouse gas emission benefits of lightweighting in automobiles: review and harmonization.

PubMed

Kim, Hyung Chul; Wallington, Timothy J

2013-06-18

Replacing conventional materials (steel and iron) with lighter alternatives (e.g., aluminum, magnesium, and composites) decreases energy consumption and greenhouse gas (GHG) emissions during vehicle use but may increase energy consumption and GHG emissions during vehicle production. There have been many life cycle assessment (LCA) studies on the benefits of vehicle lightweighting, but the wide variety of assumptions used makes it difficult to compare results from the studies. To clarify the benefits of vehicle lightweighting we have reviewed the available literature (43 studies). The GHG emissions and primary energy results from 33 studies that passed a screening process were harmonized using a common set of assumptions (lifetime distance traveled, fuel-mass coefficient, secondary weight reduction factor, fuel consumption allocation, recycling rate, and energy intensity of materials). After harmonization, all studies indicate that using aluminum, glass-fiber reinforced plastic, and high strength steel to replace conventional steel decreases the vehicle life cycle energy use and GHG emissions. Given the flexibility in options implied by the variety of materials available and consensus that these materials have substantial energy and emissions benefits, it seems likely that lightweighting will be used increasingly to improve fuel economy and reduce life cycle GHG emissions from vehicles.

Aerospace Ceramic Materials: Thermal, Environmental Barrier Coatings and SiC/SiC Ceramic Matrix Composites for Turbine Engine Applications

NASA Technical Reports Server (NTRS)

Zhu, Dongming

2018-01-01

Ceramic materials play increasingly important roles in aerospace applications because ceramics have unique properties, including high temperature capability, high stiffness and strengths, excellent oxidation and corrosion resistance. Ceramic materials also generally have lower densities as compared to metallic materials, making them excellent candidates for light-weight hot-section components of aircraft turbine engines, rocket exhaust nozzles, and thermal protection systems for space vehicles when they are being used for high-temperature and ultra-high temperature ceramics applications. Ceramic matrix composites (CMCs), including non-oxide and oxide CMCs, are also recently being incorporated in gas turbine engines for high pressure and high temperature section components and exhaust nozzles. However, the complexity and variability of aerospace ceramic processing methods, compositions and microstructures, the relatively low fracture toughness of the ceramic materials, still remain the challenging factors for ceramic component design, validation, life prediction, and thus broader applications. This ceramic material section paper presents an overview of aerospace ceramic materials and their characteristics. A particular emphasis has been placed on high technology level (TRL) enabling ceramic systems, that is, turbine engine thermal and environmental barrier coating systems and non-oxide type SiC/SiC CMCs. The current status and future trend of thermal and environmental barrier coatings and SiC/SiC CMC development and applications are described.

Effect of Peat on Physicomechanical Properties of Cemented Brick

PubMed Central

Hashim, Roslan; Kurnia, Ryan

2014-01-01

The popularity of low cost, lightweight, and environmentally affable masonry unit in building industry carries the need to investigate more flexible and adaptable brick component as well as to retain the requirements confirmed in building standards. In this study, potential use of local materials used as lightweight building materials in solving the economic problems of housing has been investigated. Experimental studies on peat added bricks have been carried out. It demonstrates the physicomechanical properties of bricks and investigates the influence of peat, sand, and cement solid bricks to the role of various types of constructional applications. The achieved compressive strength, spitting strength, flexural strength, unit weight, and ultrasonic pulse velocity are significantly reduced and the water absorption is increased with percentage wise replacement of peat as aggregate in the samples. The maximum 20% of (% mass) peat content meets the requirements of relevant well-known international standards. The experimental values illustrate that, the 44% volumetric replacement with peat did not exhibit any sudden brittle fracture even beyond the ultimate loads and a comparatively smooth surface is found. The application of peat as efficient brick substance shows a potential to be used for wall and a viable solution in the economic buildings design. PMID:24982941

Evaluating knowledge benefits of automotive lightweighting materials R&D projects.

PubMed

Peretz, Jean H; Das, Sujit; Tonn, Bruce E

2009-08-01

This paper presents a set of metrics used to evaluate short-run knowledge benefits that accrued from research and development (R&D) projects funded in fiscal years 2000-2004 by automotive lightweighting materials (ALM) of the U.S. Department of Energy (DOE). Although DOE presents to Congress energy, environmental, and security benefits and costs of its R&D efforts under the Government Performance and Results Act, DOE has yet to include knowledge benefits in that report [U.S. Department of Energy. (2007). Projected benefits of federal energy efficiency and renewable energy programs: FY2008 budget request. NREL/TP-640-41347 (March). Washington, DC: National Renewable Energy Laboratory for DOE Energy Efficiency and Renewable Energy. Retrieved February 12, 2007 from http://www1.eere.energy.gov/ba/pba/2008_benefits.html]. ALM focuses on development and validation of advanced technologies that significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost [U.S. Department of Energy. (2005a). Automotive lightweighting materials 2004 annual progress report. Washington, DC: DOE Energy Efficiency and Renewable Energy. Retrieved March 30, 2005 from http://www.eere.energy.gov/vehiclesandfuels/resources/fcvt_alm_fy04.shtml]. The ultimate goal of ALM to have lightweighter materials in vehicles hinges on many issues, including the (1) collaborative nature of ALMs R&D with the automobile industry and (2) manufacturing knowledge gained through the R&D effort. The ALM projects evaluated in this paper yielded numerous knowledge benefits in the short run. While these knowledge benefits are impressive, there remains uncertainty about whether the research will lead to incorporation of lightweight materials by the Big Three automakers into their manufacturing process and introduction of lightweight vehicles into the marketplace. The uncertainty illustrates a difference between (1) knowledge benefits and (2) energy, environmental, and security benefits emanating from R&D.

Processing and Characterization of Lightweight Syntactic Materials

DTIC Science & Technology

2016-10-01

into lightweight (aluminum, magnesium) metal matrices via various metal processing methods. The performance of the resulting foam materials under quasi ...18 3.3 Other Alloys 20 4. Testing and Characterization of LSAMs 21 4.1 Finite Element Modeling of the Quasi -static Deformation 21 4.2 Compressive...Response at Quasi -static and High Strain Rates 27 4.2.1 Materials and Methods 27 4.2.2 Results 28 4.2.3 Conclusions 35 4.3 Thermal Properties of

Atmospheric-Pressure-Spray, Chemical- Vapor-Deposited Thin-Film Materials Being Developed for High Power-to- Weight-Ratio Space Photovoltaic Applications

NASA Technical Reports Server (NTRS)

Hepp, Aloysius F.; Harris, Jerry D.; Raffaelle, Ryne P.; Banger, Kulbinder K.; Smith, Mark A.; Cowen, Jonathan E.

2001-01-01

The key to achieving high specific power (watts per kilogram) space photovoltaic arrays is the development of high-efficiency thin-film solar cells that are fabricated on lightweight, space-qualified substrates such as Kapton (DuPont) or another polymer film. Cell efficiencies of 20 percent air mass zero (AM0) are required. One of the major obstacles to developing lightweight, flexible, thin-film solar cells is the unavailability of lightweight substrate or superstrate materials that are compatible with current deposition techniques. There are two solutions for working around this problem: (1) develop new substrate or superstrate materials that are compatible with current deposition techniques, or (2) develop new deposition techniques that are compatible with existing materials. The NASA Glenn Research Center has been focusing on the latter approach and has been developing a deposition technique for depositing thin-film absorbers at temperatures below 400 C.

System Architecture of Explorer Class Spaceborne Telescopes: A look at Optimization of Cost, Testability, Risk and Operational Duty Cycle from the Perspective of Primary Mirror Material Selection

NASA Astrophysics Data System (ADS)

Hull, Anthony B.; Westerhoff, Thomas

2015-01-01

Management of cost and risk have become the key enabling elements for compelling science to be done within Explorer or M-Class Missions. We trace how optimal primary mirror selection may be co-optimized with orbit selection. And then trace the cost and risk implications of selecting a low diffusivity low thermal expansion material for low and medium earth orbits, vs. high diffusivity high thermal expansion materials for the same orbits. We will discuss that ZERODUR®, a material that has been in space for over 30 years, is now available as highly lightweighted open-back mirrors, and the attributes of these mirrors in spaceborne optical telescope assemblies. Lightweight ZERODUR® solutions are practical from mirrors < 0.3m in diameter to >4m in diameter. An example of a 1.2m lightweight ZERODUR® mirror will be discussed.

The Role of Guidance, Navigation, and Control in Hypersonic Vehicle Multidisciplinary Design and Optimization

NASA Technical Reports Server (NTRS)

Ouzts, Peter J.; Soloway, Donald I.; Moerder, Daniel D.; Wolpert, David H.; Benavides, Jose Victor

2009-01-01

Airbreathing hypersonic systems offer distinct performance advantages over rocket-based systems for space access vehicles. However, these performance advantages are dependent upon advances in current state-of-the-art technologies in many areas such as ram/scramjet propulsion integration, high temperature materials, aero-elastic structures, thermal protection systems, transition to hypersonics and hypersonic control elements within the framework of complex physics and new design methods. The complex interactions between elements of an airbreathing hypersonic vehicle represent a new paradigm in vehicle design to achieve the optimal performance necessary to meet space access mission objectives. In the past, guidance, navigation, and control (GNC) analysis often follows completion of the vehicle conceptual design process. Individual component groups design subsystems which are then integrated into a vehicle configuration. GNC is presented the task of developing control approaches to meet vehicle performance objectives given that configuration. This approach may be sufficient for vehicles where significant performance margins exist. However, for higher performance vehicles engaging the GNC discipline too late in the design cycle has been costly. For example, the X-29 experimental flight vehicle was built as a technology demonstrator. One of the many technologies to be demonstrated was the use of light-weight material composites for structural components. The use of light-weight materials increased the flexibility of the X- 29 beyond that of conventional metal alloy constructed aircraft. This effect was not considered when the vehicle control system was designed and built. The impact of this is that the control system did not have enough control authority to compensate for the effects of the first fundamental structural mode of the vehicle. As a result, the resulting pitch rate response of the vehicle was below specification and no post-design changes could recover the desired capability.

Material requirements for the High Speed Civil Transport

NASA Technical Reports Server (NTRS)

Stephens, Joseph R.; Hecht, Ralph J.; Johnson, Andrew M.

1993-01-01

Under NASA-sponsored High Speed Research (HSR) programs, the materials and processing requirements have been identified for overcoming the environmental and economic barriers of the next generation High Speed Civil Transport (HSCT) propulsion system. The long (2 to 5 hours) supersonic cruise portion of the HSCT cycle will place additional durability requirements on all hot section engine components. Low emissions combustor designs will require high temperature ceramic matrix composite liners to meet an emission goal of less than 5g NO(x) per Kg fuel burned. Large axisymmetric and two-dimensional exhaust nozzle designs are now under development to meet or exceed FAR 36 Stage III noise requirements, and will require lightweight, high temperature metallic, intermetallic, and ceramic matrix composites to reduce nozzle weight and meet structural and acoustic component performance goals. This paper describes and discusses the turbomachinery, combustor, and exhaust nozzle requirements of the High Speed Civil Transport propulsion system.

Grips for Lightweight Tensile Specimens

NASA Technical Reports Server (NTRS)

Witte, William G., Jr.; Gibson, Walter D.

1987-01-01

Set of grips developed for tensile testing of lightweight composite materials. Double-wedge design substantially increases gripping force and reduces slippage. Specimen held by grips made of hardened wedges. Assembly screwed into load cell in tensile-testing machine.

Electrochemical impregnation and cycle life of lightweight nickel electrodes for nickel-hydrogen cells

NASA Technical Reports Server (NTRS)

Britton, Doris L.

1990-01-01

Development of a high specific energy nickel electrode is the main goal of the lightweight nickel electrode program at NASA-Lewis. The approach was to improve the nickel electrode by continuing combined in-house and contract efforts to develop a more efficient and lighter weight electrode for the nickel-hydrogen cell. Lightweight plaques are used as conductive supports for the nickel hydroxide active material. These plaques are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. The electrodes are life cycle tested in a low Earth orbit regime at 40 and 80 percent depths-of-discharge.

Electrochemical impregnation and cycle life of lightweight nickel electrodes for nickel-hydrogen cells

NASA Technical Reports Server (NTRS)

Britton, Doris L.

1990-01-01

Development of a high specific energy nickel electrode is the main goal of the lightweight nickel electrode program at NASA-Lewis. The approach was to improve the nickel electrode by continuing combined in-house and contract efforts to develop a more efficient and lighter weight electrode for the nickel-hydrogen cell. Lightweight plaques are used as conductive supports for the nickel hydroxide active material. These plaques are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. The electrodes are life cycle tested in a low earth orbit regime at 40 and 80 percent depths-of-discharge.

Lightweight carbon nanotube-based structural-energy storage devices for micro unmanned systems

NASA Astrophysics Data System (ADS)

Rivera, Monica; Cole, Daniel P.; Hahm, Myung Gwan; Reddy, Arava L. M.; Vajtai, Robert; Ajayan, Pulickel M.; Karna, Shashi P.; Bundy, Mark L.

2012-06-01

There is a strong need for small, lightweight energy storage devices that can satisfy the ever increasing power and energy demands of micro unmanned systems. Currently, most commercial and developmental micro unmanned systems utilize commercial-off-the-shelf (COTS) lithium polymer batteries for their energy storage needs. While COTS lithium polymer batteries are the industry norm, the weight of these batteries can account for up to 60% of the overall system mass and the capacity of these batteries can limit mission durations to the order of only a few minutes. One method to increase vehicle endurance without adding mass or sacrificing payload capabilities is to incorporate multiple system functions into a single material or structure. For example, the body or chassis of a micro vehicle could be replaced with a multifunctional material that would serve as both the vehicle structure and the on-board energy storage device. In this paper we present recent progress towards the development of carbon nanotube (CNT)-based structural-energy storage devices for micro unmanned systems. Randomly oriented and vertically aligned CNT-polymer composite electrodes with varying degrees of flexibility are used as the primary building blocks for lightweight structural-supercapacitors. For the purpose of this study, the mechanical properties of the CNT-based electrodes and the charge-discharge behavior of the supercapacitor devices are examined. Because incorporating multifunctionality into a single component often degrades the properties or performance of individual structures, the performance and property tradeoffs of the CNT-based structural-energy storage devices will also be discussed.

Tailored material properties using textile composites

NASA Astrophysics Data System (ADS)

Pastore, C. M.

2017-10-01

Lightweighting is essential for the reduction of energy consumption in transportation. The most common approach is through the application of high specific strength and stiffness materials, such as composites and high performance aluminum alloys. One of the challenges associated with the use of advanced materials is the high cost. This paper explores the opportunities of using hybrid composites (glass and carbon, for example) with selective fiber placement to optimize the weight subject to price constraints for given components. Considering the example of a hat-section for hood reinforcement, different material configurations were modeled and developed. The required thickness of the hat section to meet the same bending stiffness as an all carbon composite beam was calculated. It was shown that selective placement of fiber around the highest moments results in a weight savings of around 14% compared to a uniformly blended hybrid with the same total material configuration. From this it is possible to estimate the materials cost of the configurations as well as the weight of the component. To determine which is best it is necessary to find an exchange constant that converts weight into cost - the penalty of carrying the extra weight. The value of this exchange constant will depend on the particular application.

Manufacturing Energy Intensity and Opportunity Analysis for Fiber-Reinforced Polymer Composites and Other Lightweight Materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Liddell, Heather; Brueske, Sabine; Carpenter, Alberta

With their high strength-to-weight ratios, fiber-reinforced polymer (FRP) composites are important materials for lightweighting in structural applications; however, manufacturing challenges such as low process throughput and poor quality control can lead to high costs and variable performance, limiting their use in commercial applications. One of the most significant challenges for advanced composite materials is their high manufacturing energy intensity. This study explored the energy intensities of two lightweight FRP composite materials (glass- and carbon-fiber-reinforced polymers), with three lightweight metals (aluminum, magnesium, and titanium) and structural steel (as a reference material) included for comparison. Energy consumption for current typical and state-of-the-artmore » manufacturing processes were estimated for each material, deconstructing manufacturing process energy use by sub-process and manufacturing pathway in order to better understand the most energy intensive steps. Energy saving opportunities were identified and quantified for each production step based on a review of applied R&D technologies currently under development in order to estimate the practical minimum energy intensity. Results demonstrate that while carbon fiber reinforced polymer (CFRP) composites have the highest current manufacturing energy intensity of all materials considered, the large differences between current typical and state-of-the-art energy intensity levels (the 'current opportunity') and between state-of-the-art and practical minimum energy intensity levels (the 'R&D opportunity') suggest that large-scale energy savings are within reach.« less

Evaluation of the Benefits Attributable to Automotive Lighweight Materials Program Research and Development Projects

DOE Office of Scientific and Technical Information (OSTI.GOV)

Das, S.

The purpose of this project is to identify and test methods appropriate for estimating the benefits attributable to research and development (R and D) projects funded by the Automotive Lightweight Materials (ALM) Program of the Office of Advanced Automotive Technologies (OAAT) of the U.S. Department of Energy (DOE). The program focuses on the development and validation of advanced lightweight materials technologies to significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost. The work supports the goals of the Partnership for a New Generation of Vehicles (PNGV). Up to thirty percentmore » of the improvement required to meet the PNGV goal of tripling vehicle fuel economy and much of its cost, safety, and recyclability goal depend on the lightweight materials. Funded projects range from basic materials science research to applied research in production environments. Collaborators on these projects include national laboratories, universities, and private sector firms, such as leading automobile manufacturers and their suppliers.« less

Application of an Instrumental and Computational Approach for Improving the Vibration Behavior of Structural Panels Using a Lightweight Multilayer Composite

PubMed Central

Sánchez, Alberto; García, Manuel; Sebastián, Miguel Angel; Camacho, Ana María

2014-01-01

This work presents a hybrid (experimental-computational) application for improving the vibration behavior of structural components using a lightweight multilayer composite. The vibration behavior of a flat steel plate has been improved by the gluing of a lightweight composite formed by a core of polyurethane foam and two paper mats placed on its faces. This composite enables the natural frequencies to be increased and the modal density of the plate to be reduced, moving about the natural frequencies of the plate out of excitation range, thereby improving the vibration behavior of the plate. A specific experimental model for measuring the Operating Deflection Shape (ODS) has been developed, which enables an evaluation of the goodness of the natural frequencies obtained with the computational model simulated by the finite element method (FEM). The model of composite + flat steel plate determined by FEM was used to conduct parametric study, and the most influential factors for 1st, 2nd and 3rd mode were identified using a multifactor analysis of variance (Multifactor-ANOVA). The presented results can be easily particularized for other cases, as it may be used in cycles of continuous improvement as well as in the product development at the material, piece, and complete-system levels. PMID:24618779

Distributed visualization framework architecture

NASA Astrophysics Data System (ADS)

Mishchenko, Oleg; Raman, Sundaresan; Crawfis, Roger

2010-01-01

An architecture for distributed and collaborative visualization is presented. The design goals of the system are to create a lightweight, easy to use and extensible framework for reasearch in scientific visualization. The system provides both single user and collaborative distributed environment. System architecture employs a client-server model. Visualization projects can be synchronously accessed and modified from different client machines. We present a set of visualization use cases that illustrate the flexibility of our system. The framework provides a rich set of reusable components for creating new applications. These components make heavy use of leading design patterns. All components are based on the functionality of a small set of interfaces. This allows new components to be integrated seamlessly with little to no effort. All user input and higher-level control functionality interface with proxy objects supporting a concrete implementation of these interfaces. These light-weight objects can be easily streamed across the web and even integrated with smart clients running on a user's cell phone. The back-end is supported by concrete implementations wherever needed (for instance for rendering). A middle-tier manages any communication and synchronization with the proxy objects. In addition to the data components, we have developed several first-class GUI components for visualization. These include a layer compositor editor, a programmable shader editor, a material editor and various drawable editors. These GUI components interact strictly with the interfaces. Access to the various entities in the system is provided by an AssetManager. The asset manager keeps track of all of the registered proxies and responds to queries on the overall system. This allows all user components to be populated automatically. Hence if a new component is added that supports the IMaterial interface, any instances of this can be used in the various GUI components that work with this interface. One of the main features is an interactive shader designer. This allows rapid prototyping of new visualization renderings that are shader-based and greatly accelerates the development and debug cycle.

Experimental analysis of energy absorption behaviour of Al-tube filled with pumice lightweight concrete under axial loading condition

NASA Astrophysics Data System (ADS)

Rajak, D. K.; Deshpande, P. G.; Kumaraswamidhas, L. A.

2017-08-01

This Paper aimed at experimental investigation of compressive behaviour of square tube filled with pumice lightweight concrete (PLC). Square section of 20×20×30 mm is investigated, which is the backbone structure. The compression deformation result shows the better folding mechanism, displacement value, and energy absorption. PLC concrete filled with aluminium thin-wall tubes has been revealed superior energy absorption capacity (EAC) under low strain rate at room temperature. Superior EAC resulted as a result of mutual deformation benefit between aluminium section and PLC is also analysed. PLC was characterised by Fourier Transform Infrared (FTIR) and Field Emission Scanning Electron Microscopy (FESEM), and Energy Dispersive X-ray Spectrometry (EDX) analysis for better understanding of material behaviour. Individual and comparative load bearing graphs is logged for better prospective of analysing. Novel approach aimed at validation of porous lightweight concrete for better lightweight EA filler material.

Carbon-carbon mirrors for exoatmospheric and space applications

NASA Astrophysics Data System (ADS)

Krumweide, Duane E.; Wonacott, Gary D.; Woida, Patrick M.; Woida, Rigel Q.; Shih, Wei

2007-09-01

The cost and leadtime associated with beryllium has forced the MDA and other defense agencies to look for alternative materials with similar structural and thermal properties. The use of carbon-carbon material, specifically in optical components has been demonstrated analytically in prior SBIR work at San Diego Composites. Carbon-carbon material was chosen for its low in-plane and through-thickness CTE (athermal design), high specific stiffness, near-zero coefficient of moisture expansion, availability of material (specifically c-c honeycomb for lightweight substrates), and compatibility with silicon monoxide (SiO) and silicon dioxide (SiO II) coatings. Subsequent development work has produced shaped carbon-carbon sandwich substrates which have been ground, polished, coated and figured using traditional optical processing. Further development has also been done on machined monolithic carbon-carbon mirror substrates which have also been processed using standard optical finishing techniques.

A mathematical model for predicting cyclic voltammograms of electronically conductive polypyrrole

NASA Technical Reports Server (NTRS)

Yeu, Taewhan; Nguyen, Trung V.; White, Ralph E.

1988-01-01

Polypyrrole is an attractive polymer for use as a high-energy-density secondary battery because of its potential as an inexpensive, lightweight, and noncorrosive electrode material. A mathematical model to simulate cyclic voltammograms for polypyrrole is presented. The model is for a conductive porous electrode film on a rotating disk electrode (RDE) and is used to predict the spatial and time dependence of concentration, overpotential, and stored charge profiles within a polypyrrole film. The model includes both faradic and capacitance charge components in the total current density expression.

A mathematical model for predicting cyclic voltammograms of electronically conductive polypyrrole

NASA Technical Reports Server (NTRS)

Yeu, Taewhan; Nguyen, Trung V.; White, Ralph E.

1987-01-01

Polypyrrole is an attractive polymer for use as a high-energy-density secondary battery because of its potential as an inexpensive, lightweight, and noncorrosive electrode material. A mathematical model to simulate cyclic voltammograms for polypyrrole is presented. The model is for a conductive porous electrode film on a rotating disk electrode (RDE) and is used to predict the spatial and time dependence of concentration, overpotential, and stored charge profiles within a polypyrrole film. The model includes both faradic and capacitance charge components in the total current density expression.

Structural Assessment of Tungsten-Epoxy Bonding in Spacecraft Composite Enclosures with Enhanced Radiation Protection

NASA Astrophysics Data System (ADS)

Kanerva, M.; Koerselman, J. R.; Revitzer, H.; Johansson, L.-S.; Sarlin, E.; Rautiainen, A.; Brander, T.; Saarela, O.

2014-06-01

Spacecraft include sensitive electronics that must be protected against radiation from the space environment. Hybrid laminates consisting of tungsten layers and carbon- fibre-reinforced epoxy composite are a potential solution for lightweight, efficient, and protective enclosure material. Here, we analysed six different surface treatments for tungsten foils in terms of the resulting surface tension components, composition, and bonding strength with epoxy. A hydrofluoric-nitric-sulfuric-acid method and a diamond-like carbon-based DIARC® coating were found the most potential surface treatments for tungsten foils in this study.

Fabrication of Porous Ceramic-Geopolymer Based Material to Improve Water Absorption and Retention in Construction Materials: A Review

NASA Astrophysics Data System (ADS)

Jamil, N. H.; Ibrahim, W. M. A. W.; Abdullah, M. M. A. B.; Sandu, A. V.; Tahir, M. F. M.

2017-06-01

Porous ceramic nowadays has been investigated for a variety of its application such as filters, lightweight structural component and others due to their specific properties such as high surface area, stability and permeability. Besides, it has the properties of low thermal conductivity. Various formation techniques making these porous ceramic properties can be tailored or further fine-tuned to obtain the optimum characteristic. Porous materials also one of the good candidate for absorption properties. Conventional construction materials are not design to have good water absorption and retention that lead to the poor performance on these criteria. Temperature is a major driving force for moisture movement and influences sorption characteristics of many constructions materials. The effect of elevated temperatures on the water absorption coefficient and retention remain as critical issue that need to be investigated. Therefore, this paper will review the process parameters in fabricating porous ceramic for absorption properties.

Life Cycle Assessment of Vehicle Lightweighting: Novel Mathematical Methods to Estimate Use-Phase Fuel Consumption.

PubMed

Kim, Hyung Chul; Wallington, Timothy J; Sullivan, John L; Keoleian, Gregory A

2015-08-18

Lightweighting is a key strategy to improve vehicle fuel economy. Assessing the life-cycle benefits of lightweighting requires a quantitative description of the use-phase fuel consumption reduction associated with mass reduction. We present novel methods of estimating mass-induced fuel consumption (MIF) and fuel reduction values (FRVs) from fuel economy and dynamometer test data in the U.S. Environmental Protection Agency (EPA) database. In the past, FRVs have been measured using experimental testing. We demonstrate that FRVs can be mathematically derived from coast down coefficients in the EPA vehicle test database avoiding additional testing. MIF and FRVs calculated for 83 different 2013 MY vehicles are in the ranges 0.22-0.43 and 0.15-0.26 L/(100 km 100 kg), respectively, and increase to 0.27-0.53 L/(100 km 100 kg) with powertrain resizing to retain equivalent vehicle performance. We show how use-phase fuel consumption can be estimated using MIF and FRVs in life cycle assessments (LCAs) of vehicle lightweighting from total vehicle and vehicle component perspectives with, and without, powertrain resizing. The mass-induced fuel consumption model is illustrated by estimating lifecycle greenhouse gas (GHG) emission benefits from lightweighting a grille opening reinforcement component using magnesium or carbon fiber composite for 83 different vehicle models.

Conjoint Forming - Technologies for Simultaneous Forming and Joining

NASA Astrophysics Data System (ADS)

Groche, P.; Wohletz, S.; Mann, A.; Krech, M.; Monnerjahn, V.

2016-03-01

The market demand for new products optimized for e. g. lightweight applications or smart components leads to new challenges in production engineering. Hybrid structures represent one promising approach. They aim at higher product performance by using a suitable combination of different materials. The developments of hybrid structures stimulate the research on joining of dissimilar materials. Since they allow for joining dissimilar materials without external heating technologies based on joining by plastic deformation seem to be of special attractiveness. The paper at hand discusses the conjoint forming approach. This approach combines forming and joining in one process. Two or more workpieces are joined while at least one workpiece is plastically deformed. After presenting the fundamental joining mechanisms, the conjoint forming approach is discussed comprehensively. Examples of conjoint processes demonstrate the effectiveness and reveal the underlying phenomena.

Electron Radiation Effects on Candidate Solar Sail Material

NASA Technical Reports Server (NTRS)

Edwards, David L.; Hollerman, William A.; Hubbs, Whitney S.; Gray, Perry A.; Wertz, George E.; Hoppe, David T.; Nehls, Mary K.; Semmel, Charles L.

2003-01-01

Solar sailing is a unique form of propulsion where a spacecraft gains momentum from incident photons. Solar sails are not limited by reaction mass and provide continual acceleration, reduced only by the lifetime of the lightweight film in the space environment and the distance to the Sun. Once thought to be difficult or impossible, solar sailing has come out of science fiction and into the realm of possibility. Any spacecraft using this propulsion method would need to deploy a thin sail that could be as large as many kilometers in extent. The availability of strong, ultra lightweight, and radiation resistant materials will determine the future of solar sailing. The National Aeronautics and Space Administration's (NASA) Marshall Space Flight Center (MSFC) is concentrating research into the utilization of ultra lightweight materials for spacecraft propulsion. The Space Environmental Effects Team at MSFC is actively characterizing candidate solar sail material to evaluate the thermo-optical and mechanical properties after exposure to space environmental effects. This paper will describe the irradiation of candidate solar sail materials to energetic electrons, in vacuum, to determine the hardness of several candidate sail materials.

Lightweight design of automobile frame based on magnesium alloy

NASA Astrophysics Data System (ADS)

Lyu, R.; Jiang, X.; Minoru, O.; Ju, D. Y.

2018-06-01

The structural performance and lightweighting of car base frame design is a challenging task due to all the performance targets that must be satisfied. In this paper, three kinds of materials (iron, aluminum and magnesium alloy) replacement along with section design optimization strategy is proposed to develop a lightweight car frame structure to satisfy the tensile and safety while reducing weight. Two kinds of cross-sections are considered as the design variables. Using Ansys static structure, the design optimization problem is solved, comparing the results of each step, structure of the base flame is optimized for lightweight.

Developments in Nano-Satellite Structural Subsystem Design at NASA-GSFC

NASA Technical Reports Server (NTRS)

Rossoni, Peter; Panetta, Peter V.

1999-01-01

The NASA-GSFC Nano-satellite Technology Development Program will enable flying constellations of tens to hundreds of nano-satellites for future NASA Space and Earth Science missions. Advanced technology components must be developed to make these future spacecraft compact, lightweight, low-power, low-cost, and survivable to a radiation environment over a two-year mission lifetime. This paper describes the efforts underway to develop lightweight, low cost, and multi-functional structures, serviceable designs, and robust mechanisms. As designs shrink, the integration of various subsystems becomes a vital necessity. This paper also addresses structurally integrated electrical power, attitude control, and thermal systems. These innovations bring associated fabrication, integration, and test challenges. Candidate structural materials and processes are examined and the merits of each are discussed. Design and fabrication processes include flat stock composite construction, cast aluminum-beryllium alloy, and an injection molded fiber-reinforced plastic. A viable constellation deployment scenario is described as well as a Phase-A Nano-satellite Pathfinder study.

Lightweight, Rack-Mountable Composite Cold Plate/Shelves

NASA Technical Reports Server (NTRS)

Hurlbert, Kathryn M.; Ruemmele, Warren; Nguyen, Hai D.; Andish, Kambiz; McCalley, Sean

2004-01-01

Rack-mountable composite-material structural components that would serve as both shelves and cold plates for removing heat from electronic or other equipment mounted on the shelves have been proposed as lightweight alternatives to all-metal cold plate/shelves now in use. A proposed cold plate/shelf would include a highly thermally conductive face sheet containing oriented graphite fibers bonded to an aluminum honeycomb core, plus an extruded stainless-steel substructure containing optimized flow passages for a cooling fluid, and an inlet and outlet that could be connected to standard manifold sections. To maximize heat-transfer efficiency, the extruded stainless-steel substructure would be connected directly to the face sheet. On the basis of a tentative design, the proposed composite cold plate/shelf would weigh about 38 percent less than does an all-aluminum cold plate in use or planned for use in some spacecraft and possibly aircraft. Although weight is a primary consideration, the tentative design offers the additional benefit of reduction of thickness to half that of the all-aluminum version.

Lightweight bio-composites based on hemp fibres produced by conventional and unconventional processes

NASA Astrophysics Data System (ADS)

Boccarusso, L.; Durante, M.; Formisano, A.; Langella, A.; Minutolo, F. Memola Capece

2017-10-01

Considering that nowadays the interest in the use of bio-composite materials is increasing more and more, this work is focused on the manufacturing of lightweight components based on hemp fibres for future applications, for example as a core for sandwich structures. Three different no-complex processes were used: a conventional hand lay-up, an unconventional infusion process and a hand lay-up process followed by injection moulding. They were used to produce bio-composite structures using an epoxy resin and/or a polyurethane foam as matrix. Depending on the process used for the manufacturing, laminates with different values of density were obtained. A detailed study in terms of both static and dynamic properties was carried out and the different mechanical behaviour for each sample typology was highlighted. The results showed that the process in which both the epoxy resin and the polyurethane foam were used as matrix allowed to obtain laminates with lower density and higher specific mechanical properties.

Additive-free thick graphene film as an anode material for flexible lithium-ion batteries.

PubMed

Rana, Kuldeep; Kim, Seong Dae; Ahn, Jong-Hyun

2015-04-28

This work demonstrates a simple route to develop mechanically flexible electrodes for Li-ion batteries (LIBs) that are usable as lightweight effective conducting networks for both cathodes and anodes. Removing electrochemically dead elements, such as binders, conducting agents and metallic current collectors, from the battery components will allow remarkable progress in this area. To investigate the feasibility of using thick, additive-free graphene films as anodes for flexible LIBs, we have synthesized and tested thick, additive-free, freestanding graphene films as anodes, first in a coin cell and further in a flexible full cell. As an anode material in a half cell, it showed a discharge capacity of about 350 mA h g(-1) and maintained nearly this capacity over 50 cycles at various current rates. This film was also tested as an anode material in a full cell with a LiCoO2 cathode and showed good electrochemical performance. Because the graphene-based flexible film showed good performance in half- and full coin cells, we used this film as a flexible anode for flexible LIBs. No conducting agent or binder was used in the anode side, which helped in realizing the flexible LIBs. Using this, we demonstrate a thin, lightweight and flexible lithium ion battery with good electrochemical performance in both its flat and bent states.

Helping Aircraft Engines Lighten Up

NASA Technical Reports Server (NTRS)

2004-01-01

High-temperature polyimide/carbon fiber matrix composites are developed by the Polymers Branch at NASA's Glenn Research Center. These materials can withstand high temperatures and have good processing properties, which make them particularly useful for jet and rocket engines and for components such as fan blades, bushings, and duct segments. Applying polyimide composites as components for aerospace structures can lead to substantial vehicle weight reductions. A typical polyimide composite is made up of layers of carbon or glass fibers glued together by a high-temperature polymer to make the material strong, stiff, and lightweight. Organic molecules containing carbon, nitrogen, oxygen, and hydrogen within the polyimide keep the material s density low, resulting in the light weight. The strength of a component or part made from a polyimide comes mainly from the reinforcing high-strength fibers. The strength of the carbon fibers coupled with the stiffness of polyimides allows engineers to make a very rigid structure without it being massive. Another benefit of a polyimide s suitability for aerospace applications is its reduced need for machining. When polyimide parts are removed from a mold, they are nearly in their final shape. Usually, very little machining is needed before a part is ready for use.

Clementine. Mining new uses for SDI technology

NASA Astrophysics Data System (ADS)

Rustan, Pedro L.

1994-01-01

Using ballistic missile defense technologies for NASA science missions can dramatically reduce program costs and development time. Described is the Clementine spacecraft scheduled for launch to flight-qualify advanced lightweight technologies. The 500-lb spacecraft, which uses lightweight components and minimal redundancy, was built by the Naval Research Laboratory in less than two years.

Process for producing nickel electrode having lightweight substrate

NASA Technical Reports Server (NTRS)

Lim, Hong S. (Inventor)

1996-01-01

A nickel electrode having a lightweight porous nickel substrate is subjected to a formation cycle involving heavy overcharging and under-discharging in a KOH electrolyte having a concentration of 26% to 31%, resulting in electrodes displaying high active material utilization.

Apparatus for forming a continuous lightweight multicell material

NASA Technical Reports Server (NTRS)

Wang, Taylor G. (Inventor); Elleman, Daniel D. (Inventor); Kendall, James M., Jr. (Inventor)

1984-01-01

An apparatus is described for producing a lightweight structural material (12), by forming gas-filled shells (38) of molten material from a matrix of nozzles (22) that form shells of very uniform size at very uniform rates. The matrix of molten shells coalesce into a multi-cell material of controlled cellular structure. The shells can be of two different sizes (38, 44) that are interspersed, to form a multicell material that has a regular cell pattern but which avoids planes of weakness and localized voids. The gas (50) in the shells can be under a high pressure, and can be a fire extinguishing gas.

Fabrication of lightweight Si/SiC LIDAR mirrors

NASA Technical Reports Server (NTRS)

Goela, Jitendra S.; Taylor, Raymond L.

1991-01-01

A new, chemical vapor deposition (CVD) process was developed for fabricating lightweight, polycrystalline silicon/silicon-carbide (Si/SiC) mirrors. The process involves three CVD steps: (1) to produce the mirror faceplate; (2) to form the lightweight backstructure, which is deposited integral to the faceplate; and (3) to deposit a layer of optical-grade material, e.g., Si, onto the front surface of the faceplate. The mirror figure and finish are fabricated into the faceplate.

Thermoelectric Energy Conversion: Future Directions and Technology Development Needs

NASA Technical Reports Server (NTRS)

Fleurial, Jean-Pierre

2007-01-01

This viewgraph presentation reviews the process of thermoelectric energy conversion along with key technology needs and challenges. The topics include: 1) The Case for Thermoelectrics; 2) Advances in Thermoelectrics: Investment Needed; 3) Current U.S. Investment (FY07); 4) Increasing Thermoelectric Materials Conversion Efficiency Key Science Needs and Challenges; 5) Developing Advanced TE Components & Systems Key Technology Needs and Challenges; 6) Thermoelectrics; 7) 200W Class Lightweight Portable Thermoelectric Generator; 8) Hybrid Absorption Cooling/TE Power Cogeneration System; 9) Major Opportunities in Energy Industry; 10) Automobile Waste Heat Recovery; 11) Thermoelectrics at JPL; 12) Recent Advances at JPL in Thermoelectric Converter Component Technologies; 13) Thermoelectrics Background on Power Generation and Cooling Operational Modes; 14) Thermoelectric Power Generation; and 15) Thermoelectric Cooling.

Shear strength of a PCBT-53 girder fabricated with lightweight self-consolidating concrete.

DOT National Transportation Integrated Search

2009-01-01

Lightweight self-consolidating concrete (LWSCC) is advantageous in the bridge industry because members fabricated with this material have a significantly lower self weight and in its fresh state, LWSCC has a low viscosity that eliminates the need for...

Component characterization and predictive modeling for green roof substrates optimized to adsorb P and improve runoff quality: A review.

PubMed

Jennett, Tyson S; Zheng, Youbin

2018-06-01

This review is a synthesis of the current knowledge regarding the effects of green roof substrate components and their retentive capacity for nutrients, particularly phosphorus (P). Substrates may behave as either sources or sinks of P depending on the components they are formulated from, and to date, the total P-adsorbing capacity of a substrate has not been quantified as the sum of the contributions of its components. Few direct links have been established among substrate components and their physicochemical characteristics that would affect P-retention. A survey of recent literature presented herein highlights the trends within individual component selection (clays and clay-like material, organics, conventional soil and sands, lightweight inorganics, and industrial wastes and synthetics) for those most common during substrate formulation internationally. Component selection will vary with respect to ease of sourcing component materials, cost of components, nutrient-retention capacity, and environmental sustainability. However, the number of distinct components considered for inclusion in green roof substrates continues to expand, as the desires of growers, material suppliers, researchers and industry stakeholders are incorporated into decision-making. Furthermore, current attempts to characterize the most often used substrate components are also presented whereby runoff quality is correlated to entire substrate performance. With the use of well-described characterization (constant capacitance model) and modeling techniques (the soil assemblage model), it is proposed that substrates optimized for P adsorption may be developed through careful selection of components with prior knowledge of their chemical properties, that may increase retention of P in plant-available forms, thereby reducing green roof fertilizer requirements and P losses in roof runoff. Copyright © 2017 Elsevier Ltd. All rights reserved.

Superalloy Lattice Block Developed for Use in Lightweight, High-Temperature Structures

NASA Technical Reports Server (NTRS)

Hebsur, Mohan G.; Whittenberger, J. Daniel; Krause, David L.

2003-01-01

Successful development of advanced gas turbine engines for aircraft will require lightweight, high-temperature components. Currently titanium-aluminum- (TiAl) based alloys are envisioned for such applications because of their lower density (4 g/cm3) in comparison to superalloys (8.5 g/cm3), which have been utilized for hot turbine engine parts for over 50 years. However, a recently developed concept (lattice block) by JAMCORP, Inc., of Willmington, Massachusetts, would allow lightweight, high-temperature structures to be directly fabricated from superalloys and, thus, take advantage of their well-known, characterized properties. In its simplest state, lattice block is composed of thin ligaments arranged in a three dimensional triangulated trusslike configuration that forms a structurally rigid panel. Because lattice block can be fabricated by casting, correctly sized hardware is produced with little or no machining; thus very low cost manufacturing is possible. Together, the NASA Glenn Research Center and JAMCORP have extended their lattice block methodology for lower melting materials, such as Al alloys, to demonstrate that investment casting of superalloy lattice block is possible. This effort required advances in lattice block pattern design and assembly, higher temperature mold materials and mold fabrication technology, and foundry practice suitable for superalloys (ref. 1). Lattice block panels have been cast from two different Ni-base superalloys: IN 718, which is the most commonly utilized superalloy and retains its strength up to 650 C; and MAR M247, which possesses excellent mechanical properties to at least 1100 C. In addition to the open-cell lattice block geometry, same-sized lattice block panels containing a thin (1-mm-thick) solid face on one side have also been cast from both superalloys. The elevated-temperature mechanical properties of the open cell and face-sheeted superalloy lattice block panels are currently being examined, and the microstructure is being characterized in terms of casting defects. In addition, a small study (ref. 3) is being undertaken with GE Aircraft Engines to determine the suitability of superalloy lattice block for engine components.

Reducing CO2 Emissions through Lightweight Design and Manufacturing

NASA Astrophysics Data System (ADS)

Carruth, Mark A.; Allwood, Julian M.; Milford, Rachel L.

2011-05-01

To meet targeted 50% reductions in industrial CO2 emissions by 2050, demand for steel and aluminium must be cut. Many steel and aluminium products include redundant material, and the manufacturing routes to produce them use more material than is necessary. Lightweight design and optimized manufacturing processes offer a means of demand reduction, whilst creating products to perform the same service as existing ones. This paper examines two strategies for demand reduction: lightweight product design; and minimizing yield losses through the product supply chain. Possible mass savings are estimated for specific case-studies on metal-intensive products, such as I-beams and food cans. These estimates are then extrapolated to other sectors to produce a global estimate for possible demand reductions. Results show that lightweight product design may offer potential mass savings of up to 30% for some products, whilst yield in the production of others could be improved by over 20%. If these two strategies could be combined for all products, global demand for steel and aluminium would be reduced by nearly 50%. The impact of demand reduction on CO2 emissions is presented, and barriers to the adoption of new, lightweight technologies are discussed.

Energy absorption characteristics of lightweight structural member by stacking conditions

NASA Astrophysics Data System (ADS)

Choi, Juho; Yang, Yongjun; Hwang, Woochae; Pyeon, Seokbeom; Min, Hanki; Yeo, Ingoo; Yang, Inyoung

2011-11-01

The recent trend in vehicle design is aimed at improving crash safety and environmental-friendliness. To solve these issues, the needs for lighter vehicle to limit exhaust gas and improve fuel economy has been requested for environmental-friendliness. Automobile design should be made for reduced weight once the safety of vehicle is maintained. In this study, composite structural members were manufactured using carbon fiber reinforced plastic (CFRP) which are representative lightweight structural materials. Carbon fiber has been researched as alternative to metals for lightweight vehicle and better fuel economy. CFRP is an anisotropic material which is the most widely adapted lightweight structural member because of their inherent design flexibility and high specific strength and stiffness. Also, variation of CFRP interface number is important to increase the energy absorption capacity. In this study, one type of circular shaped composite tube was used, combined with reinforcing foam. The stacking condition was selected to investigate the effect of the fiber orientation angle and interface number. The crashworthy behavior of circular composite material tubes subjected to static axial compression under same conditions is reported. The axial static collapse tests were carried out for each section member. The collapse modes and the energy absorption capability of the members were analyzed.

Energy absorption characteristics of lightweight structural member by stacking conditions

NASA Astrophysics Data System (ADS)

Choi, Juho; Yang, Yongjun; Hwang, Woochae; Pyeon, Seokbeom; Min, Hanki; Yeo, Ingoo; Yang, Inyoung

2012-04-01

The recent trend in vehicle design is aimed at improving crash safety and environmental-friendliness. To solve these issues, the needs for lighter vehicle to limit exhaust gas and improve fuel economy has been requested for environmental-friendliness. Automobile design should be made for reduced weight once the safety of vehicle is maintained. In this study, composite structural members were manufactured using carbon fiber reinforced plastic (CFRP) which are representative lightweight structural materials. Carbon fiber has been researched as alternative to metals for lightweight vehicle and better fuel economy. CFRP is an anisotropic material which is the most widely adapted lightweight structural member because of their inherent design flexibility and high specific strength and stiffness. Also, variation of CFRP interface number is important to increase the energy absorption capacity. In this study, one type of circular shaped composite tube was used, combined with reinforcing foam. The stacking condition was selected to investigate the effect of the fiber orientation angle and interface number. The crashworthy behavior of circular composite material tubes subjected to static axial compression under same conditions is reported. The axial static collapse tests were carried out for each section member. The collapse modes and the energy absorption capability of the members were analyzed.

Cost-Effective Uses of Lightweight Aggregate Made from Dredged Material in Construction

DOT National Transportation Integrated Search

2018-01-31

Lightweight aggregate (LWA) can be used in concrete to reduce its self-weight and improve its workability and durability. It could potentially be used as borrow for embankment construction, which is expected to reduce the stresses on the subgrade fou...

Reducing Vehicle Weight and Improving U.S. Energy Efficiency Using Integrated Computational Materials Engineering

NASA Astrophysics Data System (ADS)

Joost, William J.

2012-09-01

Transportation accounts for approximately 28% of U.S. energy consumption with the majority of transportation energy derived from petroleum sources. Many technologies such as vehicle electrification, advanced combustion, and advanced fuels can reduce transportation energy consumption by improving the efficiency of cars and trucks. Lightweight materials are another important technology that can improve passenger vehicle fuel efficiency by 6-8% for each 10% reduction in weight while also making electric and alternative vehicles more competitive. Despite the opportunities for improved efficiency, widespread deployment of lightweight materials for automotive structures is hampered by technology gaps most often associated with performance, manufacturability, and cost. In this report, the impact of reduced vehicle weight on energy efficiency is discussed with a particular emphasis on quantitative relationships determined by several researchers. The most promising lightweight materials systems are described along with a brief review of the most significant technical barriers to their implementation. For each material system, the development of accurate material models is critical to support simulation-intensive processing and structural design for vehicles; improved models also contribute to an integrated computational materials engineering (ICME) approach for addressing technical barriers and accelerating deployment. The value of computational techniques is described by considering recent ICME and computational materials science success stories with an emphasis on applying problem-specific methods.

Impacts of Vehicle Weight Reduction via Material Substitution on Life-Cycle Greenhouse Gas Emissions.

PubMed

Kelly, Jarod C; Sullivan, John L; Burnham, Andrew; Elgowainy, Amgad

2015-10-20

This study examines the vehicle-cycle and vehicle total life-cycle impacts of substituting lightweight materials into vehicles. We determine part-based greenhouse gas (GHG) emission ratios by collecting material substitution data and evaluating that alongside known mass-based GHG ratios (using and updating Argonne National Laboratory's GREET model) associated with material pair substitutions. Several vehicle parts are lightweighted via material substitution, using substitution ratios from a U.S. Department of Energy report, to determine GHG emissions. We then examine fuel-cycle GHG reductions from lightweighting. The fuel reduction value methodology is applied using FRV estimates of 0.15-0.25, and 0.25-0.5 L/(100km·100 kg), with and without powertrain adjustments, respectively. GHG breakeven values are derived for both driving distance and material substitution ratio. While material substitution can reduce vehicle weight, it often increases vehicle-cycle GHGs. It is likely that replacing steel (the dominant vehicle material) with wrought aluminum, carbon fiber reinforced plastic (CRFP), or magnesium will increase vehicle-cycle GHGs. However, lifetime fuel economy benefits often outweigh the vehicle-cycle, resulting in a net total life-cycle GHG benefit. This is the case for steel replaced by wrought aluminum in all assumed cases, and for CFRP and magnesium except for high substitution ratio and low FRV.

Combination of lightweight elements and nanostructured materials for batteries.

PubMed

Chen, Jun; Cheng, Fangyi

2009-06-16

In a society that increasingly relies on mobile electronics, demand is rapidly growing for both primary and rechargeable batteries that power devices from cell phones to vehicles. Existing batteries utilize lightweight active materials that use electrochemical reactions of ions such as H(+), OH(-) and Li(+)/Mg(2+) to facilitate energy storage and conversion. Ideal batteries should be inexpensive, have high energy density, and be made from environmentally friendly materials; batteries based on bulk active materials do not meet these requirements. Because of slow electrode process kinetics and low-rate ionic diffusion/migration, most conventional batteries demonstrate huge gaps between their theoretical and practical performance. Therefore, efforts are underway to improve existing battery technologies and develop new electrode reactions for the next generation of electrochemical devices. Advances in electrochemistry, surface science, and materials chemistry are leading to the use of nanomaterials for efficient energy storage and conversion. Nanostructures offer advantages over comparable bulk materials in improving battery performance. This Account summarizes our progress in battery development using a combination of lightweight elements and nanostructured materials. We highlight the benefits of nanostructured active materials for primary zinc-manganese dioxide (Zn-Mn), lithium-manganese dioxide (Li-Mn), and metal (Mg, Al, Zn)-air batteries, as well as rechargeable lithium ion (Li-ion) and nickel-metal hydride (Ni-MH) batteries. Through selected examples, we illustrate the effect of structure, shape, and size on the electrochemical properties of electrode materials. Because of their numerous active sites and facile electronic/ionic transfer and diffusion, nanostructures can improve battery efficiency. In particular, we demonstrate the properties of nanostructured active materials including Mg, Al, Si, Zn, MnO(2), CuV(2)O(6), LiNi(0.8)Co(0.2)O(2), LiFePO(4), Fe(2)O(3), Co(3)O(4), TiS(2), and Ni(OH)(2) in battery applications. Electrochemical investigations reveal that we generally attain larger capacities and improved kinetics for electrode materials as their average particle size decreases. Novel nanostructures such as nanowires, nanotubes, nanourchins, and porous nanospheres show lower activation energy, enhanced reactivity, improved high-rate charge/discharge capability, and more controlled structural flexibility than their bulk counterparts. In particular, anode materials such as Si nanospheres and Fe(2)O(3) nanotubes can deliver reversible capacity exceeding 500 mA.h/g. (Graphite used commercially has a theoretical capacity of 372 mA x h/g.) Nanocomposite cathode materials such as NiP-doped LiFePO(4) and metal hydroxide-coated Ni(OH)(2) nanotubes allow us to integrate functional components, which enhance electrical conductivity and suppress volume expansion. Therefore, shifting from bulk to nanostructured electrode materials could offer a revolutionary opportunity to develop advanced green batteries with large capacity, high energy and power density, and long cycle life.

Multi-material composites prepared by additive manufacturing and melt casting

NASA Astrophysics Data System (ADS)

Murialdo, Maxwell; Sullivan, Kyle; White, Bradley; LLNL MSD Collaboration

2017-06-01

Recent advances in additive manufacturing have disrupted not only means of production, but also have enabled a new parameter space of multiscale materials designs. Understanding the role of architecture to control material response is being investigated for a wide range of applications, from light-weight structural components to energetic materials. In this work, we combine 3D printing of scaffold structures with a subsequent melt-infiltration step to render an architected multi-material composite article. Both the scaffold architecture and material type were investigated. The processing challenges of filling such scaffolds using a melt-infiltration step will be discussed, along with our progress in this area. Using the combined method of printing and casting, we will discuss our path forward for testing the mechanical properties and the high-strain response of our composite architected parts. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344. IM release: LLNL-ABS-725497-DRAFT.

EFFECTS OF TEMPERATURE AND ENVIRONMENT ON MECHANICAL PROPERTIES OF TWO CHOPPED-FIBER AUTOMOTIVE STRUCTURAL COMPOSITES

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ruggles-Wrenn, M.B.

2003-10-06

The Durability of Lightweight Composite Structures Project was established at Oak Ridge National Laboratory (ORNL) by the U.S. Department of Energy to provide the experimentally-based, durability-driven design guidelines necessary to assure long-term structural integrity of automotive composite components. The initial focus of the ORNL Durability Project was on composite materials consisting of polyurethane reinforced with E-glass. Current focus of the project is on composite materials reinforced with carbon fibers. The primary purpose of this report is to provide the individual specimen test date. Basic mechanical property testing and results for two chopped-fiber composite materials, one reinforced with glass- and themore » other with carbon fiber are provided. Both materials use the same polyurethane matrix. Preforms for both materials were produced using the P4 process. Behavioral trends, effects of temperature and environment, and corresponding design knockdown factors are established for both materials. Effects of prior short-time loads and of prior thermal cycling are discussed.« less

Lightweight fuel cell powerplant components program

NASA Technical Reports Server (NTRS)

Martin, R. E.

1980-01-01

A lightweight hydrogen-oxygen alkaline fuel cell incorporated into the design of a lightweight fuel cell powerplant (LFCP) was analytically and experimentally developed. The powerplant operates with passive water removal which contributes to a lower system weight and extended operating life. A preliminary LFCP specification and design table were developed along with a lightweight power section for the LFCP design, consisting of repeating two-cell modules was designed. Two, four-cell modules were designed incorporating 0.508 sq ft active area space shuttle technology fuel cells. Over 1,200 hours of single-cell and over 8,800 hours of two-cell module testing was completed. The 0.25 sq ft active area lightweight cell design was shown to be capable of operating on propellant purity reactants out to a current density of 600ASF. Endurance testing of the two-cell module configuration exceeded the 2,500-hour LFCP voltage requirements out to 3700-hours. A two-cell module capable of operating at increased reactant pressure completed 1000 hours of operation at a 30 psia reactant pressure. A lightweight power section consisting of fifteen, two-cell modules connected electrically in series was fabricated.

Global carbon benefits of material substitution in passenger cars until 2050 and the impact on the steel and aluminum industries.

PubMed

Modaresi, Roja; Pauliuk, Stefan; Løvik, Amund N; Müller, Daniel B

2014-09-16

Light-weighting of passenger cars using high-strength steel or aluminum is a common emissions mitigation strategy. We provide a first estimate of the global impact of light-weighting by material substitution on GHG emissions from passenger cars and the steel and aluminum industries until 2050. We develop a dynamic stock model of the global car fleet and combine it with a dynamic MFA of the associated steel, aluminum, and energy supply industries. We propose four scenarios for substitution of conventional steel with high-strength steel and aluminum at different rates over the period 2010-2050. We show that light-weighting of passenger cars can become a "gigaton solution": Between 2010 and 2050, persistent light-weighting of passenger cars can, under optimal conditions, lead to cumulative GHG emissions savings of 9-18 gigatons CO2-eq compared to development business-as-usual. Annual savings can be up to 1 gigaton per year. After 2030, enhanced material recycling can lead to further reductions: closed-loop metal recycling in the automotive sector may reduce cumulative emissions by another 4-6 gigatons CO2-eq. The effectiveness of emissions mitigation by material substitution significantly depends on how the recycling system evolves. At present, policies focusing on tailpipe emissions and life cycle assessments of individual cars do not consider this important effect.

Acoustic Modeling of Lightweight Structures: A Literature Review

NASA Astrophysics Data System (ADS)

Yang, Shasha; Shen, Cheng

2017-10-01

This paper gives an overview of acoustic modeling for three kinds of typical lightweight structures including double-leaf plate system, stiffened single (or double) plate and porous material. Classical models are citied to provide frame work of theoretical modeling for acoustic property of lightweight structures; important research advances derived by our research group and other authors are introduced to describe the current state of art for acoustic research. Finally, remaining problems and future research directions are concluded and prospected briefly

NASA Tech Briefs, July 2004

NASA Technical Reports Server (NTRS)

2004-01-01

Topics: Optoelectronic Sensor System for Guidance in Docking; Hybrid Piezoelectric/Fiber-Optic Sensor Sheets; Multisensor Arrays for Greater Reliability and Accuracy; Integrated-Optic Oxygen Sensors; Ka-Band Autonomous Formation Flying Sensor; CMOS VLSI Active-Pixel Sensor for Tracking; Lightweight, Self-Deploying Foam Antenna Structures; Electrically Small Microstrip Quarter-Wave Monopole Antennas; A 2-to-28-MHz Phase-Locked Loop; Portable Electromyograph; Open-Source Software for Modeling of Nanoelectronic Devices; Software for Generating Strip Maps from SAR Data; Calibration Software for use with Jurassicprok; Software for Probabilistic Risk Reduction; Software Processes SAR Motion-Measurement Data; Improved Method of Purifying Carbon Nanotubes; Patterned Growth of Carbon Nanotubes or Nanofibers; Lightweight, Rack-Mountable Composite Cold Plate/Shelves; SiC-Based Miniature High-Temperature Cantilever Anemometer; Inlet Housing for a Partial-Admission Turbine; Lightweight Thermoformed Structural Components and Optics; Growing High-Quality InAs Quantum Dots for Infrared Lasers; Selected Papers on Protoplanetary Disks; Module for Oxygenating Water without Generating Bubbles; Coastal Research Imaging Spectrometer; Rapid Switching and Modulation by use of Coupled VCSELs; Laser-Induced-Fluorescence Photogrammetry and Videogrammetry; Laboratory Apparatus Generates Dual-Species Cold Atomic Beam; Laser Ablation of Materials for Propulsion of Spacecraft; Small Active Radiation Monitor; Hybrid Image-Plane/Stereo Manipulation; Partitioning a Gridded Rectangle into Smaller Rectangles; Digital Radar-Signal Processors Implemented in FPGAs; Part 1 of a Computational Study of a Drop-Laden Mixing Layer; and Some Improvements in Signal-Conditioning Circuits.

Recycling of MSWI fly ash by means of cementitious double step cold bonding pelletization: Technological assessment for the production of lightweight artificial aggregates.

PubMed

Colangelo, Francesco; Messina, Francesco; Cioffi, Raffaele

2015-12-15

In this work, an extensive study on the recycling of municipal solid waste incinerator fly ash by means of cold bonding pelletization is presented. The ash comes from an incineration plant equipped with rotary and stoker furnaces, in which municipal, hospital and industrial wastes are treated. Fly ash from waste incineration is classified as hazardous and cannot be utilized or even landfilled without prior treatment. The pelletization process uses cement, lime and coal fly ash as components of the binding systems. This process has been applied to several mixes in which the ash content has been varied from 50% (wt.%) up to a maximum of 70%. An innovative additional pelletization step with only cementitious binder has been performed in order to achieve satisfactory immobilization levels. The obtained lightweight porous aggregates are mostly suitable for recovery in the field of building materials with enhanced sustainability properties. Density, water absorption and crushing strength ranged from 1000 to 1600 kg/m(3), 7 to 16% and 1.3 to 6.2 MPa, respectively, and the second pelletization step increased stabilization efficiency. The feasibility of the process has been analyzed by testing also concrete specimens containing the artificial aggregates, resulting in lightweight concrete of average performance. Copyright © 2015 Elsevier B.V. All rights reserved.

New Method Developed To Purify Single Wall Carbon Nanotubes for Aerospace Applications

NASA Technical Reports Server (NTRS)

Lebron, Marisabel; Meador, Michael A.

2003-01-01

Single wall carbon nanotubes have attracted considerable attention because of their remarkable mechanical properties and electrical and thermal conductivities. Use of these materials as primary or secondary reinforcements in polymers or ceramics could lead to new materials with significantly enhanced mechanical strength and electrical and thermal conductivity. Use of carbon-nanotube-reinforced materials in aerospace components will enable substantial reductions in component weight and improvements in durability and safety. Potential applications for single wall carbon nanotubes include lightweight components for vehicle structures and propulsion systems, fuel cell components (bipolar plates and electrodes) and battery electrodes, and ultra-lightweight materials for use in solar sails. A major barrier to the successful use of carbon nanotubes in these components is the need for methods to economically produce pure carbon nanotubes in large enough quantities to not only evaluate their suitability for certain applications but also produce actual components. Most carbon nanotube synthesis methods, including the HiPCO (high pressure carbon monoxide) method developed by Smalley and others, employ metal catalysts that remain trapped in the final product. These catalyst impurities can affect nanotube properties and accelerate their decomposition. The development of techniques to remove most, if not all, of these impurities is essential to their successful use in practical applications. A new method has been developed at the NASA Glenn Research Center to purify gram-scale quantities of single wall carbon nanotubes. This method, a modification of a gas phase purification technique previously reported by Smalley and others, uses a combination of high-temperature oxidations and repeated extractions with nitric and hydrochloric acid. This improved procedure significantly reduces the amount of impurities (catalyst and nonnanotube forms of carbon) within the nanotubes, increasing their stability significantly. The onset of decomposition of the purified nanotubes (determined by thermal gravimetric analysis in air) is more than 300 C higher than that of the crude nanotubes. Transmission electron microscopy analysis of nanotubes purified by this method reveals near complete removal of iron catalyst particles. Analysis of the nanotubes using inductively coupled plasma spectroscopy revealed that the iron content of the nanotubes was reduced from 22.7 wt% in the crude nanotubes to less than 0.02 wt%. X-ray photoelectron spectroscopy revealed a decrease in iron content after purification as well as an increase in oxygen content due to the formation of carboxylic acid groups on the surface of the nanotubes. Nanotubes purified by this improved method can be readily dispersed in common organic solvents, in particular N,N-dimethylformamide, using prolonged ultrasonic treatment. These dispersions can then be used to incorporate single wall carbon nanotubes into polymer films.

Metal Coatings

NASA Technical Reports Server (NTRS)

1994-01-01

During the Apollo Program, General Magnaplate Corporation developed process techniques for bonding dry lubricant coatings to space metals. The coatings were not susceptible to outgassing and offered enhanced surface hardness and superior resistance to corrosion and wear. This development was necessary because conventional lubrication processes were inadequate for lightweight materials used in Apollo components. General Magnaplate built on the original technology and became a leader in development of high performance metallurgical surface enhancement coatings - "synergistic" coatings, - which are used in applications from pizza making to laser manufacture. Each of the coatings is designed to protect a specific metal or group of metals to solve problems encountered under operating conditions.

Advanced Aerospace Materials by Design

NASA Technical Reports Server (NTRS)

Srivastava, Deepak; Djomehri, Jahed; Wei, Chen-Yu

2004-01-01

The advances in the emerging field of nanophase thermal and structural composite materials; materials with embedded sensors and actuators for morphing structures; light-weight composite materials for energy and power storage; and large surface area materials for in-situ resource generation and waste recycling, are expected to :revolutionize the capabilities of virtually every system comprising of future robotic and :human moon and mars exploration missions. A high-performance multiscale simulation platform, including the computational capabilities and resources of Columbia - the new supercomputer, is being developed to discover, validate, and prototype next generation (of such advanced materials. This exhibit will describe the porting and scaling of multiscale 'physics based core computer simulation codes for discovering and designing carbon nanotube-polymer composite materials for light-weight load bearing structural and 'thermal protection applications.

Analysis of hazardous substances released during CFRP laser processing

NASA Astrophysics Data System (ADS)

Hustedt, Michael; Walter, Juergen; Bluemel, Sven; Jaeschke, Peter; Kaierle, Stefan

2017-02-01

Due to their outstanding mechanical properties, in particular their high specific strength parallel to the carbon fibers, carbon fiber reinforced plastics (CFRP) have a high potential regarding resource-efficient lightweight construction. Consequently, these composite materials are increasingly finding application in important industrial branches such as aircraft, automotive and wind energy industry. However, the processing of these materials is highly demanding. On the one hand, mechanical processing methods such as milling or drilling are sometimes rather slow, and they are connected with notable tool wear. On the other hand, thermal processing methods are critical as the two components matrix and reinforcement have widely differing thermophysical properties, possibly leading to damages of the composite structure in terms of pores or delamination. An emerging innovative method for processing of CFRP materials is the laser technology. As principally thermal method, laser processing is connected with the release of potentially hazardous, gaseous and particulate substances. Detailed knowledge of these process emissions is the basis to ensure the protection of man and the environment, according to the existing legal regulations. This knowledge will help to realize adequate protective measures and thus strengthen the development of CFRP laser processing. In this work, selected measurement methods and results of the analysis of the exhaust air and the air at the workplace during different laser processes with CFRP materials are presented. The investigations have been performed in the course of different cooperative projects, funded by the German Federal Ministry of Education and Research (BMBF) in the course of the funding initiative "Photonic Processes and Tools for Resource-Efficient Lightweight Structures".

Tooling Foam for Structural Composite Applications

NASA Technical Reports Server (NTRS)

DeLay, Tom; Smith, Brett H.; Ely, Kevin; MacArthur, Doug

1998-01-01

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

Component technology for space power systems

NASA Technical Reports Server (NTRS)

Finke, R. C.

1982-01-01

Progress made by NASA toward implementation of equipment for the conversion, management, and distribution of voltage power in space applications are reviewed. Work has been carried forward on components such as bipolar transistors, deep impurity semiconductors, conductors, dielectrics, magnetic devices, and rotary power transfer. Specific programs for the high voltage systems have included research on lightweight, low-cost conductors featuring graphite fibers containing electron donor materials for wires and cables with reduced mass and the conductivity of copper. Attention has also been given p-n junction technology for high-speed, high-current, high-voltage materials and diamond-like dielectric films which are hard, have high dielectric strength, and can operate up to 300 C. A transistor has been fabricated with a voltage of 1200 V at 100 A, with a gain of 10 and a 0.5 microsec rise/fall time. A 25 kW transformer has also been built which performs at 20 kHz with an efficiency of 99.2%.

Reinforced Honeycomb Panels

NASA Technical Reports Server (NTRS)

Bhat, Balakrishna T.; Akutagawa, Wesley; Wang, Taylor G.; Barber, Dan

1989-01-01

New honeycomb panel structure has increased strength and stiffness with little increase in weight. Some or all of walls of honeycomb cells reinforced with honeycomb panels having smaller cells, lightweight foam, or other reinforcing material. Strong, lightweight reinforced panels used in aircraft, car and truck bodies, cabinets for equipment and appliances, and buildings.

Lightweight solar concentrator structures, phase 2

NASA Technical Reports Server (NTRS)

Williams, Brian E.; Kaplan, Richard B.

1993-01-01

This report summarizes the results of the program conducted by Ultramet under SBIR Phase 2 Contract NAS3-25418. The objective of this program was to develop lightweight materials and processes for advanced high accuracy Space Solar Concentrators using rigidized foam for the substrate structure with an integral optical surface.

The Development of Lightweight Electronics Enclosures for Space Applications

NASA Technical Reports Server (NTRS)

Fenske, Matthew T.; Barth, Jane L.; Didion, Jeffrey R.; Mule, Peter

1999-01-01

This paper outlines the end to end effort to produce lightweight electronics enclosures for NASA GSFC electronics applications with the end goal of presenting an array of lightweight box options for a flight opportunity. Topics including the development of requirements, design of three different boxes, utilization of advanced materials and processes, and analysis and test will be discussed. Three different boxes were developed independently and in parallel. A lightweight machined Aluminum box, a cast Aluminum box and a composite box were designed, fabricated, and tested both mechanically and thermally. There were many challenges encountered in meeting the requirements with a non-metallic enclosure and the development of the composite box employed several innovative techniques.

Characterization of Candidate Solar Sail Material Exposed to Space Environmental Effects

NASA Technical Reports Server (NTRS)

Edwards, David; Hovater, Mary; Hubbs, Whitney; Wertz, George; Hollerman, William; Gray, Perry

2003-01-01

Solar sailing is a unique form of propulsion where a spacecraft gains momentum from incident photons. Solar sails are not limited by reaction mass and provide continual acceleration, reduced only by the lifetime of the lightweight film in the space environment and the distance to the Sun. Once thought to be difficult or impossible, solar sailing has come out of science fiction and into the realm of possibility. Any spacecraft using this method would need to deploy a thin sail that could be as large as many kilometers in extent. The availability of strong, ultra lightweight, and radiation resistant materials will determine the future of solar sailing. The National Aeronautics and Space Administration's Marshall Space Flight Center (MSFC) is concentrating research into the utilization of ultra lightweight materials for spacecraft propulsion. The Space Environmental Effects Team at MSFC is actively characterizing candidate solar sail material to evaluate the thermo-optical and mechanical properties after exposure to space environmental effects. This paper will describe the exposure of candidate solar sail materials to emulated space environmental effects including energetic electrons, combined electrons and Ultraviolet radiation, and hypervelocity impact of irradiated solar sail material. This paper will describe the testing procedure and the material characterization results of this investigation.

Advanced Design Heat PumpRadiator for EVA Suits

NASA Technical Reports Server (NTRS)

Izenson, Michael G.; Chen, Weibo; Passow, Christian; Phillips, Scott; Trevino, Luis

2009-01-01

Absorption cooling using a LiCl/water heat pump can enable lightweight and effective thermal control for EVA suits without venting water to the environment. The key components in the system are an absorber/radiator that rejects heat to space and a flexible evaporation cooling garment that absorbs heat from the crew member. This paper describes progress in the design, development, and testing of the absorber/radiator and evaporation cooling garment. New design concepts and fabrication approaches will significantly reduce the mass of the absorber/radiator. We have also identified materials and demonstrated fabrication approaches for production of a flexible evaporation cooling garment. Data from tests of the absorber/radiator s modular components have validated the design models and allowed predictions of the size and weight of a complete system.

The outlook for advanced transport aircraft

NASA Technical Reports Server (NTRS)

Leavens, J. M., Jr.; Schaufele, R. D.; Jones, R. T.; Steiner, J. E.; Beteille, R.; Titcomb, G. A.; Coplin, J. F.; Rowe, B. H.; Lloyd-Jones, D. J.; Overend, W. J.

1982-01-01

The technological advances most likely to contribute to advanced aircraft designs and the efficiency, performance, and financial considerations driving the development directions for new aircraft are reviewed. Fuel-efficiency is perceived as the most critical factor for any new aircraft or component design, with most gains expected to come in areas of propulsion, aerodynamics, configurations, structural designs and materials, active controls, digital avionics, laminar flow control, and air-traffic control improvements. Any component area offers an efficiency improvement of 3-12%, with a maximum of 50% possible with a 4000 m range aircraft. Advanced turboprops have potential applications in short and medium haul subsonic aircraft, while a fuel efficient SST may be possible by the year 2000. Further discussion is devoted to the pivoted oblique wing aircraft, lightweight structures, and the necessity for short payback times.

Fabrication of lightweight ceramic mirrors by means of a chemical vapor deposition process

NASA Technical Reports Server (NTRS)

Goela, Jitendra S. (Inventor); Taylor, Raymond L. (Inventor)

1991-01-01

A process to fabricate lightweigth ceramic mirrors, and in particular, silicon/silicon carbide mirrors, involves three chemical vapor deposition steps: one to produce the mirror faceplate, the second to form the lightweight backstructure which is deposited integral to the faceplate, and the third and final step which results in the deposition of a layer of optical grade material, for example, silicon, onto the front surface of the faceplate. The mirror figure and finish are fabricated into this latter material.

Improving Thermal Insulation Properties for Prefabricated Wall Components Made Of Lightweight Aggregate Concrete with Open Structure

NASA Astrophysics Data System (ADS)

Abramski, Marcin

2017-10-01

Porous concrete is commonly used in civil engineering due to its good thermal insulation properties in comparison with normal concrete and high compression strength in comparison with other building materials. Reducing of the concrete density can be obviously obtained by using lightweight aggregate (e.g. pumice). The concrete density can be further minimized by using specially graded coarse aggregate and little-to-no fine aggregates. In this way a large number of air voids arise. The aggregate particles are coated by a cement paste and bonded together with it just in contact points. Such an extremely porous concrete, called ‘lightweight aggregate concrete with open structure’ (LAC), is used in some German plants to produce prefabricated wall components. They are used mainly in hall buildings, e.g. supermarkets. The need of improving thermal insulation properties was an inspiration for the prefabrication plant managers, engineers and a scientific staff of the Technical University of Kaiserslautern / Germany to realise an interesting project. Its aim was to reduce the heat transfer coefficient for the wall components. Three different wall structure types were designed and compared in full-scale laboratory tests with originally produced wall components in terms of load-carrying capacity and stiffness. The load was applied perpendicularly to the wall plane. As the components are not originally used for load-bearing walls, but for curtain walls only, the wind load is the main load for them. The wall components were tested in horizontal position and the load was applied vertically. Totally twelve wall components 8.00 × 2.00 × 0.25m (three for every series) were produced in the prefabrication plant and tested in the University of Kaiserslautern laboratory. The designed and tested components differed from each other in the amount of expanded polystyrene (EPS), which was placed in the plant inside the wall structure. The minimal amount of it was designed in the original wall component type. Besides, two improved types of prefabricated wall had built-in steel lattice girders. The failure mode was the same for all the tested components: diagonal cracks occurred on the sides of each component due to their insufficient shear-force-capacity. The span deflection was measured during all the tests by means of LVDTs. Load-carrying capacities obtained in the tests were for all wall structure types similar and much higher (many times) than internal forces (i.e. bending moments and shear forces) calculated for a wind load acting on a typical hall building according to the German codes. An increased amount of EPS (up to 30 per cent in volume) did not influence significantly the wall structural strength. The use of the steel lattice girders caused some technological problems and led to a quality loss of the produced components. The future use of the lattice girders would require a change in the production process: it would have to be more labour consuming.

Development and characterization of fatigue resistant Aramid reinforced aluminium laminates (ARALL) for fatigue Critical aircraft components

NASA Astrophysics Data System (ADS)

Qaiser, M. H.; Umar, S.; Nauman, S.

2014-06-01

The structural weight of an aircraft has always been a controlling parameter that governs its fuel efficiency and transport capacity. In pursuit of achieving light-weight aircraft structures, high design stress levels have to be adopted and materials with high specific strength such as Aluminum etc. are to be deployed. However, an extensive spectrum of fatigue load exists at the aircraft wings and other aerodynamic components that may cause initiation and propagation of fatigue cracks and concludes in a catastrophic rupture. Fatigue is therefore the limiting design parameter in such cases and materials with high fatigue resistance are then required. A major improvement in the fatigue behavior was observed by laminating Kevlar fibers with Aluminum using epoxy. ARALL (Aramid Reinforced ALuminum Laminates) is a fatigue resistant hybrid composite that consists of layers of thin high strength aluminum alloy sheets surface bonded with aramid fibers. The intact aramid fibers tie up the fatigue cracks, thus reducing the stress intensity factor at the crack tip as a result of which the fatigue properties of can be enhanced with orders of magnitude as compared to monolithic high strength Aluminum alloy sheets. Significant amount of weight savings can be achieved in fatigue critical components in comparison with the traditional materials used in aircraft.

Density-tunable lightweight polymer composites with dual-functional ability of efficient EMI shielding and heat dissipation.

PubMed

Lee, Seung Hwan; Yu, Seunggun; Shahzad, Faisal; Kim, Woo Nyon; Park, Cheolmin; Hong, Soon Man; Koo, Chong Min

2017-09-21

Lightweight dual-functional materials with high EMI shielding performance and thermal conductivity are of great importance in modern cutting-edge applications, such as mobile electronics, automotive, aerospace, and military. Unfortunately, a clear material solution has not emerged yet. Herein, we demonstrate a simple and effective way to fabricate lightweight metal-based polymer composites with dual-functional ability of excellent EMI shielding effectiveness and thermal conductivity using expandable polymer bead-templated Cu hollow beads. The low-density Cu hollow beads (ρ ∼ 0.44 g cm -3 ) were fabricated through electroless plating of Cu on the expanded polymer beads with ultralow density (ρ ∼ 0.02 g cm -3 ). The resulting composites that formed a continuous 3D Cu network with a very small Cu content (∼9.8 vol%) exhibited excellent EMI shielding (110.7 dB at 7 GHz) and thermal conductivity (7.0 W m -1 K -1 ) with isotropic features. Moreover, the densities of the composites are tunable from 1.28 to 0.59 g cm -3 in accordance with the purpose of their applications. To the best of our knowledge, the resulting composites are the best lightweight dual-functional materials with exceptionally high EMI SE and thermal conductivity performance among synthetic polymer composites.

Experimental Observations for Determining the Maximum Torque Values to Apply to Composite Components Mechanically Joined With Fasteners (MSFC Center Director's Discretionary Fund Final Report, Proj. 03-13}

NASA Technical Reports Server (NTRS)

Thomas, F. P.

2006-01-01

Aerospace structures utilize innovative, lightweight composite materials for exploration activities. These structural components, due to various reasons including size limitations, manufacturing facilities, contractual obligations, or particular design requirements, will have to be joined. The common methodologies for joining composite components are the adhesively bonded and mechanically fastened joints and, in certain instances, both methods are simultaneously incorporated into the design. Guidelines and recommendations exist for engineers to develop design criteria and analyze and test composites. However, there are no guidelines or recommendations based on analysis or test data to specify a torque or torque range to apply to metallic mechanical fasteners used to join composite components. Utilizing the torque tension machine at NASA s Marshall Space Flight Center, an initial series of tests were conducted to determine the maximum torque that could be applied to a composite specimen. Acoustic emissions were used to nondestructively assess the specimens during the tests and thermographic imaging after the tests.

Evaluating opportunities to improve material and energy impacts in commodity supply chains

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hanes, Rebecca J.; Carpenter, Alberta

When evaluated at the scale of individual processes, next-generation technologies may be more energy and emissions intensive than current technology. Furthermore, many advanced technologies have the potential to reduce material and energy consumption in upstream or downstream processing stages. In order to fully understand the benefits and consequences of technology deployment, next-generation technologies should be evaluated in context, as part of a supply chain. This work presents the Materials Flow through Industry (MFI) supply chain modeling tool. The MFI tool is a cradle-to-gate linear network model of the US industrial sector that can model a wide range of manufacturing scenarios,more » including changes in production technology and increases in industrial energy efficiency. The MFI tool was developed to perform supply chain scale analyses in order to quantify the impacts and benefits of next-generation technologies and materials at that scale. For the analysis presented in this paper, the MFI tool is utilized to explore a case study comparing three lightweight vehicle supply chains to the supply chain of a conventional, standard weight vehicle. Several of the lightweight vehicle supply chains are evaluated under manufacturing scenarios that include next-generation production technologies and next-generation materials. Results indicate that producing lightweight vehicles is more energy and emission intensive than producing the non-lightweight vehicle, but the fuel saved during vehicle use offsets this increase. In this case study, greater reductions in supply chain energy and emissions were achieved through the application of the next-generation technologies than from application of energy efficiency increases.« less

Evaluating opportunities to improve material and energy impacts in commodity supply chains

DOE PAGES

Hanes, Rebecca J.; Carpenter, Alberta

2017-01-10

When evaluated at the scale of individual processes, next-generation technologies may be more energy and emissions intensive than current technology. Furthermore, many advanced technologies have the potential to reduce material and energy consumption in upstream or downstream processing stages. In order to fully understand the benefits and consequences of technology deployment, next-generation technologies should be evaluated in context, as part of a supply chain. This work presents the Materials Flow through Industry (MFI) supply chain modeling tool. The MFI tool is a cradle-to-gate linear network model of the US industrial sector that can model a wide range of manufacturing scenarios,more » including changes in production technology and increases in industrial energy efficiency. The MFI tool was developed to perform supply chain scale analyses in order to quantify the impacts and benefits of next-generation technologies and materials at that scale. For the analysis presented in this paper, the MFI tool is utilized to explore a case study comparing three lightweight vehicle supply chains to the supply chain of a conventional, standard weight vehicle. Several of the lightweight vehicle supply chains are evaluated under manufacturing scenarios that include next-generation production technologies and next-generation materials. Results indicate that producing lightweight vehicles is more energy and emission intensive than producing the non-lightweight vehicle, but the fuel saved during vehicle use offsets this increase. In this case study, greater reductions in supply chain energy and emissions were achieved through the application of the next-generation technologies than from application of energy efficiency increases.« less

Steel skin - SMC laminate structures for lightweight automotive manufacturing

NASA Astrophysics Data System (ADS)

Quagliato, Luca; Jang, Changsoon; Murugesan, Mohanraj; Kim, Naksoo

2017-09-01

In the present research work an innovative material, made of steel skin and sheet molding compound core, is presented and is aimed to be utilized for the production of automotive body frames. For a precise description of the laminate structure, the material properties of all the components, including the adhesive utilized as an interlayer, have been carried out, along with the simple tension test of the composite material. The result have shown that the proposed laminate structure has a specific yield strength 114% higher than 6061 T6 aluminum, 34% higher than 7075 T6 aluminum, 186% higher than AISI 304 stainless steel (30HRC) and 42% than SK5 high-strength steel (52HRC), showing its reliability and convenience for the realization of automotive components. After calibrating the material properties of the laminate structure, and utilizing as reference the simple tension results of the laminate structure, the derived material properties have been utilized for the simulation of the mechanical behavior of an automotive B-pillar. The results have been compared with those of a standard B-pillar made of steel, showing that the MS-SMC laminate structure manifests load and impact carry capacity comparable with those of high strength steel, while granting, at least, an 11% weight reduction.

Mechanical Properties of T650-35/AFR-PE-4 at Elevated Temperatures for Lightweight Aeroshell Designs

NASA Technical Reports Server (NTRS)

Whitley, Karen S.; Collins, TImothy J.

2006-01-01

Considerable efforts have been underway to develop multidisciplinary technologies for aeroshell structures that will significantly increase the allowable working temperature for the aeroshell components, and enable the system to operate at higher temperatures while sustaining performance and durability. As part of these efforts, high temperature polymer matrix composites and fabrication technologies are being developed for the primary load bearing structure (heat shield) of the spacecraft. New high-temperature resins and composite material manufacturing techniques are available that have the potential to significantly improve current aeroshell design. In order to qualify a polymer matrix composite (PMC) material as a candidate aeroshell structural material, its performance must be evaluated under realistic environments. Thus, verification testing of lightweight PMC's at aeroshell entry temperatures is needed to ensure that they will perform successfully in high-temperature environments. Towards this end, a test program was developed to characterize the mechanical properties of two candidate material systems, T650-35/AFR-PE-4 and T650-35/RP46. The two candidate high-temperature polyimide resins, AFR-PE-4 and RP46, were developed at the Air Force Research Laboratory and NASA Langley Research Center, respectively. This paper presents experimental methods, strength, and stiffness data of the T650-35/AFR-PE-4 material as a function of elevated temperatures. The properties determined during the research test program herein, included tensile strength, tensile stiffness, Poisson s ratio, compressive strength, compressive stiffness, shear modulus, and shear strength. Unidirectional laminates, a cross-ply laminate and two eight-harness satin (8HS)-weave laminates (4-ply and 10-ply) were tested according to ASTM standard methods at room and elevated temperatures (23, 316, and 343 C). All of the relevant test methods and data reduction schemes are outlined along with mechanical data. These data contribute to a database of material properties for high-temperature polyimide composites that will be used to identify the material characteristics of potential candidate materials for aeroshell structure applications.

High-Temperature, Lightweight, Self-Healing Ceramic Composites for Aircraft Engine Applications

NASA Technical Reports Server (NTRS)

Raj, Sai V.; Bhatt, Ramkrishna

2013-01-01

The use of reliable, high-temperature, lightweight materials in the manufacture of aircraft engines is expected to result in lower fossil and biofuel consumption, thereby leading to cost savings and lower carbon emissions due to air travel. Although nickel-based superalloy blades and vanes have been successfully used in aircraft engines for several decades, there has been an increased effort to develop high-temperature, lightweight, creep-resistant substitute materials under various NASA programs over the last two decades. As a result, there has been a great deal of interest in developing SiC/SiC ceramic matrix composites (CMCs) due to their higher damage tolerance compared to monolithic ceramics. Current-generation SiC/SiC ceramic matrix composites rely almost entirely on the SiC fibers to carry the load, owing to the premature cracking of the matrix during loading. Thus, the high-temperature usefulness of these CMCs falls well below their theoretical capabilities. The objective of this work is to develop a new class of high-temperature, lightweight, self-healing, SiC fiber-reinforced, engineered matrix ceramic composites.

Application of Glass Fiber Waste Polypropylene Aggregate in Lightweight Concrete – thermal properties

NASA Astrophysics Data System (ADS)

Citek, D.; Rehacek, S.; Pavlik, Z.; Kolisko, J.; Dobias, D.; Pavlikova, M.

2018-03-01

Actual paper focus on thermal properties of a sustainable lightweight concrete incorporating high volume of waste polypropylene aggregate as partial substitution of natural aggregate. In presented experiments a glass fiber reinforced polypropylene (GFPP) which is a by-product of PP tubes production, partially substituted fine natural silica aggregate in 10, 20, 30, 40 and 50 mass %. Results were compared with a reference concrete mix without plastic waste in order to quantify the effect of GFPP use on concrete properties. Main material physical parameters were studied (bulk density, matrix density without air content, and particle size distribution). Especially a thermal transport and storage properties of GFPP were examined in dependence on compaction time. For the developed lightweight concrete, thermal properties were accessed using transient impulse technique, where the measurement was done in dependence on moisture content (from the fully water saturated state to dry state). It was found that the tested lightweight concrete should be prospective construction material possessing improved thermal insulation function and the reuse of waste plastics in concrete composition was beneficial both from the environmental and financial point of view.

Life cycle assessment of vehicle lightweighting: a physics-based model of mass-induced fuel consumption.

PubMed

Kim, Hyung Chul; Wallington, Timothy J

2013-12-17

Lightweighting is a key strategy used to improve vehicle fuel economy. Replacing conventional materials (e.g., steel) with lighter alternatives (e.g., aluminum, magnesium, and composites) decreases energy consumption and greenhouse gas (GHG) emissions during vehicle use, but often increases energy consumption and GHG emissions during materials and vehicle production. Assessing the life-cycle benefits of mass reduction requires a quantitative description of the mass-induced fuel consumption during vehicle use. A new physics-based method for estimating mass-induced fuel consumption (MIF) is proposed. We illustrate the utility of this method by using publicly available data to calculate MIF values in the range of 0.2-0.5 L/(100 km 100 kg) based on 106 records of fuel economy tests by the U.S. Environmental Protection Agency for 2013 model year vehicles. Lightweighting is shown to have the most benefit when applied to vehicles with high fuel consumption and high power. Use of the physics-based model presented here would place future life cycle assessment studies of vehicle lightweighting on a firmer scientific foundation.

Rapid Fabrication of Lightweight SiC Optics using Reactive Atom Plasma (RAP) Processing

NASA Technical Reports Server (NTRS)

Fiske, Peter S.

2006-01-01

Reactive Atom Plasma (RAP) processing is a non-contact, plasma-based processing technology that can be used to generate damage-free optical surfaces. We have developed tools and processes using RAP that allow us to shape extremely lightweight mirror Surfaces made from extremely hard-to-machine materials (e.g. SiC). We will describe our latest results using RAP in combination with other technologies to produce finished lightweight SiC mirrors and also discuss applications for RAP in the rapid fabrication of mirror segments for reflective and grazing incidence telescopes.

Thermal aging of traditional and additively manufactured foams: analysis by time-temperature-superposition, constitutive, and finite-element models

DOE Office of Scientific and Technical Information (OSTI.GOV)

Maiti, A.; Weisgraber, T. H.; Small, W.

Cellular solids or foams are a very important class of materials with diverse applications ranging from thermal insulation and shock absorbing support cushions, to light-weight structural and floatation components, and constitute crucial components in a large number of industries including automotive, aerospace, electronics, marine, biomedical, packaging, and defense. In many of these applications the foam material is subjected to long periods of continuous stress, which can, over time, lead to a permanent change in structure and a degradation in performance. In this report we summarize our modeling efforts to date on polysiloxane foam materials that form an important component inmore » our systems. Aging of the materials was characterized by two measured quantities, i.e., compression set and load retention. Results of accelerated aging experiments were analyzed by an automated time-temperaturesuperposition (TTS) approach, which creates a master curve that can be used for long-term predictions (over decades) under ambient conditions. When comparing such master curves for traditional (stochastic) foams with those for recently 3D-printed (i.e., additively manufactured, or AM) foams, it became clear that AM foams have superior aging behavior. To gain deeper understanding, we imaged the microstructure of both foams using X-ray computed tomography, and performed finite-element analysis of the mechanical response within these microstructures. This indicates a wider stress variation in the stochastic foam with points of more extreme local stress as compared to the 3D printed material.« less

Three-Dimensional Cellular Structures Enhanced By Shape Memory Alloys

NASA Technical Reports Server (NTRS)

Nathal, Michael V.; Krause, David L.; Wilmoth, Nathan G.; Bednarcyk, Brett A.; Baker, Eric H.

2014-01-01

This research effort explored lightweight structural concepts married with advanced smart materials to achieve a wide variety of benefits in airframe and engine components. Lattice block structures were cast from an aerospace structural titanium alloy Ti-6Al-4V and a NiTi shape memory alloy (SMA), and preliminary properties have been measured. A finite element-based modeling approach that can rapidly and accurately capture the deformation response of lattice architectures was developed. The Ti-6-4 and SMA material behavior was calibrated via experimental tests of ligaments machined from the lattice. Benchmark testing of complete lattice structures verified the main aspects of the model as well as demonstrated the advantages of the lattice structure. Shape memory behavior of a sample machined from a lattice block was also demonstrated.

Future opportunities for advancing glucose test device electronics.

PubMed

Young, Brian R; Young, Teresa L; Joyce, Margaret K; Kennedy, Spencer I; Atashbar, Massood Z

2011-09-01

Advancements in the field of printed electronics can be applied to the field of diabetes testing. A brief history and some new developments in printed electronics components applicable to personal test devices, including circuitry, batteries, transmission devices, displays, and sensors, are presented. Low-cost, thin, and lightweight materials containing printed circuits with energy storage or harvest capability and reactive/display centers, made using new printing/imaging technologies, are ideal for incorporation into personal-use medical devices such as glucose test meters. Semicontinuous rotogravure printing, which utilizes flexible substrates and polymeric, metallic, and/or nano "ink" composite materials to effect rapidly produced, lower-cost printed electronics, is showing promise. Continuing research advancing substrate, "ink," and continuous processing development presents the opportunity for research collaboration with medical device designers. © 2011 Diabetes Technology Society.

Experimental investigation of fiberglass sandwich composite bending behaviour after severe aging condition

NASA Astrophysics Data System (ADS)

Gambaro, Carla; Lertora, Enrico; Mandolfino, Chiara

2016-10-01

Fiber Reinforced Polymer (FRP) sandwich panels are increasing their application as structural and non-structural components in all kinds of construction. By varying the material and thickness of core and face sheets, it is possible to obtain sandwich structures with different properties and performance. In particular, their advantages as lightweight and high mechanical properties make them extremely suitable for the transport industry. One of the most critical aspects regarding composite materials for engineering application is their performance after hygrothermal aging. The panels used in this study are composed of low density core, made by thermosetting resin foam with microspheres and glass fibers rolled until obtaining the required thickness, and two face sheets of the same material but realized in high density. In this study, the authors focused on the bending behaviour of this kind of sandwich panel, as received and after severe aging cycles.

A study on the strength of an armour-grade aluminum under high strain-rate loading

NASA Astrophysics Data System (ADS)

Appleby-Thomas, G. J.; Hazell, P. J.

2010-06-01

The aluminum alloy 5083 in tempers such as H32 and H131 is an established light-weight armour material. While its dynamic response under high strain-rates has been investigated elsewhere, little account of the effect of material orientation has been made. In addition, little information on its strength under such loadings is available in the literature. Here, both the longitudinal and lateral components of stress have been measured using embedded manganin stress gauges during plate-impact experiments on samples with the rolling direction aligned both orthogonal and parallel to the impact axis. The Hugoniot elastic limit, spall, and shear strengths were investigated for incident pressures in the range 1-8 GPa, providing an insight into the response of this alloy under shock loading. Further, the time dependence of lateral stress behind the shock front was investigated to give an indication of material response.

Design, fabrication, and test of lightweight shell structure, phase 2

NASA Technical Reports Server (NTRS)

1974-01-01

A cylindrical shell skirt structure 4.57 m (180 in.) in diameter and 3.66 m (144 in.) high was subjected to a design and analysis study using a wide variety of structural materials and concepts. The design loading of 1225.8 N/cm (700 lb/in.) axial compression and 245.2 N/cm (140 lb/in.) torsion is representative of that expected on a typical space tug skirt section. Structural concepts evaluated included honeycomb sandwich, truss, isogrid, and skin/stringer/frame. The materials considered included a wide variety of structural metals as well as glass, graphite, and boron-reinforced composites. The most unique characteristic of the candidate designs is that they involve the use of very thin-gage material. Fabrication and structural test of small panels and components representative of many of the candidate designs served to demonstrate proposed fabrication techniques and to verify design and analysis methods.

Large aperture telescope technology: a design for an active lightweight multi-segmented fold-out space mirror

NASA Astrophysics Data System (ADS)

Thompson, S. J.; Doel, A. P.; Whalley, M.; Edeson, R.; Edeson, R.; Tosh, I.; Poyntz-Wright, O.; Atad-Ettedgui, E.; Montgomery, D.; Nawasra, J.

2017-11-01

Large aperture telescope technology (LATT) is a design study for a differential lidar (DIAL) system; the main investigation being into suitable methods, technologies and materials for a 4-metre diameter active mirror that can be stowed to fit into a typical launch vehicle (e.g. ROKOT launcher with 2.1-metre diameter cargo) and can self-deploy - in terms of both leaving the space vehicle and that the mirrors unfold and self-align to the correct optical form within the tolerances specified. The primary mirror requirements are: main wavelength of 935.5 nm, RMS corrected wavefront error of λ/6, optical surface roughness better than 5 nm, areal density of less than 16 kg/m2 and 1-2 mirror shape corrections per orbit. The primary mirror consists of 7 segments - a central hexagonal mirror and 6 square mirror petals which unfold to form the 4-meter diameter aperture. The focus of the UK LATT consortium for this European Space Agency (ESA) funded project is on using lightweighted aluminium or carbon-fibre-composite materials for the mirror substrate in preference to more traditional materials such as glass and ceramics; these materials have a high strength and stiffness to weight ratio, significantly reducing risk of damage due to launch forces and subsequent deployment in orbit. We present an overview of the design, which includes suitable actuators for wavefront correction, petal deployment mechanisms and lightweight mirror technologies. Preliminary testing results from manufactured lightweight mirror samples will also be summarised.

Production of lightweight aggregates from washing aggregate sludge and fly ash

NASA Astrophysics Data System (ADS)

González-Corrochano, Beatriz; Alonso-Azcárate, Jacinto; Rodas, Magdalena

2010-05-01

Increasing generation of wastes is one of the main environmental problems in industrialised countries. Heat treatment at high temperatures can convert some types of wastes into ceramic products with a wide range of microstructural features and properties (Bethanis et al., 2004). A lightweight aggregate (LWA) is a granular material with a bulk density (bd) not exceeding 1.20 g/cm3 or with a particle density not exceeding 2.00 g/cm3 (UNE-EN-13055-1, 2003). They have become a focus of interest because the low particle density and the low bulk density entail a decrease in the load transmitted to the ground, and less work and effort are required to transport them (De' Gennaro et al., 2004). The benefits associated with these low densities, which are due to the formation of voids and pores, are very good thermal and acoustic insulation and materials with a good resistance to fire (Benbow, 1987; Fakhfakh et al., 2007). The objective was to recycle fly ash, used motor oil from cars and mineral wastes from washing aggregate sludge, in order to obtain a usable material such as lightweight aggregates, and also to ensure that they are of good quality for different applications. Raw materials have been physically, chemically and mineralogically characterized. On the basis of the results obtained, they were mixed, milled to a grain size of less than 200 μm (Yasuda, 1991), formed into pellets, pre-heated for 5 min and sintered in a rotary kiln at 1150°C, 1175°C, 1200°C and 1225°C for 10 and 15 min at each temperature (Theating). Effects of raw material characteristics, heating temperature and dwell time on the following LWAs properties were determined: loss on ignition (LOI), bloating index (BI), loose bulk density (bd), apparent and dry particle density (ad, dd), voids (H), water absorption (WA24h) and compressive strength (S). The products obtained were lightweight aggregates in accordance with norm UNE-EN-13055-1 (bd ≤1.20 g/cm3 or particle density ≤2.00 g/cm3). LWAs manufactured with 75%:25% and 50%:50% proportions of washing aggregate sludge:fly ash, heated at different temperatures and dwell times, were expanded LWAs (BI > 0). They showed the lowest loose bulk density, the lowest dry and apparent particle density, the lowest water absorption and the highest compressive strength. The possible applications of sintered pellets, taking into consideration compressive strength and water absorption values, could be similar to those of Arlita G3 (insulation, geotechnical applications, gardening and/or horticulture) and/or Arlita F3 (prefabricated lightweight structures and insulation lightweight concretes), two varieties of the most widely marketed LWAs in Spain. References - Benbow, J., September 1987. Mineral in fire protection construction support market. Industrial Minerals, 61-73. - Bethanis, S., Cheeseman, C.R., Sollars, C.J., 2004. Effect of sintering temperature on the properties and leaching of incinerator bottom ash. Waste Management and Research 22 (4), 255-264. - De' Gennaro, R., Cappelletti, P., Cerri, G., De' Gennaro, M., Dondi, M., Langella, A., 2004. Zeolitic tuffs as raw materials for lightweight aggregates. Applied Clay Science 25 (1-2), 71-81. - Fakhfakh, E., Hajjaji, W., Medhioub, M., Rocha, F., López-Galindo, A., Setti, M.,Kooli, F., Zargouni, F., Jamoussi, F., 2007. Effects of sand addition on production of lightweight aggregates from Tunisian smectite-rich clayey rocks. Applied Clay Science 35, 228-237. - UNE-EN-13055-1, 2003. Lightweight aggregates - lightweight aggregates for concrete, mortar and grout. - Yasuda, Y., 1991. Sewage-sludge utilization in Tokyo. Water Science and Technology 23 (10-12), 1743-1752.

Characterizing the Conductivity and Enhancing the Piezoresistivity of Carbon Nanotube-Polymeric Thin Films

PubMed Central

Zhao, Yingjun; Schagerl, Martin; Viechtbauer, Christoph

2017-01-01

The concept of lightweight design is widely employed for designing and constructing aerospace structures that can sustain extreme loads while also being fuel-efficient. Popular lightweight materials such as aluminum alloy and fiber-reinforced polymers (FRPs) possess outstanding mechanical properties, but their structural integrity requires constant assessment to ensure structural safety. Next-generation structural health monitoring systems for aerospace structures should be lightweight and integrated with the structure itself. In this study, a multi-walled carbon nanotube (MWCNT)-based polymer paint was developed to detect distributed damage in lightweight structures. The thin film’s electromechanical properties were characterized via cyclic loading tests. Moreover, the thin film’s bulk conductivity was characterized by finite element modeling. PMID:28773084

Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors

NASA Technical Reports Server (NTRS)

Vudler, Vladimir

2012-01-01

High-precision mirrors for space applications are traditionally manufactured from one piece of material, such as lightweight glass sandwich or beryllium. The purpose of this project was to develop and test the feasibility of a manufacturing process capable of producing mirrors out of welded segments of AlBeMet(Registered Trademark) (AM162H). AlBeMet(Registered Trademark) is a HIP'd (hot isostatic pressed) material containing approximately 62% beryllium and 38% aluminum. As a result, AlBeMet shares many of the benefits of both of those materials for use in high performance mirrors, while minimizing many of their weaknesses.

Development of PLA hybrid yarns for biobased self-reinforced polymer composites

NASA Astrophysics Data System (ADS)

Köhler, T.; Gries, T.; Seide, G.

2017-10-01

Lightweight materials are a necessity in various industries. Lightweight design is in the key interest of the mobility sector, e.g. the automotive and aerospace industry. This trend applies also for the consumer industries, e.g. sporting goods. In addition, the worldwide demand for replacing fossil-based materials has led to a significant growth of bioplastics. Due to their low mechanical performance and durability, their use is still limited. Therefore, it is necessary to develop biobased, sustainable polymeric materials with high stiffness, high impact and high durability without impairing recyclability at a similar price level of non-biobased solutions. Biobased self-reinforced polymer composites offer these unique properties.

Method of manufacturing lightweight thermo-barrier material

NASA Technical Reports Server (NTRS)

Blair, Winford (Inventor)

1987-01-01

A method of manufacturing thermal barrier structures comprising at least three dimpled cores separated by flat plate material with the outer surface of the flat plate material joined together by diffusion bonding.

Physics-Based Design Tools for Lightweight Ceramic Composite Turbine Components with Durable Microstructures

NASA Technical Reports Server (NTRS)

DiCarlo, James A.

2011-01-01

Under the Supersonics Project of the NASA Fundamental Aeronautics Program, modeling and experimental efforts are underway to develop generic physics-based tools to better implement lightweight ceramic matrix composites into supersonic engine components and to assure sufficient durability for these components in the engine environment. These activities, which have a crosscutting aspect for other areas of the Fundamental Aero program, are focusing primarily on improving the multi-directional design strength and rupture strength of high-performance SiC/SiC composites by advanced fiber architecture design. This presentation discusses progress in tool development with particular focus on the use of 2.5D-woven architectures and state-of-the-art constituents for a generic un-cooled SiC/SiC low-pressure turbine blade.

Light-weight extension tubes for compressed-air garden sprayers

Treesearch

Thomas W. McConkey; Charles E. Swett

1967-01-01

To hand-spray taller trees safely and efficiently, 8-, 12-, and 16-foot extension tubes for compressed-air garden sprayers were designed and built. These light-weight tubes have been used successfully for spraying white pine leaders for weevil control on the Massabesic Experimental Forest in Maine. Bill of materials and assembly instructions are included.

MSFC Combustion Devices in 2001

NASA Technical Reports Server (NTRS)

Dexter, Carol; Turner, James (Technical Monitor)

2001-01-01

The objectives of the project detailed in this viewgraph presentation were to reduce thrust assembly weights to create lighter engines and to increase the cycle life and/or operating temperatures. Information is given on material options (metal matrix composites and polymer matrix composites), ceramic matrix composites subscale liners, lightweight linear chambers, lightweight injector development, liquid/liquid preburner tasks, and vortex chamber tasks.

Synthesis, Characterization And Modeling Of Functionally Graded Multifunctional Hybrid Composites For Extreme Environments

DTIC Science & Technology

2017-04-04

research thrust areas are designed to enable the development of reliable, damage tolerant, lightweight structures with excellent thermal management...46 2. RESEARCH THRUST AREA: MULTISCALE CHARACTERIZATION AND MODELING .................................... 56 2.1 DESIGN OF MATERIALS...The research thrust areas are designed to enable the development of reliable, damage tolerant, lightweight structures with excellent thermal

Lightweight, durable lead-acid batteries

DOEpatents

Lara-Curzio, Edgar [Lenoir City, TN; An, Ke [Knoxville, TX; Kiggans, Jr., James O.; Dudney, Nancy J [Knoxville, TN; Contescu, Cristian I [Knoxville, TN; Baker, Frederick S [Oak Ridge, TN; Armstrong, Beth L [Clinton, TN

2011-09-13

A lightweight, durable lead-acid battery is disclosed. Alternative electrode materials and configurations are used to reduce weight, to increase material utilization and to extend service life. The electrode can include a current collector having a buffer layer in contact with the current collector and an electrochemically active material in contact with the buffer layer. In one form, the buffer layer includes a carbide, and the current collector includes carbon fibers having the buffer layer. The buffer layer can include a carbide and/or a noble metal selected from of gold, silver, tantalum, platinum, palladium and rhodium. When the electrode is to be used in a lead-acid battery, the electrochemically active material is selected from metallic lead (for a negative electrode) or lead peroxide (for a positive electrode).

Lightweight, durable lead-acid batteries

DOEpatents

Lara-Curzio, Edgar; An, Ke; Kiggans, Jr., James O; Dudney, Nancy J; Contescu, Cristian I; Baker, Frederick S; Armstrong, Beth L

2013-05-21

A lightweight, durable lead-acid battery is disclosed. Alternative electrode materials and configurations are used to reduce weight, to increase material utilization and to extend service life. The electrode can include a current collector having a buffer layer in contact with the current collector and an electrochemically active material in contact with the buffer layer. In one form, the buffer layer includes a carbide, and the current collector includes carbon fibers having the buffer layer. The buffer layer can include a carbide and/or a noble metal selected from of gold, silver, tantalum, platinum, palladium and rhodium. When the electrode is to be used in a lead-acid battery, the electrochemically active material is selected from metallic lead (for a negative electrode) or lead peroxide (for a positive electrode).

Aluminum Surface Texturing by Means of Laser Interference Metallurgy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, Jian; Sabau, Adrian S; Jones, Jonaaron F.

2015-01-01

The increasing use of lightweight materials, such as aluminum alloys, in auto body structures requires more effective surface cleaning and texturing techniques to improve the quality of the structural components. The present work introduces a novel surface treatment method using laser interferometry produced by two beams of a pulsed Nd:YAG laser operating at 10Hz of frequency to clean aluminum surfaces, and meanwhile creating periodic and rough surface structures. The influences of beam size, laser fluence, wavelength, and pulse number per spot are investigated. High resolution optical profiler images reveal the change of the peak-to-valley height on the laser-treated surface.

Carbon-carbon cylinder block

NASA Technical Reports Server (NTRS)

Ransone, Philip O. (Inventor)

1995-01-01

A lightweight cylinder block composed of carbon-carbon is disclosed. The use of carbon-carbon over conventional materials, such as cast iron or aluminum, reduces the weight of the cylinder block and improves thermal efficiency of the internal combustion reciprocating engine. Due to the negligible coefficient of thermal expansion and unique strength at elevated temperatures of carbon-carbon, the piston-to-cylinder wall clearance can be small, especially when the carbon-carbon cylinder block is used in conjunction with a carbon-carbon piston. Use of the carbon-carbon cylinder has the effect of reducing the weight of other reciprocating engine components allowing the piston to run at higher speeds and improving specific engine performance.

Development of advanced fuel cell system, phase 2

NASA Technical Reports Server (NTRS)

Handley, L. M.; Meyer, A. P.; Bell, W. F.

1973-01-01

A multiple task research and development program was performed to improve the weight, life, and performance characteristics of hydrogen-oxygen alkaline fuel cells for advanced power systems. Development and characterization of a very stable gold alloy catalyst was continued from Phase I of the program. A polymer material for fabrication of cell structural components was identified and its long term compatibility with the fuel cell environment was demonstrated in cell tests. Full scale partial cell stacks, with advanced design closed cycle evaporative coolers, were tested. The characteristics demonstrated in these tests verified the feasibility of developing the engineering model system concept into an advanced lightweight long life powerplant.

Design concepts for low-cost composite engine frames

NASA Technical Reports Server (NTRS)

Chamis, C. C.

1983-01-01

Design concepts for low-cost, lightweight composite engine frames were applied to the design requirements for the frame of commercial, high-bypass turbine engines. The concepts consist of generic-type components and subcomponents that could be adapted for use in different locations in the engine and to different engine sizes. A variety of materials and manufacturing methods were assessed with a goal of having the lowest number of parts possible at the lowest possible cost. The evaluation of the design concepts resulted in the identification of a hybrid composite frame which would weigh about 70 percent of the state-of-the-art metal frame and cost would be about 60 percent.

Lightweight Structures

NASA Technical Reports Server (NTRS)

Whittenberger, J. Daniel

2001-01-01

Present structural concepts for hot static structures are conventional "sheet & stringer" or truss core construction. More weight-efficient concepts such as honeycomb and lattice block are being investigated, in combination with both conventional superalloys and TiAl. Development efforts for components made from TiAl sheet are centered on lower cost methods for sheet and foil production, plus alloy development for higher temperature capability. A low-cost casting technology recently developed for aluminum and steel lattice blocks has demonstrated the required higher strength and stiffness, with weight efficiency approach- ing honeycombs. The current effort is based on extending the temperature capability by developing lattice block materials made from IN-718 and Mar-M247.

Exhaust Nozzle Materials Development for the High Speed Civil Transport

NASA Technical Reports Server (NTRS)

Grady, J. E.

1999-01-01

The United States has embarked on a national effort to develop the technology necessary to produce a Mach 2.4 High Speed Civil Transport (HSCT) for entry into service by the year 2005. The viability of this aircraft is contingent upon its meeting both economic and environmental requirements. Two engine components have been identified as critical to the environmental acceptability of the HSCT. These include a combustor with significantly lower emissions than are feasible with current technology, and a lightweight exhaust nozzle that meets community noise standards. The Enabling Propulsion Materials (EPM) program will develop the advanced structural materials, materials fabrication processes, structural analysis and life prediction tools for the HSCT combustor and low noise exhaust nozzle. This is being accomplished through the coordinated efforts of the NASA Lewis Research Center, General Electric Aircraft Engines and Pratt & Whitney. The mission of the EPM Exhaust Nozzle Team is to develop and demonstrate this technology by the year 1999 to enable its timely incorporation into HSCT propulsion systems.

Geothermal materials development

NASA Astrophysics Data System (ADS)

Kukacka, L. E.

1991-12-01

Advances in the development of new materials, the commercial availabilities of which are essential for the attainment of Hydrothermal Category Level 1 and 2 Objectives, continue to be made in the Geothermal Materials Development Project. Many successes have already been accrued and the results used commercially. In FY-91, utility company sponsored 'full cost' recovery programs based upon materials technology developed in this project were initiated on topics such as condensing heat exchangers, high temperature composites for utility vaults used in district heating systems, and corrosion resistant coatings for use in oil-fired electric generating processes. In FY-91, the DOE/GD-sponsored R&D project was focused on reducing well drilling, fluid transport and energy conversion costs. Specific activities being performed included lightweight CO2-resistant well cements, chemical systems for lost circulation control, thermally conductive and scale resistant protective linear systems, corrosion mitigation in process components at The Geysers, and elastomer-metal bonding systems needed for use in high temperature well drilling and safety related applications.

Utilization of sewage sludge in the manufacture of lightweight aggregate.

PubMed

Franus, Małgorzata; Barnat-Hunek, Danuta; Wdowin, Magdalena

2016-01-01

This paper presents a comprehensive study on the possibility of sewage sludge management in a sintered ceramic material such as a lightweight aggregate. Made from clay and sludge lightweight aggregates were sintered at two temperatures: 1100 °C (name of sample LWA1) and 1150 °C (name of sample LWA2). Physical and mechanical properties indicate that the resulting expanded clay aggregate containing sludge meets the basic requirements for lightweight aggregates. The presence of sludge supports the swelling of the raw material, thereby causing an increase in the porosity of aggregates. The LWA2 has a lower value of bulk particle density (0.414 g/cm(3)), apparent particle density (0.87 g/cm(3)), and dry particle density (2.59 g/cm(3)) than it is in the case of LWA1 where these parameters were as follows: bulk particle density 0.685 g/cm(3), apparent particle density 1.05 g/cm(3), and dry particle density 2.69 g/cm(3). Water absorption and porosity of LWA1 (WA = 14.4 %, P = 60 %) are lower than the LWA2 (WA = 16.2 % and P = 66 %). This is due to the higher heating temperature of granules which make the waste gases, liberating them from the decomposition of organic sewage sludge. The compressive strength of LWA2 aggregate is 4.64 MPa and for LWA1 is 0.79 MPa. Results of leaching tests of heavy metals from examined aggregates have shown that insoluble metal compounds are placed in silicate and aluminosilicate structure of the starting materials (clays and sludges), whereas soluble substances formed crystalline skeleton of the aggregates. The thermal synthesis of lightweight aggregates from clay and sludge mixture is a waste-free method of their development.

GATE Center of Excellence at UAB in Lightweight Materials for Automotive Applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

2011-07-31

This report summarizes the accomplishments of the UAB GATE Center of Excellence in Lightweight Materials for Automotive Applications. The first Phase of the UAB DOE GATE center spanned the period 2005-2011. The UAB GATE goals coordinated with the overall goals of DOE's FreedomCAR and Vehicles Technologies initiative and DOE GATE program. The FCVT goals are: (1) Development and validation of advanced materials and manufacturing technologies to significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost; (2) To provide a new generation of engineers and scientists with knowledge and skills inmore » advanced automotive technologies. The UAB GATE focused on both the FCVT and GATE goals in the following manner: (1) Train and produce graduates in lightweight automotive materials technologies; (2) Structure the engineering curricula to produce specialists in the automotive area; (3) Leverage automotive related industry in the State of Alabama; (4) Expose minority students to advanced technologies early in their career; (5) Develop innovative virtual classroom capabilities tied to real manufacturing operations; and (6) Integrate synergistic, multi-departmental activities to produce new product and manufacturing technologies for more damage tolerant, cost-effective, and lighter automotive structures.« less

Topology Optimization of Lightweight Lattice Structural Composites Inspired by Cuttlefish Bone

NASA Astrophysics Data System (ADS)

Hu, Zhong; Gadipudi, Varun Kumar; Salem, David R.

2018-03-01

Lattice structural composites are of great interest to various industries where lightweight multifunctionality is important, especially aerospace. However, strong coupling among the composition, microstructure, porous topology, and fabrication of such materials impedes conventional trial-and-error experimental development. In this work, a discontinuous carbon fiber reinforced polymer matrix composite was adopted for structural design. A reliable and robust design approach for developing lightweight multifunctional lattice structural composites was proposed, inspired by biomimetics and based on topology optimization. Three-dimensional periodic lattice blocks were initially designed, inspired by the cuttlefish bone microstructure. The topologies of the three-dimensional periodic blocks were further optimized by computer modeling, and the mechanical properties of the topology optimized lightweight lattice structures were characterized by computer modeling. The lattice structures with optimal performance were identified.

Progress in the development of lightweight nickel electrode

NASA Technical Reports Server (NTRS)

Britton, Doris L.

1992-01-01

The use of the lightweight nickel electrode, in place of the heavy-sintered state-of-the-art nickel electrode, will lead to improvements in specific energy and performance of the nickel-hydrogen cell. Preliminary testing indicates that a nickel fiber mat is a promising support candidate for the nickel hydroxide active material. Nickel electrodes made from fiber mats, with nickel and cobalt powder added to the fiber, were tested at LeRC. To date, over 8000 cycles have been accumulated, at 40 percent depth-of-discharge, using the lightweight fiber electrode, in a boiler plate nickel-hydrogen cell.

Manufacturing Precise, Lightweight Paraboloidal Mirrors

NASA Technical Reports Server (NTRS)

Hermann, Frederick Thomas

2006-01-01

A process for fabricating a precise, diffraction- limited, ultra-lightweight, composite- material (matrix/fiber) paraboloidal telescope mirror has been devised. Unlike the traditional process of fabrication of heavier glass-based mirrors, this process involves a minimum of manual steps and subjective judgment. Instead, this process involves objectively controllable, repeatable steps; hence, this process is better suited for mass production. Other processes that have been investigated for fabrication of precise composite-material lightweight mirrors have resulted in print-through of fiber patterns onto reflecting surfaces, and have not provided adequate structural support for maintenance of stable, diffraction-limited surface figures. In contrast, this process does not result in print-through of the fiber pattern onto the reflecting surface and does provide a lightweight, rigid structure capable of maintaining a diffraction-limited surface figure in the face of changing temperature, humidity, and air pressure. The process consists mainly of the following steps: 1. A precise glass mandrel is fabricated by conventional optical grinding and polishing. 2. The mandrel is coated with a release agent and covered with layers of a carbon- fiber composite material. 3. The outer surface of the outer layer of the carbon-fiber composite material is coated with a surfactant chosen to provide for the proper flow of an epoxy resin to be applied subsequently. 4. The mandrel as thus covered is mounted on a temperature-controlled spin table. 5. The table is heated to a suitable temperature and spun at a suitable speed as the epoxy resin is poured onto the coated carbon-fiber composite material. 6. The surface figure of the optic is monitored and adjusted by use of traditional Ronchi, Focault, and interferometric optical measurement techniques while the speed of rotation and the temperature are adjusted to obtain the desired figure. The proper selection of surfactant, speed or rotation, viscosity of the epoxy, and temperature make it possible to obtain the desired diffraction-limited, smooth (1/50th wave) parabolic outer surface, suitable for reflective coating. 7. A reflective coat is applied by use of conventional coating techniques. 8. Once the final figure is set, a lightweight structural foam is applied to the rear of the optic to ensure stability of the figure.

Three experiments to support the design of lightweight comfortable vehicle seats.

PubMed

Vink, P; Franz, M; Kamp, I; Zenk, R

2012-01-01

Seats need to be more lightweight for airplanes, cars, busses and even trains to contribute to a better environment and to reduce energy consumption. However, a reduction in comfort due to weight reduction is not preferable, which opens a new area of research: improving comfort with a minimum of material or with lightweight materials and systems. In this paper three experiments are performed to test the effects of light weight seats and parts of a seat on comfort. The first experiment shows that a new developed light weight massage system improves comfort and reduces muscle activity. The second experiment shows that the automatic seat adjustment without motors improves the comfort as well. The third experiment showed that a light weight seat following closely the human body contour is experienced on many aspects in the same way as current more heavy seats. More research and models will be needed in this ergonomic field which needs more attention.

Cost efficient carbon fibre reinforced thermoplastics with in-situ polymerization of polyamide

NASA Astrophysics Data System (ADS)

Köhler, T.; Akdere, M.; Röding, T.; Gries, T.; Seide, G.

2017-10-01

Lightweight design has gained more and more relevance over the last decades. Especially in automotive industry it is of paramount importance to reduce weight and save fuel. At the same time the demand for safety and performance increases the components’ weight. To reach a trade-off between driving comfort and efficiency new lightweight materials have to be developed. One possible solution is the usage of carbon fibre reinforced thermoplastics (CFRTP) as a lightweight substitute material. In contrast to conventional carbon fibre reinforced plastics (CFRP), CFRTPs are cheaper and have a higher impact resistance. Furthermore they are characterized by hot forming ability, weldability and recyclability. However, the impregnation of the textile requires high pressure, because of the melted polymer’s high viscosity. A new innovative approach for CFRTP is the usage of in-situ polymerization with ɛ-caprolactam as matrix, which has a much lower viscosity and thus requires much lower pressure for impregnation and consolidation.

Faster, Better, Cheaper: A ZERODUR® low-expansion, light-weight present path toward affordable spaceborne telescopes

NASA Astrophysics Data System (ADS)

Hull, Anthony B.; Westerhoff, Thomas

2014-06-01

For competed missions, payload costs are often the discriminate of whether or not outstanding science can be selected to fly. Optical Telescope Assemblies (OTAs) encompass a significant fraction of the payload cost, and mirror aperture and stability are usually are key to the science merit. The selection of the primary mirror approach drives architecture decisions for the rest of the OTA and even payload. We look at the ways OTA architecture is affected by the PM selection, and specifically at the benefits of selecting a low expansion material. We will also review recent advances in ZERODUR® fabrication which make this low-expansion material relevant in situations where affordable, lightweight mirrors can enable the apertures needed for science merit. Extreme Lightweight ZERODUR® Mirrors (ELZM) are available in apertures from 0.3m to over 4m. SCHOTT has recently demonstrated a relevant 1.2m ELZM substrate.

The Cost of Automotive Polymer Composites: A Review and Assessment of DOE's Lightweight Materials Composites Research

DOE Office of Scientific and Technical Information (OSTI.GOV)

Das, S.

2001-01-26

Polymer composite materials have been a part of the automotive industry for several decades, with early application in the 1953 Corvette. These materials have been used for applications with low production volumes, because of their shortened lead times and lower investment costs relative to conventional steel fabrication. Important drivers of the growth of polymer composites have been the reduced weight and parts consolidation opportunities the material offers, as well as design flexibility, corrosion resistance, material anisotropy, and mechanical properties. Although these benefits are well recognized by the industry, polymer composite use has been dampened by high material costs, slow productionmore » rates, and to a lesser extent, concerns about recyclability. Also impeding large scale automotive applications is a curious mixture of concerns about material issues such as crash energy absorption, recycling challenges, competitive and cost pressures, the industry's general lack of experience and comfort with the material, and industry concerns about its own capabilities (Flynn and Belzowski 1995). Polymer composite materials are generally made of two or more material components--fibers, either glass or carbon, reinforced in the matrix of thermoset or thermoplastic polymer materials. The glass-reinforced thermoset composites are the most commonly used composite in automotive applications today, but thermoplastic composites and carbon fiber-reinforced thermosets also hold potential. It has been estimated that significant use of glass-reinforced polymers as structural components could yield a 20-35% reduction in vehicle weight. More importantly, the use of carbon fiber-reinforced materials could yield a 40-65% reduction in weight.« less

Lightweight flywheel containment

DOEpatents

Smith, James R.

2001-01-01

A lightweight flywheel containment composed of a combination of layers of various material which absorb the energy of a flywheel structural failure. The various layers of material act as a vacuum barrier, momentum spreader, energy absorber, and reaction plate. The flywheel containment structure has been experimentally demonstrated to contain carbon fiber fragments with a velocity of 1,000 m/s and has an aerial density of less than 6.5 g/square centimeters. The flywheel containment, may for example, be composed of an inner high toughness structural layer, and energy absorbing layer, and an outer support layer. Optionally, a layer of impedance matching material may be utilized intermediate the flywheel rotor and the inner high toughness layer.

Lightweight flywheel containment

DOEpatents

Smith, James R.

2004-06-29

A lightweight flywheel containment composed of a combination of layers of various material which absorb the energy of a flywheel structural failure. The various layers of material act as a vacuum barrier, momentum spreader, energy absorber, and reaction plate. The flywheel containment structure has been experimentally demonstrated to contain carbon fiber fragments with a velocity of 1,000 m/s and has an aerial density of less than 6.5 g/square centimeters. The flywheel containment, may for example, be composed of an inner high toughness structural layer, and energy absorbing layer, and an outer support layer. Optionally, a layer of impedance matching material may be utilized intermediate the flywheel rotor and the inner high toughness layer.

Emergency housing systems from three-dimensional engineered fiberboard : temporary building systems for lightweight, portable, easy-to-assemble, reusable, recyclable, and biodegradable structures

Treesearch

Jerrold E. Winandy; John F. Hunt; Christopher Turk; James R. Anderson

2006-01-01

Following natural disasters (such as hurricanes, tornados, or tsunamis), when civilians become displaced, or when military troops are deployed overseas, temporary housing is often a critical need. The USDA Forest Products Laboratory recently developed a lightweight, transportable, reusable, and recyclable biocomposite building material—threedimensional engineered...

Examining the Relationship Between Ballistic and Structural Properties of Lightweight Thermoplastic Unidirectional Composite Laminates

DTIC Science & Technology

2011-08-01

Kevlar KM2® Style 705 PVB phenolic woven aramid composite was included. A developmental unidirectional thermoplastic aramid fiber, Honeywell...Examining the Relationship Between Ballistic and Structural Properties of Lightweight Thermoplastic Unidirectional Composite Laminates by...Unidirectional Composite Laminates Lionel R. Vargas-Gonzalez, Shawn M. Walsh, and James C. Gurganus Weapons and Materials Research Directorate, ARL

Analysis of stress concentration in the Dutton groove regions of the Super Lightweight External Tank

NASA Astrophysics Data System (ADS)

Ahmed, R.

1995-05-01

Because the 2195 aluminum-lithium material of the super lightweight external tank (SLWT ET) has a lower toughness than the 2219 aluminum used in previous ET's, careful attention must be paid to stress concentrations. This report details the analysis performed on some of the stress concentrations in the orthogrid panels of the liquid hydrogen tank.

The Feasibility of Palm Kernel Shell as a Replacement for Coarse Aggregate in Lightweight Concrete

NASA Astrophysics Data System (ADS)

Itam, Zarina; Beddu, Salmia; Liyana Mohd Kamal, Nur; Ashraful Alam, Md; Issa Ayash, Usama

2016-03-01

Implementing sustainable materials into the construction industry is fast becoming a trend nowadays. Palm Kernel Shell is a by-product of Malaysia’s palm oil industry, generating waste as much as 4 million tons per annum. As a means of producing a sustainable, environmental-friendly, and affordable alternative in the lightweight concrete industry, the exploration of the potential of Palm Kernel Shell to be used as an aggregate replacement was conducted which may give a positive impact to the Malaysian construction industry as well as worldwide concrete usage. This research investigates the feasibility of PKS as an aggregate replacement in lightweight concrete in terms of compressive strength, slump test, water absorption, and density. Results indicate that by using PKS for aggregate replacement, it increases the water absorption but decreases the concrete workability and strength. Results however, fall into the range acceptable for lightweight aggregates, hence it can be concluded that there is potential to use PKS as aggregate replacement for lightweight concrete.

The utilization of stone ash on cellular lightweight concrete

NASA Astrophysics Data System (ADS)

Karolina, R.; Sianipar, Y. G. C.

2018-02-01

Lightweight concrete brick is a brick which made of cement, sand, water, and foam as the basic composition. This brick are divided into 2, based on the foam used such as AAC (Autoclave Aerated Concrete) that use aluminium paste and CLC(Cellular Lightweight Concrete) that use foaming agent from BASF as its foaming material. In this trial, the lightweight brick that are ging to be use are the CLC with foaming agent as its foaming material with the mixture of stone ash that are produced by the Stone Crusher with spesific gravity 2666 kg/m3 as their partly sand substitution . In this research, the stone ash variant that are used are 10%, 15%, and 20% from the amount of sand that planned before. After casting, the result of the 10% will receive a reduction of compressive strength while an increasing in absorption as 25.07% and 39.005% and the 15% variant will recieve a reduction of compressive strength as much as 65.8% and a reduction of absorption as much as 17.441% and the 20% variant will recieve a reduction of compressive strength as much as 67.4% while an increasing of absorption as much as 17.956%.

Cellular Magnesium Matrix Foam Composites for Mechanical Damping Applications

NASA Astrophysics Data System (ADS)

Shunmugasamy, Vasanth Chakravarthy; Mansoor, Bilal; Gupta, Nikhil

2016-01-01

The damping characteristics of metal alloys and metal matrix composites are relevant to the automotive, aerospace, and marine structures. Use of lightweight materials can help in increasing payload capacity and in decreasing fuel consumption. Lightweight composite materials possessing high damping capabilities that can be designed as structural members can greatly benefit in addressing these needs. In this context, the damping properties of lightweight metals such as aluminum and magnesium and their respective composites have been studied in the existing literature. This review focuses on analyzing the damping properties of aluminum and magnesium alloys and their cellular composites. The damping properties of various lightweight alloys and composites are compared on the basis of their density to understand the potential for weight saving in structural applications. Magnesium alloys are observed to possess better damping properties in comparison to aluminum. However, aluminum matrix syntactic foams reinforced with silicon carbide hollow particles possess a damping capacity and density comparable to magnesium alloy. By using the data presented in the study, composites with specific compositions and properties can be selected for a given application. In addition, the comparison of the results helps in identifying the areas where attention needs to be focused to address the future needs.

Super flame-retardant lightweight rime-like carbon-phenolic nanofoam

PubMed Central

Cheng, Haiming; Hong, Changqing; Zhang, Xinghong; Xue, Huafei; Meng, Songhe; Han, Jiecai

2016-01-01

The desire for lightweight nanoporous materials with high-performance thermal insulation and efficient anti-ablation resistance for energy conservation and thermal protection/insulation has greatly motivated research and development recently. The main challenge to synthesize such lightweight materials is how to balance the relationship of low thermal conductivity and flame retardancy. Herein, we propose a new concept of lightweight “rime-like” structured carbon-phenolic nanocomposites to solve this problem, where the 3D chopped network-structured carbon fiber (NCF) monoliths are incorporated with nanoporous phenolic aerogel to retain structural and functional integrity. The nanometer-scaled porous phenolic (NP) was synthesized through polymerization-induced phase separation and ambient pressure drying using phenolic resin (PR) solution as reaction source, ethylene glycol (EG) as solvent and hexamethylenetetramine (HMTA) as catalyst. We demonstrate that the as-prepared NCF-NP nanocomposite exhibits with a low density of 0.25–0.35 g/cm3, low thermal conductivity of 0.125 Wm−1K−1 and outstanding flame retardancy exceeding 2000 °C under arc-jet wind tunnel simulation environment. Our results show that the synthesis strategy is a promising approach for producing nanocomposites with excellent high-temperature heat blocking property. PMID:27629114

Super flame-retardant lightweight rime-like carbon-phenolic nanofoam

NASA Astrophysics Data System (ADS)

Cheng, Haiming; Hong, Changqing; Zhang, Xinghong; Xue, Huafei; Meng, Songhe; Han, Jiecai

2016-09-01

The desire for lightweight nanoporous materials with high-performance thermal insulation and efficient anti-ablation resistance for energy conservation and thermal protection/insulation has greatly motivated research and development recently. The main challenge to synthesize such lightweight materials is how to balance the relationship of low thermal conductivity and flame retardancy. Herein, we propose a new concept of lightweight “rime-like” structured carbon-phenolic nanocomposites to solve this problem, where the 3D chopped network-structured carbon fiber (NCF) monoliths are incorporated with nanoporous phenolic aerogel to retain structural and functional integrity. The nanometer-scaled porous phenolic (NP) was synthesized through polymerization-induced phase separation and ambient pressure drying using phenolic resin (PR) solution as reaction source, ethylene glycol (EG) as solvent and hexamethylenetetramine (HMTA) as catalyst. We demonstrate that the as-prepared NCF-NP nanocomposite exhibits with a low density of 0.25-0.35 g/cm3, low thermal conductivity of 0.125 Wm-1K-1 and outstanding flame retardancy exceeding 2000 °C under arc-jet wind tunnel simulation environment. Our results show that the synthesis strategy is a promising approach for producing nanocomposites with excellent high-temperature heat blocking property.

High-performance green semiconductor devices: materials, designs, and fabrication

NASA Astrophysics Data System (ADS)

Jung, Yei Hwan; Zhang, Huilong; Gong, Shaoqin; Ma, Zhenqiang

2017-06-01

From large industrial computers to non-portable home appliances and finally to light-weight portable gadgets, the rapid evolution of electronics has facilitated our daily pursuits and increased our life comforts. However, these rapid advances have led to a significant decrease in the lifetime of consumer electronics. The serious environmental threat that comes from electronic waste not only involves materials like plastics and heavy metals, but also includes toxic materials like mercury, cadmium, arsenic, and lead, which can leak into the ground and contaminate the water we drink, the food we eat, and the animals that live around us. Furthermore, most electronics are comprised of non-renewable, non-biodegradable, and potentially toxic materials. Difficulties in recycling the increasing amount of electronic waste could eventually lead to permanent environmental pollution. As such, discarded electronics that can naturally degrade over time would reduce recycling challenges and minimize their threat to the environment. This review provides a snapshot of the current developments and challenges of green electronics at the semiconductor device level. It looks at the developments that have been made in an effort to help reduce the accumulation of electronic waste by utilizing unconventional, biodegradable materials as components. While many semiconductors are classified as non-biodegradable, a few biodegradable semiconducting materials exist and are used as electrical components. This review begins with a discussion of biodegradable materials for electronics, followed by designs and processes for the manufacturing of green electronics using different techniques and designs. In the later sections of the review, various examples of biodegradable electrical components, such as sensors, circuits, and batteries, that together can form a functional electronic device, are discussed and new applications using green electronics are reviewed.

Large-area, lightweight and thick biomimetic composites with superior material properties via fast, economic, and green pathways.

PubMed

Walther, Andreas; Bjurhager, Ingela; Malho, Jani-Markus; Pere, Jaakko; Ruokolainen, Janne; Berglund, Lars A; Ikkala, Olli

2010-08-11

Although remarkable success has been achieved to mimic the mechanically excellent structure of nacre in laboratory-scale models, it remains difficult to foresee mainstream applications due to time-consuming sequential depositions or energy-intensive processes. Here, we introduce a surprisingly simple and rapid methodology for large-area, lightweight, and thick nacre-mimetic films and laminates with superior material properties. Nanoclay sheets with soft polymer coatings are used as ideal building blocks with intrinsic hard/soft character. They are forced to rapidly self-assemble into aligned nacre-mimetic films via paper-making, doctor-blading or simple painting, giving rise to strong and thick films with tensile modulus of 45 GPa and strength of 250 MPa, that is, partly exceeding nacre. The concepts are environmentally friendly, energy-efficient, and economic and are ready for scale-up via continuous roll-to-roll processes. Excellent gas barrier properties, optical translucency, and extraordinary shape-persistent fire-resistance are demonstrated. We foresee advanced large-scale biomimetic materials, relevant for lightweight sustainable construction and energy-efficient transportation.

Stiff, Thermally Stable and Highly Anisotropic Wood-Derived Carbon Composite Monoliths for Electromagnetic Interference Shielding.

PubMed

Yuan, Ye; Sun, Xianxian; Yang, Minglong; Xu, Fan; Lin, Zaishan; Zhao, Xu; Ding, Yujie; Li, Jianjun; Yin, Weilong; Peng, Qingyu; He, Xiaodong; Li, Yibin

2017-06-28

Electromagnetic interference (EMI) shielding materials for electronic devices in aviation and aerospace not only need lightweight and high shielding effectiveness, but also should withstand harsh environments. Traditional EMI shielding materials often show heavy weight, poor thermal stability, short lifetime, poor tolerance to chemicals, and are hard-to-manufacture. Searching for high-efficiency EMI shielding materials overcoming the above weaknesses is still a great challenge. Herein, inspired by the unique structure of natural wood, lightweight and highly anisotropic wood-derived carbon composite EMI shielding materials have been prepared which possess not only high EMI shielding performance and mechanical stable characteristics, but also possess thermally stable properties, outperforming those metals, conductive polymers, and their composites. The newly developed low-cost materials are promising for specific applications in aerospace electronic devices, especially regarding extreme temperatures.

Lightweight Ablative and Ceramic Thermal Protection System Materials for NASA Exploration Systems Vehicles

NASA Technical Reports Server (NTRS)

Valentine, Peter G.; Lawrence, Timothy W.; Gubert, Michael K.; Milos, Frank S.; Kiser, James D.; Ohlhorst, Craig W.; Koenig, John R.

2006-01-01

As a collaborative effort among NASA Centers, the "Lightweight Nonmetallic Thermal Protection Materials Technology" Project was set up to assist mission/vehicle design trade studies, to support risk reduction in thermal protection system (TPS) material selections, to facilitate vehicle mass optimization, and to aid development of human-rated TPS qualification and certification plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on advanced heatshields that allow reductions in spacecraft mass by minimizing propellant requirements. Information will be presented on candidate materials for such reentry approaches and on screening tests conducted (material property and space environmental effects tests) to evaluate viable candidates. Seventeen materials, in three classes (ablatives, tiles, and ceramic matrix composites), were studied. In additional to physical, mechanical, and thermal property tests, high heat flux laser tests and simulated-reentry oxidation tests were performed. Space environmental effects testing, which included exposures to electrons, atomic oxygen, and hypervelocity impacts, was also conducted.

Investigation on the cold rolling and structuring of cold sprayed copper-coated steel sheets

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Wiesner, S.; Gerdt, L.; Senge, S.; Hirt, G.

2017-03-01

A current driving force of research is lightweight design. One of the approaches to reduce the weight of a component without causing an overall stiffness decrease is the use of multi-material components. One of the main challenges of this approach is the low bonding strength between different materials. Focusing on steel-aluminum multi-material components, thermally sprayed copper coatings can come into use as a bonding agent between steel sheets and high pressure die cast aluminum to improve the bonding strength. This paper presents a combination of cold gas spraying of copper coatings and their subsequent structuring by rolling as surface pretreatment method of the steel inserts. Therefore, flat rolling experiments are performed with samples in “as sprayed” and heat treated conditions to determine the influence of the rolling process on the bond strength and the formability of the coating. Furthermore, the influence of the rolling on the roughness and the hardness of the coating was examined. In the next step, the coated surface was structured, to create a surface topology suited for a form closure connection in a subsequent high-pressure die casting process. No cracks were observed after the cold rolling process with a thickness reduction of up to ε = 14 % for heat treated samples. Structuring of heat treated samples could be realized without delamination and cracking.

Optical design of common aperture, common focal plane, multispectral optics for military applications

NASA Astrophysics Data System (ADS)

Thompson, Nicholas Allan

2013-06-01

With recent developments in multispectral detector technology, the interest in common aperture, common focal plane multispectral imaging systems is increasing. Such systems are particularly desirable for military applications, where increased levels of target discrimination and identification are required in cost-effective, rugged, lightweight systems. During the optical design of dual waveband or multispectral systems, the options for material selection are limited. This selection becomes even more restrictive for military applications, where material resilience, thermal properties, and color correction must be considered. We discuss the design challenges that lightweight multispectral common aperture systems present, along with some potential design solutions. Consideration is given to material selection for optimum color correction, as well as material resilience and thermal correction. This discussion is supported using design examples currently in development at Qioptiq.

Lightweight fibrous nickel electrodes for nickel-hydrogen batteries

NASA Technical Reports Server (NTRS)

Britton, Doris L.

1989-01-01

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art sintered nickel electrodes. Lightweight fibrous materials or plaques are used as conductive supports for the nickel hydroxide active material. These materials are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C, 1.37C, 2.0C, and 2.74C. The electrodes that pass the initial tests are life cycle-tested in a low Earth orbit regime at 80 percent depth of discharge.

Modifications of a Composite-Material Combustion Chamber

NASA Technical Reports Server (NTRS)

Williams, Brian E.; McNeal, Shawn R.

2005-01-01

Two short reports discuss modifications of a small, lightweight combustion chamber that comprises a carbon/carbon composite outer shell and an iridium/ rhenium inner liner. The first report discusses chamber design modifications made as results of hot-fire tests and post-test characterization. The Books & Reports 32 NASA Tech Briefs, June 2005 modifications were intended to serve a variety of purposes, including improving fabrication, reducing thermal-expansion mismatch stresses, increasing strength-to-weight ratios of some components, and improving cooling of some components. The second report discusses (1) the origin of stress in the mismatch between the thermal expansions of the Ir/Re liner and a niobium sleeve and flange attached to the carbon/ carbon shell and (2) a modification intended to relieve the stress. The modification involves the redesign of an inlet connection to incorporate a compressible seal between the Ir/Re liner and the Nb flange. A nickel alloy was selected as the seal material on the basis of its thermal-expansion properties and its ability to withstand the anticipated stresses, including the greatest stresses caused by the high temperatures to be used in brazing during fabrication.

Nondestructive Evaluation of Advanced Materials with X-ray Phase Mapping

NASA Technical Reports Server (NTRS)

Hu, Zhengwei

2005-01-01

X-ray radiation has been widely used for imaging applications since Rontgen first discovered X-rays over a century ago. Its large penetration depth makes it ideal for the nondestructive visualization of the internal structure and/or defects of materials unobtainable otherwise. Currently used nondestructive evaluation (NDE) tools, X-ray radiography and tomography, are absorption-based, and work well in heavy-element materials where density or composition variations due to internal structure or defects are high enough to produce appreciable absorption contrast. However, in many cases where materials are light-weight and/or composites that have similar mass absorption coefficients, the conventional absorption-based X-ray methods for NDE become less useful. Indeed, the light-weight and ultra-high-strength requirements for the most advanced materials used or developed for current flight mission and future space exploration pose a great challenge to the standard NDE tools in that the absorption contrast arising from the internal structure of these materials is often too weak to be resolved. In this presentation, a solution to the problem, the use of phase information of X-rays for phase contrast X-ray imaging, will be discussed, along with a comparison between the absorption-based and phase-contrast imaging methods. Latest results on phase contrast X-ray imaging of lightweight Space Shuttle foam in 2D and 3D will be presented, demonstrating new opportunities to solve the challenging issues encountered in advanced materials development and processing.

Enabling lightweight designs by a new laser based approach for joining aluminum to steel

NASA Astrophysics Data System (ADS)

Brockmann, Rüdiger; Kaufmann, Sebastian; Kirchhoff, Marc; Candel-Ruiz, Antonio; Müllerschön, Oliver; Havrilla, David

2015-03-01

As sustainability is an essential requirement, lightweight design becomes more and more important, especially for mobility. Reduced weight ensures more efficient vehicles and enables better environmental impact. Besides the design, new materials and material combinations are one major trend to achieve the required weight savings. The use of Carbon Fiber Reinforced Plastics (abbr. CFRP) is widely discussed, but so far high volume applications are rarely to be found. This is mainly due to the fact that parts made of CFRP are much more expensive than conventional parts. Furthermore, the proper technologies for high volume production are not yet ready. Another material with a large potential for lightweight design is aluminum. In comparison to CFRP, aluminum alloys are generally more affordable. As aluminum is a metallic material, production technologies for high volume standard cutting or joining applications are already developed. In addition, bending and deep-drawing can be applied. In automotive engineering, hybrid structures such as combining high-strength steels with lightweight aluminum alloys retain significant weight reduction but also have an advantage over monolithic aluminum - enhanced behavior in case of crash. Therefore, since the use of steel for applications requiring high mechanical properties is unavoidable, methods for joining aluminum with steel parts have to be further developed. Former studies showed that the use of a laser beam can be a possibility to join aluminum to steel parts. In this sense, the laser welding process represents a major challenge, since both materials have different thermal expansion coefficients and properties related to the behavior in corrosive media. Additionally, brittle intermetallic phases are formed during welding. A promising approach to welding aluminum to steel is based on the use of Laser Metal Deposition (abbr. LMD) with deposit materials in the form of powders. Within the present work, the advantages of this approach in comparison to conventional processes, as well as expected limitations are described.

Review of the Fuel Saving, Life Cycle GHG Emission, and Ownership Cost Impacts of Lightweighting Vehicles with Different Powertrains.

PubMed

Luk, Jason M; Kim, Hyung Chul; De Kleine, Robert; Wallington, Timothy J; MacLean, Heather L

2017-08-01

The literature analyzing the fuel saving, life cycle greenhouse gas (GHG) emission, and ownership cost impacts of lightweighting vehicles with different powertrains is reviewed. Vehicles with lower powertrain efficiencies have higher fuel consumption. Thus, fuel savings from lightweighting internal combustion engine vehicles can be higher than those of hybrid electric and battery electric vehicles. However, the impact of fuel savings on life cycle costs and GHG emissions depends on fuel prices, fuel carbon intensities and fuel storage requirements. Battery electric vehicle fuel savings enable reduction of battery size without sacrificing driving range. This reduces the battery production cost and mass, the latter results in further fuel savings. The carbon intensity of electricity varies widely and is a major source of uncertainty when evaluating the benefits of fuel savings. Hybrid electric vehicles use gasoline more efficiently than internal combustion engine vehicles and do not require large plug-in batteries. Therefore, the benefits of lightweighting depend on the vehicle powertrain. We discuss the value proposition of the use of lightweight materials and alternative powertrains. Future assessments of the benefits of vehicle lightweighting should capture the unique characteristics of emerging vehicle powertrains.

Durability of Geopolymer Lightweight Concrete Infilled LECA in Seawater Exposure

NASA Astrophysics Data System (ADS)

Razak, R. A.; Abdullah, M. M. A. B.; Yahya, Z.; Hamid, M. S. A.

2017-11-01

This paper describes a development of lightweight concrete using lightweight expanded clay aggregate (LECA) in fly ash (FA) based geopolymer immersed in seawater. The objective of this research is to compare the performance of geopolymer concrete (GPC) with ordinary Portland cement (OPC) concrete infilled lightweight expanded clay aggregate (LECA) in seawater exposure. Geopolymer concrete is produced by using alkaline activator to activate the raw material, FA. The highest compressive strength of this study is 42.0 MPa at 28 days and 49.8 MPa at 60 days. The density for this concrete is in the range of 1580 kg/m3 to 1660 kg/m3. The result for water absorption is in the range of 6.82% to 14.72%. However, the test results of weight loss is in the range between 0.30% to 0.43%.

Potential of scrap tire rubber as lightweight aggregate in flowable fill.

PubMed

Pierce, C E; Blackwell, M C

2003-01-01

Flowable fill is a self-leveling and self-compacting material that is rapidly gaining acceptance and application in construction, particularly in transportation and utility earthworks. When mixed with concrete sand, standard flowable fill produces a mass density ranging from 1.8 to 2.3 g/cm(3) (115-145 pcf). Scrap tires can be granulated to produce crumb rubber, which has a granular texture and ranges in size from very fine powder to coarse sand-sized particles. Due to its low specific gravity, crumb rubber can be considered a lightweight aggregate. This paper describes an experimental study on replacing sand with crumb rubber in flowable fill to produce a lightweight material. To assess the technical feasibility of using crumb rubber, the fluid- and hardened-state properties of nine flowable fill mixtures were measured. Mixture proportions were varied to investigate the effects of water-to-cement ratio and crumb rubber content on fill properties. Experimental results indicate that crumb rubber can be successfully used to produce a lightweight flowable fill (1.2-1.6 g/cm(3) [73-98 pcf]) with excavatable 28-day compressive strengths ranging from 269 to 1194 kPa (39-173 psi). Using a lightweight fill reduces the applied stress on underlying soils, thereby reducing the potential for bearing capacity failure and minimizing soil settlement. Based on these results, a crumb rubber-based flowable fill can be used in a substantial number of construction applications, such as bridge abutment fills, trench fills, and foundation support fills.

Investigation on bending failure to characterize crashworthiness of 6xxx-series aluminium sheet alloys with bending-tension test procedure

NASA Astrophysics Data System (ADS)

Henn, Philipp; Liewald, Mathias; Sindel, Manfred

2018-05-01

As lightweight design as well as crash performance are crucial to future car body design, exact material characterisation is important to use materials at their full potential and reach maximum efficiency. Within the scope of this paper, the potential of newly established bending-tension test procedure to characterise material crashworthiness is investigated. In this test setup for the determination of material failure, a buckling-bending test is coupled with a subsequent tensile test. If prior bending load is critical, tensile strength and elongation in the subsequent tensile test are dramatically reduced. The new test procedure therefore offers an applicable definition of failure as the incapacity of energy consumption in subsequent phases of the crash represents failure of a component. In addition to that, the correlation of loading condition with actual crash scenarios (buckling and free bending) is improved compared to three- point bending test. The potential of newly established bending-tension test procedure to characterise material crashworthiness is investigated in this experimental studys on two aluminium sheet alloys. Experimental results are validated with existing ductility characterisation from edge compression test.

Evaluation and comparison of a lightweight bamboo composite

NASA Astrophysics Data System (ADS)

Loth, Andreas; Berwing, Michael; Förster, Ralf

2016-10-01

The demand for fast changing production lines and other facilities needs new lightweight and stable systems for partitioning walls. There is also a need for ecological products for this application. The wood like grass bamboo provides a wide potential to substitute conventional wood. A composite lightweight honeycomb like bamboo board was developed and compared with reinforced and unreinforced plywood specimen. The acquired mechanical properties gave a promising result for the usability of bamboo as basis material for wide span boards. It can be manufactured with minimal technical investments, that suits also well for regions with little industry. The ecological assessment of the structure is very positive.

LFT foam - Lightweight potential for semi-structural components through the use of long-glass-fiber-reinforced thermoplastic foams

NASA Astrophysics Data System (ADS)

Roch, A.; Huber, T.; Henning, F.; Elsner, P.

2014-05-01

Investigations on PP-LGF30 foam sandwiches have been carried out using different manufacturing processes: standard injection molding, MuCell® and LFT-D foam. Both chemical and physical blowing agents were applied. Precision mold opening (breathing mold technology) was selected for the foaming process. The integral foam design, which can be conceived as a sandwich structure, helps to save material in the neutral axis area and maintains a distance between load-bearing, unfoamed skin layers. The experiments showed that, at a constant mass per unit area, integral foams have a significantly higher flexural rigidity than compact components, due to their greater area moment of inertia after foaming: with an increase of the wall thickness from 3.6 mm to 4.4 mm compared to compact construction, the flexural rigidity increased by 75 %. With a final wall thickness of 5.8 mm an increase of 300 % was measured. Compared to non-reinforced components that show significant embrittlement during foaming, the energy absorption capacity (impact strength) of LFT foam components remains almost constant.

Nanotube Heterojunctions and Endo-Fullerenes for Nanoelectronics

NASA Technical Reports Server (NTRS)

Srivastava, Deepak; Menon, M.; Andriotis, Antonis; Cho, K.; Park, Jun; Biegel, Bryan A. (Technical Monitor)

2002-01-01

Topics discussed include: (1) Light-Weight Multi-Functional Materials: Nanomechanics; Nanotubes and Composites; Thermal/Chemical/Electrical Characterization; (2) Biomimetic/Revolutionary Concepts: Evolutionary Computing and Sensing; Self-Heating Materials; (3) Central Computing System: Molecular Electronics; Materials for Quantum Bits; and (4) Molecular Machines.

Electrolysis Propulsion for Spacecraft Applications

NASA Technical Reports Server (NTRS)

deGroot, Wim A.; Arrington, Lynn A.; McElroy, James F.; Mitlitsky, Fred; Weisberg, Andrew H.; Carter, Preston H., II; Myers, Blake; Reed, Brian D.

1997-01-01

Electrolysis propulsion has been recognized over the last several decades as a viable option to meet many satellite and spacecraft propulsion requirements. This technology, however, was never used for in-space missions. In the same time frame, water based fuel cells have flown in a number of missions. These systems have many components similar to electrolysis propulsion systems. Recent advances in component technology include: lightweight tankage, water vapor feed electrolysis, fuel cell technology, and thrust chamber materials for propulsion. Taken together, these developments make propulsion and/or power using electrolysis/fuel cell technology very attractive as separate or integrated systems. A water electrolysis propulsion testbed was constructed and tested in a joint NASA/Hamilton Standard/Lawrence Livermore National Laboratories program to demonstrate these technology developments for propulsion. The results from these testbed experiments using a I-N thruster are presented. A concept to integrate a propulsion system and a fuel cell system into a unitized spacecraft propulsion and power system is outlined.

Fabrication and testing of silver-hydrogen cells

NASA Technical Reports Server (NTRS)

Klein, M. G.

1978-01-01

The development and life testing of single electrode and multi electrode stacks to optimize the individual components and characterize the performance of a silver hydrogen battery system are described. A NASA-developed inorganic separator material was used as the main separator within the cells. Single electrode test cells were cycled at 75% of nominal capacity out through approximately 1,000 cycles in a number of cases where deterioration in performance was observed. This deterioration appears to be a decay in usable capacity of the silver electrode; but the exact mechanism is still unidentified. Twenty ampere-hour boilerplate test cells consisting of a stack of ten silver electrodes and twenty hydrogen electrodes were cycled also at 75% depth of discharge. The oldest stack achieved 522 stable cycles to the end of the program. Weight analysis of light-weight cells showed that 50 ampere-hour cells with improved components could be capable of as much as 40 watt hours per pound.

Construction of three-dimensional graphene interfaces into carbon fiber textiles for increasing deposition of nickel nanoparticles: flexible hierarchical magnetic textile composites for strong electromagnetic shielding

NASA Astrophysics Data System (ADS)

Bian, Xing-Ming; Liu, Lin; Li, Hai-Bing; Wang, Chan-Yuan; Xie, Qing; Zhao, Quan-Liang; Bi, Song; Hou, Zhi-Ling

2017-01-01

Since manipulating electromagnetic waves with electromagnetic active materials for environmental and electric engineering is a significant task, here a novel prototype is reported by introducing reduced graphene oxide (RGO) interfaces in carbon fiber (CF) networks for a hierarchical carbon fiber/reduced graphene oxide/nickel (CF-RGO-Ni) composite textile. Upon charaterizations of the microscopic morphologies, electrical and magnetic properties, the presence of three-dimensional RGO interfaces and bifunctional nickel nanoparticles substantially influences the related physical properties in the resulting hierarchical composite textiles. Eletromagnetic interference (EMI) shielding performance suggests that the hierarchical composite textiles hold a strong shielding effectiveness greater than 61 dB, showing greater advantages than conventional polymeric and foamy shielding composites. As a polymer-free lightweight structure, flexible CF-RGO-Ni composites of all electromagnetic active components offer unique understanding of the multi-scale and multiple mechanisms in electromagnetic energy consumption. Such a novel prototype of shielding structures along with convenient technology highlight a strategy to achieve high-performance EMI shielding, coupled with a universal approach for preparing advanced lightweight composites with graphene interfaces.

Construction of three-dimensional graphene interfaces into carbon fiber textiles for increasing deposition of nickel nanoparticles: flexible hierarchical magnetic textile composites for strong electromagnetic shielding.

PubMed

Bian, Xing-Ming; Liu, Lin; Li, Hai-Bing; Wang, Chan-Yuan; Xie, Qing; Zhao, Quan-Liang; Bi, Song; Hou, Zhi-Ling

2017-01-27

Since manipulating electromagnetic waves with electromagnetic active materials for environmental and electric engineering is a significant task, here a novel prototype is reported by introducing reduced graphene oxide (RGO) interfaces in carbon fiber (CF) networks for a hierarchical carbon fiber/reduced graphene oxide/nickel (CF-RGO-Ni) composite textile. Upon charaterizations of the microscopic morphologies, electrical and magnetic properties, the presence of three-dimensional RGO interfaces and bifunctional nickel nanoparticles substantially influences the related physical properties in the resulting hierarchical composite textiles. Eletromagnetic interference (EMI) shielding performance suggests that the hierarchical composite textiles hold a strong shielding effectiveness greater than 61 dB, showing greater advantages than conventional polymeric and foamy shielding composites. As a polymer-free lightweight structure, flexible CF-RGO-Ni composites of all electromagnetic active components offer unique understanding of the multi-scale and multiple mechanisms in electromagnetic energy consumption. Such a novel prototype of shielding structures along with convenient technology highlight a strategy to achieve high-performance EMI shielding, coupled with a universal approach for preparing advanced lightweight composites with graphene interfaces.

Demonstration Project for a Multi-Material Lightweight Prototype Vehicle as Part of the Clean Energy Dialogue with Canada

DOE Office of Scientific and Technical Information (OSTI.GOV)

Skszek, Tim

2015-12-29

The intent of the Multi-Material Lightweight Vehicle (“MMLV”) was to assess the feasibility of achieving a significant level of vehicle mass reduction, enabling engine downsizing resulting in a tangible fuel reduction and environmental benefit. The MMLV project included the development of two (2) lightweight vehicle designs, referred to as Mach-I and Mach-II MMLV variants, based on a 2013 Ford production C/D segment production vehicle (Fusion). Weight comparison, life cycle assessment and limited full vehicle testing are included in the project scope. The Mach-I vehicle variant was comprised of materials and processes that are commercially available or previously demonstrated. The 363more » kg mass reduction associated with the Mach-I design enabled use of a one-liter, three-cylinder, gasoline turbocharged direct injection engine, maintaining the performance and utility of the baseline vehicle. The full MMLV project produced seven (7) MMLV Mach-I “concept vehicles” which were used for testing and evaluation. The full vehicle tests confirmed that MMLV Mach-I concept vehicle performed approximately equivalent to the baseline 2013 Ford Fusion vehicle thereby validating the design of the multi material lightweight vehicle design. The results of the Life Cycle Assessment, conducted by third party consultant, indicated that if the MMLV Mach-I design was built and operated in North America for 250,000 km (155,343 miles) it would produce significant environmental and fuel economy benefits including a 16% reduction in Global Warming Potential (GWP) and 16% reduction in Total Primary Energy (TPE). The LCA calculations estimated the combined fuel economy of 34 mpg (6.9 l/100 km) associated with the MMLV Mach-I Design compared to 28 mpg (8.4 l/100 km) for the 2013 Ford Fusion.« less

The influence of partial replacement of hemp shives by expanded perlite on physical properties of hemp-lime composite

NASA Astrophysics Data System (ADS)

Brzyski, Przemysław; Widomski, Marcin

2017-07-01

The use of waste plants in building materials production is consistent with the principles of sustainable development, including waste management, CO2 balance, biodegradability of the material e.g. after building demolition. The porous structure of plant materials determines their usability as the insulation materials. An example of plant applicable in the construction industry is the industrial hemp. The shives are produced from the wooden core of the hemp stem as lightweight insulating filler in the composite based on lime binder. The discussed hemp-lime composite, due to the presence of lightweight, porous organic aggregates exhibits satisfactory thermal insulation properties and is used as filling and insulation of walls (as well as roofs and floors) in buildings of the wooden frame construction. The irregular shape of shives and their low density causes nonhomogenous compaction of composite and the formation of voids between the randomly arranged shives. In this paper the series of hemp-lime composites were tested. Apart from hemp shives, an additional aggregate - expanded perlite was used as a fine, lightweight, thermal insulating filler. Application of the additional aggregate was aimed to fill the voids between hemp shives and to investigate its influence on the physical properties of composite: apparent density, total porosity, water absorption and thermal conductivity.

Additive manufactured x-ray optics for astronomy

NASA Astrophysics Data System (ADS)

Atkins, Carolyn; Feldman, Charlotte; Brooks, David; Watson, Stephen; Cochrane, William; Roulet, Melanie; Doel, Peter; Willingale, Richard; Hugot, Emmanuel

2017-08-01

Additive manufacturing, more commonly known as 3D printing, has become a commercially established technology for rapid prototyping and the fabrication of bespoke intricate parts. Optical components, such as mirrors and lenses, are now being fabricated via additive manufacturing, where the printed substrate is polished in a post-processing step. One application of additively manufactured optics could be within the astronomical X-ray community, where there is a growing need to demonstrate thin, lightweight, high precision optics for a beyond Chandra style mission. This paper will follow a proof-of-concept investigation, sponsored by the UK Space Agency's National Space Technology Programme, into the feasibility of applying additive manufacturing in the production of thin, lightweight, precision X-ray optics for astronomy. One of the benefits of additive manufacturing is the ability to construct intricate lightweighting, which can be optimised to minimise weight while ensuring rigidity. This concept of optimised lightweighting will be applied to a series of polished additively manufactured test samples and experimental data from these samples, including an assessment of the optical quality and the magnitude of any print-through, will be presented. In addition, the finite element analysis optimisations of the lightweighting development will be discussed.

Method for Making a Carbon-Carbon Cylinder Block

NASA Technical Reports Server (NTRS)

Ransone, Phillip O. (Inventor)

1997-01-01

A method for making a lightweight cylinder block composed of carbon-carbon is disclosed. The use of carbon-carbon over conventional materials. such as cast iron or aluminum, reduces the weight of the cylinder block and improves thermal efficiency of the internal combustion reciprocating engine. Due to the negligible coefficient of thermal expansion and unique strength at elevated temperatures of carbon-carbon, the piston-to-cylinder wall clearance can be small, especially when the carbon-carbon cylinder block is used in conjunction with a carbon-carbon piston. Use of the carbon-carbon cylinder block has the effect of reducing the weight of other reciprocating engine components allowing the piston to run at higher speeds and improving specific engine performance.

Compton imaging tomography technique for NDE of large nonuniform structures

NASA Astrophysics Data System (ADS)

Grubsky, Victor; Romanov, Volodymyr; Patton, Ned; Jannson, Tomasz

2011-09-01

In this paper we describe a new nondestructive evaluation (NDE) technique called Compton Imaging Tomography (CIT) for reconstructing the complete three-dimensional internal structure of an object, based on the registration of multiple two-dimensional Compton-scattered x-ray images of the object. CIT provides high resolution and sensitivity with virtually any material, including lightweight structures and organics, which normally pose problems in conventional x-ray computed tomography because of low contrast. The CIT technique requires only one-sided access to the object, has no limitation on the object's size, and can be applied to high-resolution real-time in situ NDE of large aircraft/spacecraft structures and components. Theoretical and experimental results will be presented.

A New Thermal Treatment Process of Low Value Volcanic Glass towards the Production of Expanded Material and its Use on CNTs’ Synthesis as Substrate Material

NASA Astrophysics Data System (ADS)

Angelopoulos, Panagiotis M.; Samouhos, Michail; Taxiarchou, Maria; Tsakiridis, P.; Haggman, John; Joyce, Paul

2018-05-01

Pitchstone is a naturally occurring volcanic glass that contains considerable amount of chemically bound water (> 6 % wt). Due to its high water content, its direct thermal processing in conventional expansion furnaces towards the production of lightweight material, similar to expanded perlite, is practically impossible. In the current research paper a sophisticated 2 stage process is presented that consists of a partial dehydration and an expansion stage towards the production of high quality expanded material. After proper treatment, low-value volcanic glass is transformed to frothy, lightweight material of closed external surface and apparent density of 52 kg·m-3 that can be used in various branches of the industry. The material produced is used as substrate for the development of multiwall CNTs through CVD method. Dense multiwall CNT clusters were identified on expanded pitchstone surface, thus rendering the material suitable for such application.

ULE design considerations for a 3m class light weighted mirror blank for E-ELT M5

NASA Astrophysics Data System (ADS)

Fox, Andrew; Hobbs, Tom; Edwards, Mary; Arnold, Matthew; Sawyer, Kent

2016-07-01

It is expected that the next generation of large ground based astronomical telescopes will need large fast-steering/tip-tilt mirrors made of ultra-lightweight construction. These fast-steering mirrors are used to continuously correct for atmospheric disturbances and telescope vibrations. An example of this is the European Extremely Large Telescope (E-ELT) M5 lightweight mirror, which is part of the Tip-Tilt/Field-Stabilization Unit. The baseline design for the E-ELT M5 mirror, as presented in the E-ELT Construction Proposal, is a closed-back ULE mirror with a lightweight core using square core cells. Corning Incorporated (Corning) has a long history of manufacturing lightweight mirror blanks using ULE in a closed-back construction, going back to the 1960's, and includes the Hubble Space Telescope primary mirror, Subaru Telescope secondary and tertiary mirrors, the Magellan I and II tertiary mirrors, and Kepler Space Telescope primary mirror, among many others. A parametric study of 1-meter class lightweight mirror designs showed that Corning's capability to seal a continuous back sheet to a light-weighted core structure provides superior mirror rigidity, in a near-zero thermal expansion material, relative to other existing technologies in this design space. Corning has investigated the parametric performance of several design characteristics for a 3-meter class lightweight mirror blank for the E-ELT M5. Finite Element Analysis was performed on several design scenarios to obtain weight, areal density, and first Eigen frequency. This paper presents an overview of Corning ULE and lightweight mirror manufacturing capabilities, the parametric performance of design characteristics for 1-meter class and 3-meter class lightweight mirrors, as well as the manufacturing advantages and disadvantages of those characteristics.

IBE-Lite: a lightweight identity-based cryptography for body sensor networks.

PubMed

Tan, Chiu C; Wang, Haodong; Zhong, Sheng; Li, Qun

2009-11-01

A body sensor network (BSN) is a network of sensors deployed on a person's body for health care monitoring. Since the sensors collect personal medical data, security and privacy are important components in a BSN. In this paper, we developed IBE-Lite, a lightweight identity-based encryption suitable for sensors in a BSN. We present protocols based on IBE-Lite that balance security and privacy with accessibility and perform evaluation using experiments conducted on commercially available sensors.

Process combinations for the manufacturing of metal-plastic hybrid parts

NASA Astrophysics Data System (ADS)

Drossel, W.-G.; Lies, C.; Albert, A.; Haase, R.; Müller, R.; Scholz, P.

2016-03-01

The usage of innovative lightweight materials and processing technologies gains importance in manifold industrial scopes. Especially for moving parts and mobility products the weight is decisively. The aerospace and automotive industries use light and high-strength materials to reduce weight and energy consumption and thereby improve the performance of their products. Composites with reinforced plastics are of particular importance. They offer a low density in combination with high specific stiffness and strength. A pure material substitution through reinforced plastics is still not economical. The approach of using hybrid metal-plastic structures with the principle of “using the right material at the right place” is a promising solution for the economical realization of lightweight structures with a high achievement potential. The article shows four innovative manufacturing possibilities for the realization of metal-plastic-hybrid parts.

Common aperture multispectral optics for military applications

NASA Astrophysics Data System (ADS)

Thompson, N. A.

2012-06-01

With the recent developments in multi-spectral detector technology the interest in common aperture, common focal plane multi-spectral imaging systems is increasing. Such systems are particularly desirable for military applications where increased levels of target discrimination and identification are required in cost-effective, rugged, lightweight systems. During the optical design of dual waveband or multi-spectral systems, the options for material selection are limited. This selection becomes even more restrictive for military applications as material resilience and thermal properties must be considered in addition to colour correction. In this paper we discuss the design challenges that lightweight multi-spectral common aperture systems present along with some potential design solutions. Consideration will be given to material selection for optimum colour correction as well as material resilience and thermal correction. This discussion is supported using design examples that are currently in development at Qioptiq.

Laser Transmission Welding of CFRTP Using Filler Material

NASA Astrophysics Data System (ADS)

Berger, Stefan; Schmidt, Michael

In the automotive industry the increasing environmental awareness is reflected through consistent lightweight construction. Especially the use of carbon fiber reinforced thermoplastics (CFRTP) plays an increasingly important role. Accordingto the material substitution, the demand for adequate joining technologies is growing. Therefore, laser transmission welding with filler material provides a way to combine two opaque joining partners by using process specific advantages of the laser transmission welding process. After introducing the new processing variant and the used experimental setup, this paper investigates the process itselfand conditions for a stable process. The influence of the used process parameters on weld quality and process stability is characterized by tensile shear tests. The successfully performed joining of PA 6 CF 42 organic sheets using natural PA 6 as filler material underlines the potential of the described joining method for lightweight design and other industrial applications.

Improved Joining of Metal Components to Composite Structures

NASA Technical Reports Server (NTRS)

Semmes, Edmund

2009-01-01

Systems requirements for complex spacecraft drive design requirements that lead to structures, components, and/or enclosures of a multi-material and multifunctional design. The varying physical properties of aluminum, tungsten, Invar, or other high-grade aerospace metals when utilized in conjunction with lightweight composites multiply system level solutions. These multi-material designs are largely dependent upon effective joining techAn improved method of joining metal components to matrix/fiber composite material structures has been invented. The method is particularly applicable to equipping such thin-wall polymer-matrix composite (PMC) structures as tanks with flanges, ceramic matrix composite (CMC) liners for high heat engine nozzles, and other metallic-to-composite attachments. The method is oriented toward new architectures and distributing mechanical loads as widely as possible in the vicinities of attachment locations to prevent excessive concentrations of stresses that could give rise to delaminations, debonds, leaks, and other failures. The method in its most basic form can be summarized as follows: A metal component is to be joined to a designated attachment area on a composite-material structure. In preparation for joining, the metal component is fabricated to include multiple studs projecting from the aforementioned face. Also in preparation for joining, holes just wide enough to accept the studs are molded into, drilled, or otherwise formed in the corresponding locations in the designated attachment area of the uncured ("wet') composite structure. The metal component is brought together with the uncured composite structure so that the studs become firmly seated in the holes, thereby causing the composite material to become intertwined with the metal component in the joining area. Alternately, it is proposed to utilize other mechanical attachment schemes whereby the uncured composite and metallic parts are joined with "z-direction" fasteners. The resulting "wet" assembly is then subjected to the composite-curing heat treatment, becoming a unitary structure. It should be noted that this new art will require different techniques for CMC s versus PMC's, but the final architecture and companion curing philosophy is the same. For instance, a chemical vapor infiltration (CVI) fabrication technique may require special integration of the pre-form and

Crashworthiness analysis using advanced material models in DYNA3D

DOE Office of Scientific and Technical Information (OSTI.GOV)

Logan, R.W.; Burger, M.J.; McMichael, L.D.

1993-10-22

As part of an electric vehicle consortium, LLNL and Kaiser Aluminum are conducting experimental and numerical studies on crashworthy aluminum spaceframe designs. They have jointly explored the effect of heat treat on crush behavior and duplicated the experimental behavior with finite-element simulations. The major technical contributions to the state of the art in numerical simulation arise from the development and use of advanced material model descriptions for LLNL`s DYNA3D code. Constitutive model enhancements in both flow and failure have been employed for conventional materials such as low-carbon steels, and also for lighter weight materials such as aluminum and fiber compositesmore » being considered for future vehicles. The constitutive model enhancements are developed as extensions from LLNL`s work in anisotropic flow and multiaxial failure modeling. Analysis quality as a function of level of simplification of material behavior and mesh is explored, as well as the penalty in computation cost that must be paid for using more complex models and meshes. The lightweight material modeling technology is being used at the vehicle component level to explore the safety implications of small neighborhood electric vehicles manufactured almost exclusively from these materials.« less

Electro-Statically Stricted Polymers (ESSP)

NASA Technical Reports Server (NTRS)

Liu, C.; Bar-Cohen, Y.; Leary, S.

1999-01-01

Miniature, lightweight, miser actuators that operate similar to biological muscles can be used to develop robotic devices with unmatched capabilities and impact many technology areas. Electroactive polymers (EAP) offer the potential to producing such actuators and their main attractive feature is their ability to induce relatively large bending or longitudinal strain. EAP actuators can change the paradigm about the complexity of robots, where robotic components such as motors, gears, bearings, and others can be eliminated with simple drive mechanisms. Generally, these materials produce a relatively low force and the applications that can be considered at the current state of the art are relatively limited. While improved material are being developed there is a need for methods to develop longitudinal actuators that can contract similar to muscles. In this study, the authors began investigating the electromechanical behavior of polymers in reaction to a complex configuration of electric fields. A computer model was used to simulate the electromechanical response. Efforts were made to develop both the material basis as well as the electromechanical modeling of the actuator.

An Analysis of the Relationship between Casualty Risk Per Crash and Vehicle Mass and Footprint for Model Year 2003-2010 Light-Duty Vehicles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wenzel, Tom P.

The Department of Energy’s (DOE) Vehicle Technologies Office funds research on development of technologies to improve the fuel economy of both light- and heavy-duty vehicles, including advanced combustion systems, improved batteries and electric drive systems, and new lightweight materials. Of these approaches to increase fuel economy and reduce fuel consumption, reducing vehicle mass through more extensive use of strong lightweight materials is perhaps the easiest and least expensive method; however, there is a concern that reducing vehicle mass may lead to more fatalities. Lawrence Berkeley National Laboratory (LBNL) has conducted several analyses to better understand the relationship between vehicle mass,more » size and safety, in order to ameliorate concerns that down-weighting vehicles will inherently lead to more fatalities. These analyses include recreating the regression analyses conducted by the National Highway Traffic Safety Administration (NHTSA) that estimate the relationship between mass reduction and U.S. societal fatality risk per vehicle mile of travel (VMT), while holding vehicle size (i.e. footprint, wheelbase times track width) constant; these analyses are referred to as LBNL Phase 1 analysis. In addition, LBNL has conducted additional analysis of the relationship between mass and the two components of risk per VMT, crash frequency (crashes per VMT) and risk once a crash has occurred (risk per crash); these analyses are referred to as LBNL Phase 2 analysis.« less

CryoTEM as an Advanced Analytical Tool for Materials Chemists.

PubMed

Patterson, Joseph P; Xu, Yifei; Moradi, Mohammad-Amin; Sommerdijk, Nico A J M; Friedrich, Heiner

2017-07-18

Morphology plays an essential role in chemistry through the segregation of atoms and/or molecules into different phases, delineated by interfaces. This is a general process in materials synthesis and exploited in many fields including colloid chemistry, heterogeneous catalysis, and functional molecular systems. To rationally design complex materials, we must understand and control morphology evolution. Toward this goal, we utilize cryogenic transmission electron microscopy (cryoTEM), which can track the structural evolution of materials in solution with nanometer spatial resolution and a temporal resolution of <1 s. In this Account, we review examples of our own research where direct observations by cryoTEM have been essential to understanding morphology evolution in macromolecular self-assembly, inorganic nucleation and growth, and the cooperative evolution of hybrid materials. These three different research areas are at the heart of our approach to materials chemistry where we take inspiration from the myriad examples of complex materials in Nature. Biological materials are formed using a limited number of chemical components and under ambient conditions, and their formation pathways were refined during biological evolution by enormous trial and error approaches to self-organization and biomineralization. By combining the information on what is possible in nature and by focusing on a limited number of chemical components, we aim to provide an essential insight into the role of structure evolution in materials synthesis. Bone, for example, is a hierarchical and hybrid material which is lightweight, yet strong and hard. It is formed by the hierarchical self-assembly of collagen into a macromolecular template with nano- and microscale structure. This template then directs the nucleation and growth of oriented, nanoscale calcium phosphate crystals to form the composite material. Fundamental insight into controlling these structuring processes will eventually allow us to design such complex materials with predetermined and potentially unique properties.

Polymer/Carbon Nanotube Networks for Smart, Self-Repairing and Light-Weighted Nanocomposites

DTIC Science & Technology

2012-11-05

was develop smart, strong, and light-weight polymer/carbon nanotube (CNT) composites which will sense tribologically induced damages and self-heal by...light-weight polymer/carbon nanotube (CNT) composites which will sense tribologically induced damages and self-heal by inhibiting such degradation...one of support references for EPSRC instrument grant application for Micro Materials NanoTest Vantage Testing Suite with NTX4Controller. The grant

Mineral resource of the month: perlite

USGS Publications Warehouse

,

2010-01-01

The article talks about perlite, which is a mineral used as an aggregate for lightweight construction products, filler for paints and horticultural soil blends. Perlite comes from viscous lava, mined and processed to produce lightweight material that competes with pumice, exfoliated vermiculite and expanded clay and shale. It is mined in about 35 countries that include Greece, Japan and the U.S. Other uses include insulation, concrete and plaster aggregate, and stonewashing.

Lightweight, Durable Army Antennas Using Carbon Nanotube Technology

DTIC Science & Technology

2013-01-01

may be adjusted by collecting the sheet on a revolving substrate conveyor belt (e.g., Teflon belt ), as shown in figure 15 (12). SEM images of the... designated by other authorized documents. Citation of manufacturer’s or trade names does not constitute an official endorsement or approval of the use...CNT) materials to produce lightweight, flexible, and durable alternatives to existing and future Army antenna designs is explored through fabrication

Metal matrix composite structural panel construction

NASA Technical Reports Server (NTRS)

Mcwithey, R. R.; Royster, D. M. (Inventor); Bales, T. T.

1983-01-01

Lightweight capped honeycomb stiffeners for use in fabricating metal or metal/matrix exterior structural panels on aerospace type vehicles and the process for fabricating same are disclosed. The stiffener stringers are formed in sheets, cut to the desired width and length and brazed in spaced relationship to a skin with the honeycomb material serving directly as the required lightweight stiffeners and not requiring separate metal encasement for the exposed honeycomb cells.

Orthotic devices using lightweight composite materials

NASA Technical Reports Server (NTRS)

Harrison, E., Jr.

1983-01-01

Potential applications of high strength, lightweight composite technology in the orthotic field were studied. Several devices were designed and fabricated using graphite-epoxy composite technology. Devices included shoe plates, assistive walker devices, and a Simes prosthesis reinforcement. Several other projects having medical application were investigated and evaluations were made of the potential for use of composite technology. A seat assembly was fabricated using sandwich construction techniques for the Total Wheelchair Project.

Low CTE glass, SiC & Beryllium for lightweight mirror substrates

NASA Astrophysics Data System (ADS)

Geyl, Roland; Cayrel, Marc

2005-10-01

This paper is intended to analyze the relative merits of low CTE glass, SiC and Beryllium as candidates for lightweight mirror substrates in connection with real practical experience and example or three major projects using these three materials and running presently at SAGEM-REOSC. Beryllium and SiC have nice thermal and mechanical properties but machined glass ceramic can still well compete technically or economically in some cases.

Lightweight ZERODUR: a cost-effective thermally stable approach to both large and small spaceborne telescopes

NASA Astrophysics Data System (ADS)

Hull, Tony; Westerhoff, Thomas

2014-06-01

ZERODUR®, known as the "gold standard" material for systems which require dimensional stability in the presence of gradients and transients, is now available lightweighted to the 85% to 90% level for use in high performance spaceborne telescopes and sensor systems. This establishes a design option that may have cost, testability, performance and risk advantages for an entire sensor system payload. The technical approach to making these primary mirrors is the same, whether the aperture is <0.3m to <4.0m. Since each mirror blank is made from a single monolithic billet of near zero-expansion, isotropic and homogeneous ZERODUR® material, the resulting mirror is very stable over a wide range of scenes and orbits, with minimal to no need for ancillary thermal stability and wavefront sensing and control systems. Telescopes using ZERODUR® and low expansion metering structures can accommodate thermal design challenges of both non-thermal (UV, VIS, LLLTV, NIR, SWIR and mm) and thermal (MWIR, LWIR) imaging systems, and deliver optimal performance. This lightweight mirror technology is discussed, with actual examples by SCHOTT of 0.3m and 1.2m mirrors presented. Lightweight ZERODUR® mirrors offer superior optical performance, attractive cost and aggressive lead times, and are available to present and future spaceborne sensor trades.

The effect of foaming agent doses on lightweight geopolymer concrete metakaolin based

NASA Astrophysics Data System (ADS)

Risdanareni, Puput; Hilmi, Aldi; Susanto, Prijono Bagus

2017-04-01

The aims of this study is to obtain optimal doses of foaming agent on lightweight geopolymer concrete using fly Ash (FA) and metakaolin (MK) as raw materials. Several test was conducted in order to obtained characteristics of geopolymer lightweight concrete using foaming agent with different doses. The levels of foaming agent used was 0%, 0.3%, 0.6% and 0.9% from the binder weight. Level of metakolin content of 25% by precursor mass were applied in this research. In addition, activator solution with the ratio of Na2SiO3 / NaOH of 2 and Concentration of NaOH of 10 Molar were performed in this research. Doses of foaming agent of 0%, 0.3%, 0.6% and 0.9% by weight of the binder was used. Based on test results obtained, the best mechanical and physical properties of lightweight concrete was owned by speciment with doses of foam 0%. The recommended foam dosage is 0.3% due to its fair enough mechanical and physical properties of lightweight geopolymer concrete produced.

Lightweight Combat Vehicle S and T Campaign

DTIC Science & Technology

2014-10-06

research in nano-materials, self - healing /diagnosing materials, multi-functional materials, and environmentally acceptable materials. The application...research includes nano-materials, self - healing /diagnosing materials, multi-functional materials, and environmentally acceptable materials.5 The 2003...hubs must be led by a not-for-profit organization, provide 50% cost share match, and are expected to become self -sufficient in 5 years. So far, all

The Application of Metal Matrix Composite Materials in Propulsion System Valves

NASA Technical Reports Server (NTRS)

Laszar, John; Shah, Sandeep; Kashalikar, Uday; Rozenoyer, Boris

2003-01-01

Metal Matrix Composite (MMC) materials have been developed and used in many applications to reduce the weight of components where weight and deflection are the driving design requirement. MMC materials are being developed for use in some propulsion system components, such as turbo-pumps and thrust chambers. However, to date, no propulsion system valves have been developed that take advantage of the materials unique properties. The stiffness of MMC's could help keep valves light or improve life where deflection is the design constraint (such as seal and bearing locations). The low CTE of the materials might allow the designer to reduce tolerances and clearances producing better performance and lighter weight valves. Using unique manufacturing processes allow parts to be plated/coated for longer life and allow joining either by welding or threading/bolting. Additionally, casting of multi part pre-forms to form a single part can lead to designs that would be hard or impossible to manufacture with other methods. Therefore, NASA's Marshall Space Flight Center (MSFC) has developed and tested a prototype propulsion system valve that utilizes these materials to demonstrate these advantages. Through design and testing, this effort will determine the best use of these materials in valves designed to achieve the goal of a highly reliable and lightweight propulsion system. This paper is a continuation of the paper, The Application of Metal Matrix Composite Materials In Propulsion System Valves, presented at the JANNAF Conference held in April, 2002. Fabrication techniques employed, valve development, and valve test results will be discussed in this paper.

Cost-effective lightweight mirrors for aerospace and defense

NASA Astrophysics Data System (ADS)

Woodard, Kenneth S.; Comstock, Lovell E.; Wamboldt, Leonard; Roy, Brian P.

2015-05-01

The demand for high performance, lightweight mirrors was historically driven by aerospace and defense (A&D) but now we are also seeing similar requirements for commercial applications. These applications range from aerospace-like platforms such as small unmanned aircraft for agricultural, mineral and pollutant aerial mapping to an eye tracking gimbaled mirror for optometry offices. While aerospace and defense businesses can often justify the high cost of exotic, low density materials, commercial products rarely can. Also, to obtain high performance with low overall optical system weight, aspheric surfaces are often prescribed. This may drive the manufacturing process to diamond machining thus requiring the reflective side of the mirror to be a diamond machinable material. This paper summarizes the diamond machined finishing and coating of some high performance, lightweight designs using non-exotic substrates to achieve cost effective mirrors. The results indicate that these processes can meet typical aerospace and defense requirements but may also be competitive in some commercial applications.

Building Block Approach' for Structural Analysis of Thermoplastic Composite Components for Automotive Applications

NASA Astrophysics Data System (ADS)

Carello, M.; Amirth, N.; Airale, A. G.; Monti, M.; Romeo, A.

2017-12-01

Advanced thermoplastic prepreg composite materials stand out with regard to their ability to allow complex designs with high specific strength and stiffness. This makes them an excellent choice for lightweight automotive components to reduce mass and increase fuel efficiency, while maintaining the functionality of traditional thermosetting prepreg (and mechanical characteristics) and with a production cycle time and recyclability suited to mass production manufacturing. Currently, the aerospace and automotive sectors struggle to carry out accurate Finite Elements (FE) component analyses and in some cases are unable to validate the obtained results. In this study, structural Finite Elements Analysis (FEA) has been done on a thermoplastic fiber reinforced component designed and manufactured through an integrated injection molding process, which consists in thermoforming the prepreg laminate and overmolding the other parts. This process is usually referred to as hybrid molding, and has the provision to reinforce the zones subjected to additional stresses with thermoformed themoplastic prepreg as required and overmolded with a shortfiber thermoplastic resin in single process. This paper aims to establish an accurate predictive model on a rational basis and an innovative methodology for the structural analysis of thermoplastic composite components by comparison with the experimental tests results.

New Technology for the Fire Attire

NASA Technical Reports Server (NTRS)

1982-01-01

Although little can be done to reduce the risks of firefighting, something can be done to curb the injuries and fatalities. This is the goal of Project FIRES, a program jointly sponsored by NASA and the Federal Emergency Management Agency's U.S. Fire Administration with technical management provided by Marshall Space Flight Center. Project FIRES (Firefighter's Integrated Response Equipment System) involves applications of advanced materials and design concepts, derived from Apollo to update existing gear which does not adequately protect against many of the hazards encountered in fire suppression activities. A major focus of the effort involves application to the FIRES ensemble of lightweight, fire-resistant, heat-protective materials originally developed for use in astronauts' space suits or in spacecraft components which require thermal protection. Data from the fourteen municipal fire departments participating in the field evaluation will form a basis for development of new nationwide protective ensemble students.

DOE Office of Scientific and Technical Information (OSTI.GOV)

none,

The Lightweight Materials activity (LM) within the Vehicle Technologies Program focuses on the development and validation of advanced materials and manufacturing technologies to significantly reduce light and heavy duty vehicle weight without compromising other attributes such as safety, performance, recyclability, and cost.

Integrating Materials, Manufacturing, Design and Validation for Sustainability in Future Transport Systems

NASA Astrophysics Data System (ADS)

Price, M. A.; Murphy, A.; Butterfield, J.; McCool, R.; Fleck, R.

2011-05-01

The predictive methods currently used for material specification, component design and the development of manufacturing processes, need to evolve beyond the current `metal centric' state of the art, if advanced composites are to realise their potential in delivering sustainable transport solutions. There are however, significant technical challenges associated with this process. Deteriorating environmental, political, economic and social conditions across the globe have resulted in unprecedented pressures to improve the operational efficiency of the manufacturing sector generally and to change perceptions regarding the environmental credentials of transport systems in particular. There is a need to apply new technologies and develop new capabilities to ensure commercial sustainability in the face of twenty first century economic and climatic conditions as well as transport market demands. A major technology gap exists between design, analysis and manufacturing processes in both the OEMs, and the smaller companies that make up the SME based supply chain. As regulatory requirements align with environmental needs, manufacturers are increasingly responsible for the broader lifecycle aspects of vehicle performance. These include not only manufacture and supply but disposal and re-use or re-cycling. In order to make advances in the reduction of emissions coupled with improved economic efficiency through the provision of advanced lightweight vehicles, four key challenges are identified as follows: Material systems, Manufacturing systems, Integrated design methods using digital manufacturing tools and Validation systems. This paper presents a project which has been designed to address these four key issues, using at its core, a digital framework for the creation and management of key parameters related to the lifecycle performance of thermoplastic composite parts and structures. It aims to provide capability for the proposition, definition, evaluation and demonstration of advanced lightweight structures for new generation vehicles in the context of whole life performance parameters.

Lightweight Ceramic Composition of Carbon Silicon Oxygen and Boron

NASA Technical Reports Server (NTRS)

Leiser, Daniel B. (Inventor); Hsu, Ming-Ta (Inventor); Chen, Timothy S. (Inventor)

1997-01-01

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

Artificial lightweight aggregates as utilization for future ashes - A case study.

PubMed

Sarabèr, Angelo; Overhof, Robert; Green, Terry; Pels, Jan

2012-01-01

In the future, more electricity in the Netherlands will be produced using coal with co-combustion. Due to this, the generated annual ash volume will increase and the chemical composition will be influenced. One of the options for utilization if present markets are saturated and for use of fly ashes with different compositions, is as raw material for lightweight aggregates. This was selected as one of the best utilizations options regarding potential ash volume to be applied, environmental aspects and status of technology. Because of this, a study has been performed to assess the potential utilization of fly ash for the production of lightweight aggregate. Lightweight aggregate has been produced in a laboratory scale rotary kiln. The raw material consisted of class F fly ash with high free lime content. An addition of 8% clay was necessary to get green pellets with sufficient green strength. The basic properties of the produced lightweight aggregate and its behaviour in concrete have been investigated. The concrete has a good compressive strength and its leaching behaviour meets the most stringent requirements of Dutch environmental regulations. The carbon foot print of concrete will be negatively influenced if only the concrete itself is taken into account, but the reduction of the volume weight has advantages regarding design, transport emissions and isolation properties which may counteract this. In the Dutch situation the operational costs are higher than expected potential selling price for the LWA, which implies that the gate fee for the fly ash is negative. Copyright © 2011 Elsevier Ltd. All rights reserved.

Critical factors affecting life cycle assessments of material choice for vehicle mass reduction

EPA Science Inventory

This review examines the use of life-cycle assessments (LCAs) to compare different lightweight materials being developed to improve light-duty vehicle fuel economy. Vehicle manufacturers are designing passenger cars and light-duty trucks using lighter weight materials and design ...

On the thermoelastic analysis of solar cell arrays and related material properties

NASA Technical Reports Server (NTRS)

Salama, M. A.; Bouquet, F. L.

1976-01-01

Accurate prediction of failure of solar cell arrays requires accuracy in the computation of thermally induced stresses. This was accomplished by using the finite element technique. Improved procedures for stress calculation were introduced together with failure criteria capable of describing a wide range of ductile and brittle material behavior. The stress distribution and associated failure mechanisms in the N-interconnect junction of two solar cell designs were then studied. In such stress and failure analysis, it is essential to know the thermomechanical properties of the materials involved. Measurements were made of properties of materials suitable for the design of lightweight arrays: microsheet-0211 glass material for the solar cell filter, and Kapton-H, Kapton F, Teflon, Tedlar, and Mica Ply PG-402 for lightweight substrates. The temperature-dependence of the thermal coefficient of expansion for these materials was determined together with other properties such as the elastic moduli, Poisson's ratio, and the stress-strain behavior up to failure.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kreutzbruck, M.; Brackrock, D.; Brekow, G.

Lightweight components are increasingly used in different industrial sectors such as transportation, energy generation and automotive. This growing field includes different types of CFRP-structures, hybrid materials and glued components showing - compared to their pure metallic counterparts- a significant more complicated structure in terms of internal interfaces and anisotropy of material parameters. In this work we present the use of matrix phased array to increase the amount of obtained information to enhance the inspection quality. We used different types of carbon materials such as 6 mm thick uni- and bidirectional prepreg specimens containing impact damages. The latter were introduced withmore » different energy levels ranging from 1.3 to 7.2 J. By scanning a 2.25 MHz matrix array with 6 × 10 elements above the prepreg surface and using different angels of incidence a complete 3D-image was generated which allows the detection of defects as small as 1mm in a depth of 4 mm. A comparison with conventional approaches show that the signal-to-noise ratio can be highly increased. This enables us to visualize the region of damage within the impact zone, clearly showing the cone-like damage distribution along increasing material depth. The detection quality allows the estimation of the opening angles of the cone shaped damage, which can be used for further evaluation and quantitation of energy dependent impact damages.« less

Avian Feathers: An Examination of Lightweight Resilience and Bioinspired Designs

NASA Astrophysics Data System (ADS)

Sullivan, Tarah Naoe

In bird flight, the majority of the wing surface consists of highly refined and hierarchically organized beta-keratinous feathers. Thus, flight feathers contain ingenious combinations of components that optimize lift, stiffness, aerodynamics, and damage resistance. Their design involves two main parts: a central shaft which prescribes stiffness and lateral vanes that allow for the capture of air. Within the feather vane, barbs branch from the shaft and barbules branch from barbs, forming a flat surface and ensuring lift. Microhooks at the end of barbules hold barbs tightly together, providing a close-knit, unified structure and enabling repair of the vane through the reattachment of un-hooked junctions. In this dissertation, unique aspects of feather architecture are explored to uncover principles translatable to the design of modern aerospace materials and structures. Specifically, understudied aspects of the feather's lightweight yet resilient properties are investigated. This research has revealed several novel characteristics of the feather. Allometric scaling relationships are developed linking the geometry of a bird's wing components to its flight characteristics and total mass. Barbule spacing within the feather vane is found to be 8-16 microm for birds ranging from 0.02-11 kg. Additionally, it is discovered that strength is recovered with the shape recovery property of feathers, and a mechanism for this phenomenon is proposed. Barbule adhesion within the vane is found to prevent barbs from twisting in flexure, maintaining the vane's stiffness, and the extent to which unzipping these connections affects the feather's ability to capture air is related to barb shape. Directional permeability of the feather vane is experimentally confirmed and related to the intricate microstructure of barbules. Lastly, the exceptional architecture of the feather motivated the design of novel bioinspired structures with tailored and unique properties. The avian feather serves as an excellent springboard for designs that can be adapted to enhance synthetic materials and structures.

The effectiveness of stone ash and volcanic ash of mount Sinabung as a filler on the initial strength of self-compacting concrete

NASA Astrophysics Data System (ADS)

Karolina, R.; Muhammad, W.; Saragih, M. D. S. M.; Mustaqa, T.

2018-02-01

Self Compacting Concrete is a concrete variant that has a high degree of workability and also has great initial strength, but low water cement factor. It is also self-flowable that can be molded on formwork with a very little or no compacted use of compactors. This concrete, using a variety of aggregate sizes, aggregate portions and superplasticizer admixture to achieve a special viscosity that allows it to flow on its own without the aid of a compactor. Lightweight concrete brick is a type of brick made from cement, sand, water, and developers. Lightweight concrete bricks are divided into 2 based on the developed materials used are AAC (Autoclave Aerated Concrete) using aluminum paste and CLC (Cellular Lightweight Concrete) that use Foaming Agent from BASF as a developer material. In this experiment, the lightweight bricks that will be made are CLC type which uses Foaming Agent as the developer material by mixing the Ash Stone produced by Stone Crusher machine which has the density of 2666 kg / m3 as Partial Pair Substitution. In this study the variation of Ash Stone used is 10%, 15%, and 20% of the planned amount of sand. After doing the tasting the result is obtained for 10% variation. Compressive Strength and Absorption Increase will decrease by 25.07% and 39.005% and Variation of 15% compressive strength will decrease by 65,8% and decrease of absorbtion equal to 17,441% and variation of 20% compressive strength will decreased by 67,4 and absorption increase equal to 17,956%.

Gemini-Titan (GT)-8 - Lightweight Suit - MSC

NASA Image and Video Library

1965-12-06

S65-60035 (6 Dec. 1965) --- The new light-weight spacesuit planned for possible use during the Gemini-7 mission is modeled by Fred R. Spross, Gemini Support Office, Crew Systems Division. The spacesuit weighs 16 pounds, including the aviator's crash helmet. The suit is designed so that it may be partially or completely removed during flight. It has two layers of material while the previously used Gemini spacesuit has four layers. Photo credit: NASA

Wood: a construction material for tall buildings

NASA Astrophysics Data System (ADS)

Wimmers, Guido

2017-12-01

Wood has great potential as a building material, because it is strong and lightweight, environmentally friendly and can be used in prefabricated buildings. However, only changes in building codes will make wood competitive with steel and concrete.

Clinching for sheet materials

PubMed Central

He, Xiaocong

2017-01-01

Abstract Latest developments in the clinching of sheet materials are reviewed in this article. Important issues are discussed, such as tool design, process parameters and joinability of some new lightweight sheet materials. Hybrid and modified clinching processes are introduced to a general reader. Several unaddressed issues in the clinching of sheet materials are identified. PMID:28656065

Lightweight and efficient microwave absorbing materials based on walnut shell-derived nano-porous carbon.

PubMed

Qiu, Xu; Wang, Lixi; Zhu, Hongli; Guan, Yongkang; Zhang, Qitu

2017-06-08

Lightweight microwave absorbing materials have drawn tremendous attention. Herein, nano-porous biomass carbon materials have been prepared by carbonization with a subsequent potassium hydroxide activation of walnut shells and the microwave absorption properties have also been investigated. The obtained samples have large specific surface areas with numerous micropores and nanopores. The sample activated at 600 °C with a specific surface area of 736.2 m 2 g -1 exhibits the most enhanced microwave absorption performance. It has the maximum reflection loss of -42.4 dB at 8.88 GHz and the effective absorption bandwidth (reflection loss below -10 dB) is 1.76 GHz (from 8.08 GHz to 9.84 GHz), corresponding to a thickness of 2 mm. Additionally, the effective absorption bandwidth can reach 2.24 GHz (from 10.48 GHz to 12.72 GHz) when the absorber thickness is 1.5 mm. Three-dimensional porous architecture, interfacial polarization relaxation loss, and the dipolar relaxation loss make a great contribution to the excellent microwave absorption performance. In contrast, the non-activated sample with lower specific surface area (435.3 m 2 g -1 ) has poor microwave absorption performance due to a poor dielectric loss capacity. This comparison highlights the role of micropores and nanopores in improving the dielectric loss property of porous carbon materials. To sum up, porous biomass carbon has great potential to become lightweight microwave absorbers. Moreover, KOH is an efficient activation agent in the fabrication of carbonaceous materials.

Space Shuttle External Tank Project status

NASA Technical Reports Server (NTRS)

Davis, R. M.

1980-01-01

The External Tank Project is reviewed with emphasis on the DDT&E and production phases and the lightweight tank development. It is noted that the DDT&E phase is progressing well with the structural and ground vibration test article programs complete, the propulsion test article program progressing well, and the component qualification and verification testing 92% complete. New tools and facilities are being brought on line to support the increased build rate for the production phase. The lightweight tank, which will provide additional payload in orbit, is progressing to schedule with first delivery in early 1982.

Rigid open-cell polyurethane foam for cryogenic insulation

NASA Technical Reports Server (NTRS)

Faddoul, J. R.; Lindquist, C. R.; Niendorf, L. R.; Nies, G. E.; Perkins, P. J., Jr.

1971-01-01

Lightweight polyurethane foam assembled in panels is effective spacer material for construction of self-evacuating multilayer insulation panels for cryogenic liquid tanks. Spacer material separates radiation shields with barrier that minimizes conductive and convective heat transfer between shields.

Improved Helmet-Padding Material

NASA Technical Reports Server (NTRS)

Dawn, Frederic S.; Weiss, Fred R.; Eck, John D.

1994-01-01

Polyimide foamed into lightweight padding material for use in helmets. Exhibits increased resistance to ignition, combustion, and impact, and it outgasses less. Foam satisfies offgassing and toxicity requirements of NASA/JSC criteria (NHB80601B). Helmets containing this improved padding material used by firefighters, police, offshore drilling technicians, construction workers, miners, and race-car drivers.

Bioinspired fabrication and characterization of a synthetic fish skin for the protection of soft materials.

PubMed

Funk, Natasha; Vera, Marc; Szewciw, Lawrence J; Barthelat, Francois; Stoykovich, Mark P; Vernerey, Franck J

2015-03-18

The scaled skin of fish is a high-performance natural armor that represents a source of inspiration for novel engineering designs. In this paper, we present a biomimetic fish skin material, fabricated with a design and components that are simple, that achieves many of the advantageous attributes of natural materials, including the unique combination of flexibility and mechanical robustness. The bioinspired fish skin material is designed to replicate the structural, mechanical, and functional aspects of a natural teleost fish skin comprised of leptoid-like scales, similar to that of the striped red mullet Mullus surmuletus. The man-made fish skin material consists of a low-modulus elastic mesh or "dermis" layer that holds rigid, plastic scales. The mechanics of the synthetic material is characterized under in-plane, bending, and indentation modes of deformation and is successfully described by theoretical deformation models that have been developed. This combined experimental and modeling approach elucidates the critical mechanisms by which the composite material achieves its unique properties and provides design rules that allow for the engineering of scaled skins. Such artificial scaled skins that are flexible, lightweight, transparent, and robust under mechanical deformation may thus have potential as thin protective coatings for soft materials.

KSC-08pd2083

NASA Image and Video Library

2008-07-18

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope is unwrapped and ready for final processing for launch. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in late July. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2082

NASA Image and Video Library

2008-07-18

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center cuts away the protective wrapping from the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in late July. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

Lightweight nickel electrode for nickel hydrogen cells and batteries

NASA Technical Reports Server (NTRS)

Britton, D. L.

1986-01-01

The nickel electrode was identified as the heaviest component of the nickel hydrogen (NiH2) battery. The NASA Lewis Research Center is developing nickel electrodes for NiH2 battery devices which will be lighter in weight and have higher energy densities when cycled under a low Earth orbit regime at deep depths of discharge. Lightweight plaques are first exposed to 31 percent potassium hydroxide for 3 months to determine their suitability for use as electrode substrates from a chemical corrosion standpoint. Pore size distribution and porosity of the plaques are then measured. The lightweight plaques examined are nickel foam, nickel felt, nickel plastic and nickel plated graphite. Plaques are then electrochemically impregnated in an aqueous solution. Initial characterization tests of the impregnated plaques are performed at five discharge levels, C/2, 1.0 C, 1.37 C, 2.0C, and 2.74 C rates. Electrodes that passed the initial characterization screening test will be life cycle tested. Lightweight electrodes are approximately 30 to 50 percent lighter in weight than the sintered nickel electrode.

Tailored Buckling Microlattices as Reusable Light-Weight Shock Absorbers.

PubMed

Frenzel, Tobias; Findeisen, Claudio; Kadic, Muamer; Gumbsch, Peter; Wegener, Martin

2016-07-01

Structures and materials absorbing mechanical (shock) energy commonly exploit either viscoelasticity or destructive modifications. Based on a class of uniaxial light-weight geometrically nonlinear mechanical microlattices and using buckling of inner elements, either a sequence of snap-ins followed by irreversible hysteretic - yet repeatable - self-recovery or multistability is achieved, enabling programmable behavior. Proof-of-principle experiments on three-dimensional polymer microstructures are presented. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Strategic Defense Initiative Program: Extent of Foreign Participation

DTIC Science & Technology

1990-02-07

the Air Force to a West German company, . Chemical Lasers project, for fabrication of a lightweight hig mirror . The firished product will be a 70...centimeter mirror lightweight, uncool"P glass ceramic material with no tus.rm. Two contracts, totaling $1.7 million, were au-arded under th Definition...Ground-Based Free The ground-based laser system concept is to fire a free electrru Electron Laser Project beam generated on the ground to a mirror relay

Stealing the Sword: Limiting Terrorist Use of Advanced Conventional Weapons

DTIC Science & Technology

2007-01-01

ammunition, are combined (see Figure 2.9 for a handgun concept that features four barrels , two with lethal and two with nonlethal ammunition). Other...Weapons Figure 2.9 A Four- Barreled Concept Handgun Mortar Systems Mortars have long been regarded as cheap, lightweight, short-range artillery. Mortars are...Terrorists? 37 manner).63 An example of an advance in lightweight materials for mor- tars is the development of the carbon fiber composite barrel in the

2010 Vehicle Technologies Market Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ward, Jacob; Davis, Stacy Cagle; Diegel, Susan W

2011-06-01

In the past five years, vehicle technologies have advanced on a number of fronts: power-train systems have become more energy efficient, materials have become more lightweight, fuels are burned more cleanly, and new hybrid electric systems reduce the need for traditional petroleum-fueled propulsion. This report documents the trends in market drivers, new vehicles, and component suppliers. This report is supported by the U.S. Department of Energy s (DOE s) Vehicle Technologies Program, which develops energy-efficient and environmentally friendly transportation technologies that will reduce use of petroleum in the United States. The long-term aim is to develop "leap frog" technologies thatmore » will provide Americans with greater freedom of mobility and energy security, while lowering costs and reducing impacts on the environment.« less

High energy density micro-fiber based nickel electrode for aerospace batteries

NASA Technical Reports Server (NTRS)

Francisco, Jennifer; Chiappetti, Dennis; Coates, Dwaine

1996-01-01

The nickel electrode is the specific energy limiting component in battery systems such as nickel-hydrogen, nickel-metal hydride and nickel-zinc. Lightweight, high energy density nickel electrodes have been developed which deliver in excess of 180 mAh/g at the one-hour discharge rate. These electrodes are based on a highly porous, nickel micro-fiber (less than 10 micron diameter) substrate, electrochemically impregnated with nickel-hydroxide active material. Electrodes are being tested both as a flooded half-cell and in full nickel-hydrogen and nickel-metal hydride cells. The electrode technology developed is applicable to commercial nickel-based batteries for applications such as electric vehicles, cellular telephones and laptop computers and for low-cost, high energy density military and aerospace applications.

Structure and mechanical properties of naturally occurring lightweight foam-filled cylinder--the peacock's tail coverts shaft and its components.

PubMed

Liu, Z Q; Jiao, D; Meyers, M A; Zhang, Z F

2015-04-01

Feather shaft, which is primarily featured by a cylinder filled with foam, possesses a unique combination of mechanical robustness and flexibility with a low density through natural evolution and selection. Here the hierarchical structures of peacock's tail coverts shaft and its components are systematically characterized from millimeter to nanometer length scales. The variations in constituent and geometry along the length are examined. The mechanical properties under both dry and wet conditions are investigated. The deformation and failure behaviors and involved strengthening, stiffening and toughening mechanisms are analyzed qualitatively and quantitatively and correlated to the structures. It is revealed that the properties of feather shaft and its components have been optimized through various structural adaptations. Synergetic strengthening and stiffening effects can be achieved in overall rachis owing to increased failure resistance. This study is expected to aid in deeper understandings on the ingenious structure-property design strategies developed by nature, and accordingly, provide useful inspiration for the development of high-performance synthetic foams and foam-filled materials. Copyright © 2015 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Characterization Testing of the Teledyne Passive Breadboard Fuel Cell Powerplant

NASA Technical Reports Server (NTRS)

Loyselle, Patricia; Prokopius, Kevin

2011-01-01

NASA's Exploration Technology Development Program (ETDP) is tasked with the development of enabling and enhancing technologies for NASA's exploration missions. As part of that initiative, the return to the Moon requires a reliable, efficient, and lightweight fuel cell powerplant system to provide power to the Altair Lunar Lander and for lunar surface systems. Fuel cell powerplants are made up of two basic parts; the fuel cell itself and the supporting ancillary subsystem. This subsystem is designed to deliver reactants to the fuel cell and remove product water and waste heat from the fuel cell. Typically, fuel cell powerplant ancillary subsystems rely upon pumps and active water separation techniques to accomplish these tasks for closed hydrogen/oxygen systems. In a typical system, these components are the largest contributors to the overall parasitic power load of the fuel cell powerplant. A potential step towards the development of an efficient lightweight power system is to maximize the use of "passive" or low-power ancillary components as a replacement to these high-power load components

Solar energy panel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hyman, M.

1980-03-04

A light-weight, low-cost and high efficiency solar panel includes a light-weight rectangular wood frame which surrounds and houses a copper absorber plate. A pair of spaced glazings, formed from plastic film materials, are disposed above the absorber to define a pair of enclosed air spaces. The lower glazing is capable of withstanding high temperatures and the upper glazing material is capable of providing good weather resistance. The material of the upper glazing extends fully about the frame to protect the entire frame from weathering. Insulation is provided beneath the absorber plate. The frame rests on top of a bottom sheetmore » of insulative foam plastic which is wrapped in a plastic envelope. The surrounding film of the outer glazing is bonded securely to the envelope to encase the entire panel within a protective sealed envelope of weather-resistant plastic film.« less

Extreme lightweight ZERODUR mirrors (ELZM): supporting characteristics for spaceborne applications

NASA Astrophysics Data System (ADS)

Hull, Tony; Westerhoff, Thomas

2014-08-01

Extreme Lightweight ZERODUR® Mirrors (ELZM) have been developed expressly to provide architects of spaceborne missions a new, cost-effective, option for implementation of medium and large Optical Telescope Assemblies (OTAs, up to 4+ meters in diameter). ZERODUR® is a traditional material in space with over a 30 year heritage. We will discuss the attributes of the material and fabrication methods to aggressively reduce weight to an extent now routinely available. Recent and emerging independent measurements of material properties will confirm the utility of this approach for new generations of OTAs. Data on dimensional stability over a broad practical temperature range will be referenced, as will recent mechanical strength data. Other data confirming suitability for use in space will be referenced. We will discuss how this data can be used for the architecture of a ELZM based cost-effective spaceborne OTA.

Lightweight ZERODUR: Validation of Mirror Performance and Mirror Modeling Predictions

NASA Technical Reports Server (NTRS)

Hull, Tony; Stahl, H. Philip; Westerhoff, Thomas; Valente, Martin; Brooks, Thomas; Eng, Ron

2017-01-01

Upcoming spaceborne missions, both moderate and large in scale, require extreme dimensional stability while relying both upon established lightweight mirror materials, and also upon accurate modeling methods to predict performance under varying boundary conditions. We describe tests, recently performed at NASA's XRCF chambers and laboratories in Huntsville Alabama, during which a 1.2 m diameter, f/1.2988% lightweighted SCHOTT lightweighted ZERODUR(TradeMark) mirror was tested for thermal stability under static loads in steps down to 230K. Test results are compared to model predictions, based upon recently published data on ZERODUR(TradeMark). In addition to monitoring the mirror surface for thermal perturbations in XRCF Thermal Vacuum tests, static load gravity deformations have been measured and compared to model predictions. Also the Modal Response(dynamic disturbance) was measured and compared to model. We will discuss the fabrication approach and optomechanical design of the ZERODUR(TradeMark) mirror substrate by SCHOTT, its optical preparation for test by Arizona Optical Systems (AOS). Summarize the outcome of NASA's XRCF tests and model validations

Lightweight ZERODUR®: Validation of mirror performance and mirror modeling predictions

NASA Astrophysics Data System (ADS)

Hull, Anthony B.; Stahl, H. Philip; Westerhoff, Thomas; Valente, Martin; Brooks, Thomas; Eng, Ron

2017-01-01

Upcoming spaceborne missions, both moderate and large in scale, require extreme dimensional stability while relying both upon established lightweight mirror materials, and also upon accurate modeling methods to predict performance under varying boundary conditions. We describe tests, recently performed at NASA’s XRCF chambers and laboratories in Huntsville Alabama, during which a 1.2m diameter, f/1.29 88% lightweighted SCHOTT lightweighted ZERODUR® mirror was tested for thermal stability under static loads in steps down to 230K. Test results are compared to model predictions, based upon recently published data on ZERODUR®. In addition to monitoring the mirror surface for thermal perturbations in XRCF Thermal Vacuum tests, static load gravity deformations have been measured and compared to model predictions. Also the Modal Response (dynamic disturbance) was measured and compared to model. We will discuss the fabrication approach and optomechanical design of the ZERODUR® mirror substrate by SCHOTT, its optical preparation for test by Arizona Optical Systems (AOS), and summarize the outcome of NASA’s XRCF tests and model validations.

Lightweight, Flexible, High-Performance Carbon Nanotube Cables Made by Scalable Flow Coating.

PubMed

Mirri, Francesca; Orloff, Nathan D; Forster, Aaron M; Ashkar, Rana; Headrick, Robert J; Bengio, E Amram; Long, Christian J; Choi, April; Luo, Yimin; Walker, Angela R Hight; Butler, Paul; Migler, Kalman B; Pasquali, Matteo

2016-02-01

Coaxial cables for data transmission are ubiquitous in telecommunications, aerospace, automotive, and robotics industries. Yet, the metals used to make commercial cables are unsuitably heavy and stiff. These undesirable traits are particularly problematic in aerospace applications, where weight is at a premium and flexibility is necessary to conform with the distributed layout of electronic components in satellites and aircraft. The cable outer conductor (OC) is usually the heaviest component of modern data cables; therefore, exchanging the conventional metallic OC for lower weight materials with comparable transmission characteristics is highly desirable. Carbon nanotubes (CNTs) have recently been proposed to replace the metal components in coaxial cables; however, signal attenuation was too high in prototypes produced so far. Here, we fabricate the OC of coaxial data cables by directly coating a solution of CNTs in chlorosulfonic acid (CSA) onto the cable inner dielectric. This coating has an electrical conductivity that is approximately 2 orders of magnitude greater than the best CNT OC reported in the literature to date. This high conductivity makes CNT coaxial cables an attractive alternative to commercial cables with a metal (tin-coated copper) OC, providing comparable cable attenuation and mechanical durability with a 97% lower component mass.

Microgravity Manufacturing Via Fused Deposition

NASA Technical Reports Server (NTRS)

Cooper, K. G.; Griffin, M. R.

2003-01-01

Manufacturing polymer hardware during space flight is currently outside the state of the art. A process called fused deposition modeling (FDM) can make this approach a reality by producing net-shaped components of polymer materials directly from a CAE model. FDM is a rapid prototyping process developed by Stratasys, Inc.. which deposits a fine line of semi-molten polymer onto a substrate while moving via computer control to form the cross-sectional shape of the part it is building. The build platen is then lowered and the process is repeated, building a component directly layer by layer. This method enables direct net-shaped production of polymer components directly from a computer file. The layered manufacturing process allows for the manufacture of complex shapes and internal cavities otherwise impossible to machine. This task demonstrated the benefits of the FDM technique to quickly and inexpensively produce replacement components or repair broken hardware in a Space Shuttle or Space Station environment. The intent of the task was to develop and fabricate an FDM system that was lightweight, compact, and required minimum power consumption to fabricate ABS plastic hardware in microgravity. The final product of the shortened task turned out to be a ground-based breadboard device, demonstrating miniaturization capability of the system.

Ultra-Lightweight Hybrid Thin-Film Solar Cells: A Survey of Enabling Technologies for Space Power Applications

NASA Technical Reports Server (NTRS)

Hepp, Aloysius F.; McNatt, Jeremiah S.; Bailey, Sheila G.; Dickman, John E.; Raffaelle, Ryne P.; Landi, Brian J.; Anctil, Annick; DiLeo, Roberta; Jin, Michael H.-C.; Lee, Chung-Young;

A lightweight pumped hydrazine orbit maneuvering space vehicle

NASA Astrophysics Data System (ADS)

Whitehead, J. C.

1992-01-01

An orbital maneuvering vehicle has a pair of opposed cylindrical piston tanks for hydrazine, and four transverse liquid rocket engines along a longitudinal plane. A new kind of pumped rocket propulsion provides maneuvering thrust on demand, and free-piston pumps which can rapidly start and stop are radially oriented between thrusters. A major advantage of this configuration is that the tanks can be close together, which maximizes the vehicle's longitudinal bending stiffness while minimizing the mass of the central bridging structure. The impulses from pump exhaust and piston reciprocation are directed through the system mass center, so they apply no disturbance torques. All high-temperature components are located on the outside of the central structure, where they are free to expand and radiate heat without detrimental effects. Virtually all lightweight components have been fabricated and tested, and photographs of hardware subassemblies are presented.

Developing a GIS for CO2 analysis using lightweight, open source components

NASA Astrophysics Data System (ADS)

Verma, R.; Goodale, C. E.; Hart, A. F.; Kulawik, S. S.; Law, E.; Osterman, G. B.; Braverman, A.; Nguyen, H. M.; Mattmann, C. A.; Crichton, D. J.; Eldering, A.; Castano, R.; Gunson, M. R.

2012-12-01

There are advantages to approaching the realm of geographic information systems (GIS) using lightweight, open source components in place of a more traditional web map service (WMS) solution. Rapid prototyping, schema-less data storage, the flexible interchange of components, and open source community support are just some of the benefits. In our effort to develop an application supporting the geospatial and temporal rendering of remote sensing carbon-dioxide (CO2) data for the CO2 Virtual Science Data Environment project, we have connected heterogeneous open source components together to form a GIS. Utilizing widely popular open source components including the schema-less database MongoDB, Leaflet interactive maps, the HighCharts JavaScript graphing library, and Python Bottle web-services, we have constructed a system for rapidly visualizing CO2 data with reduced up-front development costs. These components can be aggregated together, resulting in a configurable stack capable of replicating features provided by more standard GIS technologies. The approach we have taken is not meant to replace the more established GIS solutions, but to instead offer a rapid way to provide GIS features early in the development of an application and to offer a path towards utilizing more capable GIS technology in the future.

Interlocking multi-material components made of structured steel sheets and high-pressure die cast aluminium

NASA Astrophysics Data System (ADS)

Senge, S.; Brachmann, J.; Hirt, G.; Bührig-Polaczek, A.

2017-10-01

Lightweight design is a major driving force of innovation, especially in the automotive industry. Using hybrid components made of two or more different materials is one approach to reduce the vehicles weight and decrease fuel consumption. As a possible way to increase the stiffness of multi-material components, this paper presents a process chain to produce such components made of steel sheets and high-pressure die cast aluminium. Prior to the casting sequence the steel sheets are structured in a modified rolling process which enables continuous interlocking with the aluminium. Two structures manufactured by this rolling process are tested. The first one is a channel like structure and the second one is a channel like structure with undercuts. These undercuts enable the formation of small anchors when the molten aluminium fills them. The correlation between thickness reduction during rolling and the shape of the resulting structure was evaluated for both structures. It can be stated that channels with a depth of up to 0.5 mm and a width of 1 mm could be created. Undercuts with different size depending on the thickness reduction could be realised. Subsequent aluminium high-pressure die casting experiments were performed to determine if the surface structure can be filled gap-free with molten aluminium during the casting sequence and if a gap-free connection can be achieved after contraction of the aluminium. The casting experiments showed that both structures could be filled during the high-pressure die casting. The channel like structure results in a gap between steel and aluminium after contraction of the cast metal whereas the structure with undercuts leads to a good interlocking resulting in a gap-free connection.

Basic Research Plan.

DTIC Science & Technology

1996-05-01

detection, catalysts for enhancing and controlling energetic reactions, synthesis of new compounds (e.g., narrow band-gap materials and non-linear...design for synthesis of advanced materials Fabricate porous lightweight and resilient structural materials with novel properties and uses Demonstrate...elements for 10 nm computer memory elements Demonstrate enhanced propellants and explosives with nanoparticle surface chemistry Demonstrate sensing of

The Evaluation of Vehicle Mass Reduction and Material Choice in Life Cycle Assessments: Key Factors and Dynamic Industries

EPA Science Inventory

Developments in the realm of lightweight materials for automotive use continue to be announced by the industry and by academia. This session will provide new and updated information on new generation of materials. Additionally, this session will focus on the key topics involved i...

Optimization of radiation shielding material aiming at compactness, lightweight, and low activation for a vehicle-mounted accelerator-driven D-T neutron source.

PubMed

Cai, Yao; Hu, Huasi; Lu, Shuangying; Jia, Qinggang

2018-05-01

To minimize the size and weight of a vehicle-mounted accelerator-driven D-T neutron source and protect workers from unnecessary irradiation after the equipment shutdown, a method to optimize radiation shielding material aiming at compactness, lightweight, and low activation for the fast neutrons was developed. The method employed genetic algorithm, combining MCNP and ORIGEN codes. A series of composite shielding material samples were obtained by the method step by step. The volume and weight needed to build a shield (assumed as a coaxial tapered cylinder) were adopted to compare the performance of the materials visually and conveniently. The results showed that the optimized materials have excellent performance in comparison with the conventional materials. The "MCNP6-ACT" method and the "rigorous two steps" (R2S) method were used to verify the activation grade of the shield irradiated by D-T neutrons. The types of radionuclide, the energy spectrum of corresponding decay gamma source, and the variation in decay gamma dose rate were also computed. Copyright © 2018 Elsevier Ltd. All rights reserved.

Test Plans. Lightweight Durable TPS: Tasks 1,2,4,5, and 6

NASA Technical Reports Server (NTRS)

Greenberg, H. S.; Tu, Tina

1994-01-01

The objective of this task is to develop the fluted core flexible blankets, also referred to as the Tailorable Advanced Blanket Insulation (TABI), to a technology readiness level (TRL) of 6. This task is one of the six tasks under TA 3, Lightweight Durable TPS study, of the Single Stage to Orbit (SSTO) program. The purpose of this task is to develop a durable and low maintenance flexible TPS blanket material to be implemented on the SSTO vehicle.

Recycling steel-manufacturing slag and harbor sediment into construction materials.

PubMed

Wei, Yu-Ling; Lin, Chang-Yuan; Cheng, Shao-Hsiang; Wang, H Paul

2014-01-30

Mixtures consisting of harbor sediment and slag waste from steel industry containing toxic components are fired to produce non-hazardous construction materials. The fired pellets become lighter as firing temperature increases. At a sintering temperature of ≦1050°C, the fired pellets are in a form of brick-like product, while at 1100°C, they become lightweight aggregates. Calcium silicate, kyanite, and cristobalite are newly formed in the pellets after firing, demonstrating that calcium oxide acts as a flux component and chemically reacted with Si- and/or Al-containing components to promote sintering. Dioxin/furan content present in the pure slag is 0.003ng I-TEQg(-1) and, for the fired pellet consisting of slag and sediment, the content appears to be destructed and diminishes to 0.0003ng I-TEQg(-1) after 950°C-firing; while it is 0.002ng I-TEQg(-1) after firing at 1100°C, suggesting that dioxins/furans in the 950°C-fired pellets have a greater chance to escape to atmosphere due to a slower sintering reaction and/or that construction of dioxins/furans from molten chloride salts co-exists with their destruction. Multiple toxicity characteristic leaching procedure extracts Cu, Cr, Zn, Se, Cd, Pb, Ba, As, and Hg from all fired products at negligible levels. Copyright © 2013 Elsevier B.V. All rights reserved.

Wood-based Tri-Axial Sandwich Composite Materials: Design, Fabrication, Testing, Modeling and Application

Treesearch

Jinghao Li; John F. Hunt; Shaoqin Gong; Zhiyong Cai

2014-01-01

As the demand for sustainable materials increases, there are unique challenges and opportunities to develop light-weight green composites materials for a wide range of applications. Thus wood-based composite materials from renewable forests may provide options for some niche applications while helping to protect our environment. In this paper, the wood-based tri-axial...

Thermal Applications for Advanced Metallic Materials (Preprint)

DTIC Science & Technology

2007-01-01

Mondolfo, L.E., Aluminum Alloys-Structure and Properties . 1976: Butterworths. 21. Tritt, T.M. and M.A. Subramanian, Thermoelectric Materials...for Potential Thermoelectric Applications. MRS Bulletin, 2006. 31(March): p. 206-210. 32. Rao, A.M., X. Ji, and T.M. Tritt, Properties of...conductivity metallic composites; lightweight metallic phase-change materials for managing thermal transients; high-efficiency thermoelectric materials for

Lightweight, Flexible Solar Cells on Stainless Steel Foil and Polymer for Space and Stratospheric Applications

NASA Technical Reports Server (NTRS)

Beernink, Kevin; Guha, Subhendu; Yang, Jeff; Banerjee, Arindam; Lord, Ken; DeMaggio, Greg; Liu, Frank; Pietka, Ginger; Johnson, Todd; Reinhout, Melanie;

Cyclic Parameter Refinement of 4S-10 Hybrid Flux-Switching Motor for Lightweight Electric Vehicle

NASA Astrophysics Data System (ADS)

Rani, J. Abd; Sulaiman, E.; Kumar, R.

2017-08-01

A great deal of attention has been given to the reduction of lighting the vehicle because the lighter the vehicle the energy consumption is comparatively low. Hence, the lightweight electric vehicle was introduced for lower carbon footprint and the sizing of the vehicle itself. One of the components to reduce the weight of the vehicle is the propulsion system which comprised of electric motor functioning as the source of torque to drive the propulsion system of the machine. This paper presents the refinement methodology for the optimized design of the 4S-10P E-Core hybrid excitation flux switching motor. The purpose of the refinement methodology is to improve the torque production of the optimized motor. The result of the successful improvement of the torque production is justifiable for a lightweight electric vehicle to drive the propulsion system.

Experimental study on combined cold forging process of backward cup extrusion and piercing

NASA Astrophysics Data System (ADS)

Henry, Robinson; Liewald, Mathias

2018-05-01

A reduction in material usage of cold forged components while maintaining the functional requirements can be achieved using hollow or tubular preforms. These preforms are used to meet lightweight requirements and to decrease production costs of cold formed components. To increase production efficiency in common multi-stage cold forming processes, manufacturing of hollow preforms by combining the processes backward cup extrusion and piercing was established and will be discussed in this paper. Corresponding investigations and experimental studies are reported in this article. The objectives of the experimental investigations have been the detection of significant process parameters, determination of process limits for the combined processes and validation of the numerical investigations. In addition, the general influence concerning surface quality and diameter tolerance of hollow performs are discussed in this paper. The final goal is to summarize a guideline for industrial application, moreover, to transfer the knowledge to industry, as regards what are required part geometries to reduce the number of forming stages as well as tool cost.

Structure-property relations and modeling of small crack fatigue behavior of various magnesium alloys

NASA Astrophysics Data System (ADS)

Bernard, Jairus Daniel

Lightweight structural components are important to the automotive and aerospace industries so that better fuel economy can be realized. Magnesium alloys in particular are being examined to fulfill this need due to their attractive stiffness- and strength-to-weight ratios when compared to other materials. However, when introducing a material into new roles, one needs to properly characterize its mechanical properties. Fatigue behavior is especially important considering aerospace and automotive component applications. Therefore, quantifying the structure-property relationships and accurately predicting the fatigue behavior for these materials are vital. This study has two purposes. The first is to quantify the structure-property relationships for the fatigue behavior in an AM30 magnesium alloy. The second is to use the microstructural-based MultiStage Fatigue (MSF) model in order to accurately predict the fatigue behavior of three magnesium alloys: AM30, Elektron 21, and AZ61. While some studies have previously quantified the MSF material constants for several magnesium alloys, detailed research into the fatigue regimes, notably the microstructurally small crack (MSC) region, is lacking. Hence, the contribution of this work is the first of its kind to experimentally quantify the fatigue crack incubation and MSC regimes that are used for the MultiStage Fatigue model. Using a multi-faceted experimental approach, these regimes were explored with a replica method that used a dual-stage silicone based compound along with previously published in situ fatigue tests. These observations were used in calibrating the MultiStage Fatigue model.

Opto-Mechanical Analyses for Performance Optimization of Lightweight Grazing-Incidence Mirrors

NASA Technical Reports Server (NTRS)

Roche, Jacqueline; Kolodziejczak, Jeff; Odell, Steve; Eisner, Ronald; Ramsey, Brian; Gubarev, Mikhail

2013-01-01

New technology in grazing-incidence mirror fabrication and assembly is necessary to achieve sub-arcsecond optics for large-area x-ray telescopes. In order to define specifications, an understanding of performance sensitivity to design parameters is crucial. MSFC is undertaking a systematic study to specify a mounting approach, mirror substrate, and testing method. Because the lightweight mirrors are typically flimsy, they are susceptible to significant distortion due to mounting and gravitational forces. Material properties of the mirror substrate along with its thickness and dimensions significantly affect the distortions caused by mounting and gravity. A parametric study of these properties and their relationship to mounting and testing schemes will indicate specifications for the design of the next generation of lightweight grazing-incidence mirrors. Initial results will be reported.

Opto-mechanical Analyses for Performance Optimization of Lightweight Grazing-incidence Mirrors

NASA Technical Reports Server (NTRS)

Roche, Jacqueline M.; Kolodziejczak, Jeffery J.; Odell, Stephen L.; Elsner, Ronald F.; Weisskopf, Martin C.; Ramsey, Brian; Gubarev, Mikhail V.

2013-01-01

New technology in grazing-incidence mirror fabrication and assembly is necessary to achieve subarcsecond optics for large-area x-ray telescopes. In order to define specifications, an understanding of performance sensitivity to design parameters is crucial. MSFC is undertaking a systematic study to specify a mounting approach, mirror substrate, and testing method. Lightweight mirrors are typically flimsy and are, therefore, susceptible to significant distortion due to mounting and gravitational forces. Material properties of the mirror substrate along with its dimensions significantly affect the distortions caused by mounting and gravity. A parametric study of these properties and their relationship to mounting and testing schemes will indicate specifications for the design of the next generation of lightweight grazing-incidence mirrors. Here we report initial results of this study.

Opto-mechanical Analyses for Performance Optimization of Lightweight Grazing-incidence Mirrors

NASA Technical Reports Server (NTRS)

Roche, Jacqueline; Kolodsiejczak, Jeffrey; Odell, Stephen; Elsner, Ronald; Weisskopf, Martin; Ramsey, Brian; Gubarev, Mikhail

2013-01-01

New technology in grazing-incidence mirror fabrication and assembly is necessary to achieve sub-arcsecond optics for large-area x-ray telescopes. In order to define specifications, an understanding of performance sensitivity to design parameters is crucial. MSFC is undertaking a systematic study to specify a mounting approach, mirror substrate, and testing method. Because the lightweight mirrors are typically flimsy, they are susceptible to significant distortion due to mounting and gravitational forces. Material properties of the mirror substrate along with its thickness and dimensions significantly affect the distortions caused by mounting and gravity. A parametric study of these properties and their relationship to mounting and testing schemes will indicate specifications for the design of the next generation of lightweight grazing-incidence mirrors. Initial results will be reported.

Lightweight Thermal Protection System for Atmospheric Entry

NASA Technical Reports Server (NTRS)

Stewart, David; Leiser, Daniel

2007-01-01

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.

Hybrid Solar Cells: Materials, Interfaces, and Devices

NASA Astrophysics Data System (ADS)

Mariani, Giacomo; Wang, Yue; Kaner, Richard B.; Huffaker, Diana L.

Photovoltaic technologies could play a pivotal role in tackling future fossil fuel energy shortages, while significantly reducing our carbon dioxide footprint. Crystalline silicon is pervasively used in single junction solar cells, taking up 80 % of the photovoltaic market. Semiconductor-based inorganic solar cells deliver relatively high conversion efficiencies at the price of high material and manufacturing costs. A great amount of research has been conducted to develop low-cost photovoltaic solutions by incorporating organic materials. Organic semiconductors are conjugated hydrocarbon-based materials that are advantageous because of their low material and processing costs and a nearly unlimited supply. Their mechanical flexibility and tunable electronic properties are among other attractions that their inorganic counterparts lack. Recently, collaborations in nanotechnology research have combined inorganic with organic semiconductors in a "hybrid" effort to provide high conversion efficiencies at low cost. Successful integration of these two classes of materials requires a profound understanding of the material properties and an exquisite control of the morphology, surface properties, ligands, and passivation techniques to ensure an optimal charge carrier generation across the hybrid device. In this chapter, we provide background information of this novel, emerging field, detailing the various approaches for obtaining inorganic nanostructures and organic polymers, introducing a multitude of methods for combining the two components to achieve the desired morphologies, and emphasizing the importance of surface manipulation. We highlight several studies that have fueled new directions for hybrid solar cell research, including approaches for maximizing efficiencies by controlling the morphologies of the inorganic component, and in situ molecular engineering via electrochemical polymerization of a polymer directly onto the inorganic nanowire surfaces. In the end, we provide some possible future directions for advancing the field, with a focus on flexible, lightweight, semitransparent, and low-cost photovoltaics.

Thermomechanical Fatigue Durability of T650-35/PMR-15 Sheet-Molding Compound Evaluated

NASA Technical Reports Server (NTRS)

Castelli, Michael G.

1999-01-01

High-performance polymer matrix composites (PMC's) continue to be the focus of a number of research efforts aimed at developing cost-effective, lightweight material alternatives for advanced aerospace and aeropropulsion applications. These materials not only offer significant advantages in specific stiffness and strength over their current metal counterparts, but they can be designed and manufactured to eliminate joints and fasteners by combining individual components into integral subassemblies, thus making them extremely attractive for commercial applications. With much emphasis on the low-cost manufacturing aspects of advanced composite structures, there is heightened interest in high-performance sheet-molding compounds (SMC's). Researchers at the NASA Lewis Research Center, in cooperation with the Allison Advanced Development Company, completed an investigation examining the use of T650-35/PMR-15 SMC for a midstage inner-vane endwall application within a gas turbine engine compressor. This component resides in the engine flow path and is subjected not only to high airflow rates, but also to elevated temperatures and pressures. This application is unique in that it represents a very aggressive use of high-performance SMC's, raising obvious concerns related to durability and property retention in the presence of microstructural damage. Therefore, it was necessary to evaluate the fatigue behavior and damage tolerance of this material subjected to a representative thermomechanical fatigue (TMF) mission-cycle loading spectrum.

Non-destructive testing of satellite nozzles made of carbon fibre ceramic matrix composite, C/SiC

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rebelo Kornmeier, J.; Hofmann, M.; Schmidt, S.

Carbon fibre ceramic matrix composite materials, C/SiC, are excellent candidates as lightweight structural materials for high performance hot structures such as in aerospace applications. Satellite nozzles are manufactured from C/SiC, using, for instance, the Liquid Polymer Infiltration (LPI) process. In this article the applicability of different non-destructive analysis methods for the characterisation of C/SiC components will be discussed. By using synchrotron and neutron tomography it is possible to characterise the C/SiC material in each desired location or orientation. Synchrotron radiation using tomography on small samples with a resolution of 1.4 {mu}m, i.e. the fibre scale, was used to characterise threemore » dimensionally fibre orientation and integrity, matrix homogeneity and dimensions and distributions of micro pores. Neutron radiation tomography with a resolution of about 300 {mu}m was used to analyse the over-all C/SiC satellite nozzle component with respect to the fibre content. The special solder connection of a C/SiC satellite nozzle to a metallic ring was also successfully analysed by neutron tomography. In addition, the residual stress state of a temperature tested satellite nozzle was analysed non-destructively in depth by neutron diffraction. The results revealed almost zero stress for the principal directions, radial, axial and tangential, which can be considered to be the principal directions.« less

Experimental study on the warm forming and quenching behavior for hot stamping of high-strength aluminum alloys

NASA Astrophysics Data System (ADS)

Degner, J.; Horn, A.; Merklein, M.

2017-09-01

Within the last decades, stringent regulations on fuel consumption, CO2 emissions and product recyclability forced the automotive sector to implement new strategies within the field of car body manufacturing. Due to their low density and good corrosion resistance, aluminum became one of the most relevant lightweight materials. Recently, especially high- strength aluminum alloys for structural components gained importance. Since the low formability of these alloys limits their application, there is a need for novel process strategies in order to enhance the forming behavior. One promising approach is the hot stamping of aluminum alloys. The combination of quenching and forming in one step after solution heat treatment leads to a significant improvement of the formability. Furthermore, higher manufacturing accuracy can be achieved due to reduced spring back. Within this contribution, the influence of forming temperature on the subsequent material behavior and the heat transfer during quenching will be analyzed. Therefore, the mechanical and thermal material characteristics such as flow behavior and heat transfer coefficient during hot stamping are investigated.

Silicon carbide optics for space and ground based astronomical telescopes

NASA Astrophysics Data System (ADS)

Robichaud, Joseph; Sampath, Deepak; Wainer, Chris; Schwartz, Jay; Peton, Craig; Mix, Steve; Heller, Court

2012-09-01

Silicon Carbide (SiC) optical materials are being applied widely for both space based and ground based optical telescopes. The material provides a superior weight to stiffness ratio, which is an important metric for the design and fabrication of lightweight space telescopes. The material also has superior thermal properties with a low coefficient of thermal expansion, and a high thermal conductivity. The thermal properties advantages are important for both space based and ground based systems, which typically need to operate under stressing thermal conditions. The paper will review L-3 Integrated Optical Systems - SSG’s (L-3 SSG) work in developing SiC optics and SiC optical systems for astronomical observing systems. L-3 SSG has been fielding SiC optical components and systems for over 25 years. Space systems described will emphasize the recently launched Long Range Reconnaissance Imager (LORRI) developed for JHU-APL and NASA-GSFC. Review of ground based applications of SiC will include supporting L-3 IOS-Brashear’s current contract to provide the 0.65 meter diameter, aspheric SiC secondary mirror for the Advanced Technology Solar Telescope (ATST).

Stiff, light, strong and ductile: nano-structured High Modulus Steel.

PubMed

Springer, H; Baron, C; Szczepaniak, A; Uhlenwinkel, V; Raabe, D

2017-06-05

Structural material development for lightweight applications aims at improving the key parameters strength, stiffness and ductility at low density, but these properties are typically mutually exclusive. Here we present how we overcome this trade-off with a new class of nano-structured steel - TiB 2 composites synthesised in-situ via bulk metallurgical spray-forming. Owing to the nano-sized dispersion of the TiB 2 particles of extreme stiffness and low density - obtained by the in-situ formation with rapid solidification kinetics - the new material has the mechanical performance of advanced high strength steels, and a 25% higher stiffness/density ratio than any of the currently used high strength steels, aluminium, magnesium and titanium alloys. This renders this High Modulus Steel the first density-reduced, high stiffness, high strength and yet ductile material which can be produced on an industrial scale. Also ideally suited for 3D printing technology, this material addresses all key requirements for high performance and cost effective lightweight design.

Lightweight Ceramics for Aeroacoustic Applications

NASA Technical Reports Server (NTRS)

Kwan, H. W.; Spamer, G. T.; Yu, J.; Yasukawa, B.

1997-01-01

The use of a HTP (High Temperature Performance) ceramic foam for aeroacoustic applications is investigated. HTP ceramic foam is a composition of silica and alumina fibers developed by LMMS. This foam is a lightweight high-temperature fibrous bulk material with small pore size, ultra high porosity, and good strength. It can be used as a broadband noise absorber at both room and high temperature (up to 1800 F). The investigation included an acoustic assessment as well as material development, and environmental and structural evaluations. The results show that the HTP ceramic foam provides good broadband noise absorbing capability and adequate strength when incorporating the HTP ceramic foam system into a honeycomb sandwich structure. On the other hand, the material is sensitive to Skydrol and requires further improvements. Good progress has been made in the impedance model development. A relationship between HTP foam density, flow resistance, and tortuosity will be established in the near future. Additional effort is needed to investigate the coupling effects between face sheet and HTP foam material.

Multifunctional Stiff Carbon Foam Derived from Bread.

PubMed

Yuan, Ye; Ding, Yujie; Wang, Chunhui; Xu, Fan; Lin, Zaishan; Qin, Yuyang; Li, Ying; Yang, Minglong; He, Xiaodong; Peng, Qingyu; Li, Yibin

2016-07-06

The creation of stiff yet multifunctional three-dimensional porous carbon architecture at very low cost is still challenging. In this work, lightweight and stiff carbon foam (CF) with adjustable pore structure was prepared by using flour as the basic element via a simple fermentation and carbonization process. The compressive strength of CF exhibits a high value of 3.6 MPa whereas its density is 0.29 g/cm(3) (compressive modulus can be 121 MPa). The electromagnetic interference (EMI) shielding effectiveness measurements (specific EMI shielding effectiveness can be 78.18 dB·cm(3)·g(-1)) indicate that CF can be used as lightweight, effective shielding material. Unlike ordinary foam structure materials, the low thermal conductivity (lowest is 0.06 W/m·K) with high resistance to fire makes CF a good candidate for commercial thermal insulation material. These results demonstrate a promising method to fabricate an economical, robust carbon material for applications in industry as well as topics regarding environmental protection and improvement of energy efficiency.

Process design of press hardening with gradient material property influence

NASA Astrophysics Data System (ADS)

Neugebauer, R.; Schieck, F.; Rautenstrauch, A.

2011-05-01

Press hardening is currently used in the production of automotive structures that require very high strength and controlled deformation during crash tests. Press hardening can achieve significant reductions of sheet thickness at constant strength and is therefore a promising technology for the production of lightweight and energy-efficient automobiles. The manganese-boron steel 22MnB5 have been implemented in sheet press hardening owing to their excellent hot formability, high hardenability, and good temperability even at low cooling rates. However, press-hardened components have shown poor ductility and cracking at relatively small strains. A possible solution to this problem is a selective increase of steel sheet ductility by press hardening process design in areas where the component is required to deform plastically during crash tests. To this end, process designers require information about microstructure and mechanical properties as a function of the wide spectrum of cooling rates and sequences and austenitizing treatment conditions that can be encountered in production environments. In the present work, a Continuous Cooling Transformation (CCT) diagram with corresponding material properties of sheet steel 22MnB5 was determined for a wide spectrum of cooling rates. Heating and cooling programs were conducted in a quenching dilatometer. Motivated by the importance of residual elasticity in crash test performance, this property was measured using a micro-bending test and the results were integrated into the CCT diagrams to complement the hardness testing results. This information is essential for the process design of press hardening of sheet components with gradient material properties.

Process design of press hardening with gradient material property influence

DOE Office of Scientific and Technical Information (OSTI.GOV)

Neugebauer, R.; Professorship for Machine Tools and Forming Technology, TU Chemnitz; Schieck, F.

Press hardening is currently used in the production of automotive structures that require very high strength and controlled deformation during crash tests. Press hardening can achieve significant reductions of sheet thickness at constant strength and is therefore a promising technology for the production of lightweight and energy-efficient automobiles. The manganese-boron steel 22MnB5 have been implemented in sheet press hardening owing to their excellent hot formability, high hardenability, and good temperability even at low cooling rates. However, press-hardened components have shown poor ductility and cracking at relatively small strains. A possible solution to this problem is a selective increase of steelmore » sheet ductility by press hardening process design in areas where the component is required to deform plastically during crash tests. To this end, process designers require information about microstructure and mechanical properties as a function of the wide spectrum of cooling rates and sequences and austenitizing treatment conditions that can be encountered in production environments. In the present work, a Continuous Cooling Transformation (CCT) diagram with corresponding material properties of sheet steel 22MnB5 was determined for a wide spectrum of cooling rates. Heating and cooling programs were conducted in a quenching dilatometer. Motivated by the importance of residual elasticity in crash test performance, this property was measured using a micro-bending test and the results were integrated into the CCT diagrams to complement the hardness testing results. This information is essential for the process design of press hardening of sheet components with gradient material properties.« less

Effects of sodium hydroxide (NaOH) solution concentration on fly ash-based lightweight geopolymer

NASA Astrophysics Data System (ADS)

Ibrahim, W. M. W.; Hussin, K.; Abdullah, M. M. A.; Kadir, A. A.; Deraman, L. M.

2017-09-01

In this study, the effects of NaOH concentration on properties of fly ash-based lightweight geopolymer were investigated. Lightweight geopolymer was produced using fly ash as source materials and synthetic foaming agents as air entraining agent. The alkaline solutions used in this study are combination of sodium hydroxide (NaOH) and sodium silicate (Na2SiO3) solution. Different molarities of NaOH solution (6M, 8M, 10M, 12M, and 14M) are taken for preparation of 50 x 50 x 50 mm cubes of lightweight geopolymer. The ratio of fly ash/alkaline solution, Na2SiO3/NaOH solution, foaming agent/water and foam/geopolymer paste were kept constant at 2.0, 2.5, 1:10 and 1:1 respectively. The samples were cured at 80°C for 24 hours and left at room temperature for tested at 7 days of ageing. Physical and mechanical properties such as density, water absorption, compressive strength and microstructure property were determined from the cube dried samples. The results show that the NaOH molarity had effects on the properties of lightweight geopolymer with the optimum NaOH molarity found is 12M due to the high strength of 15.6 MPa, lower water absorption (7.3%) and low density (1440 kg/m3). Microstructure analysis shows that the lightweight geopolymer contain some porous structure and unreacted fly ash particles remains.

CESIC: a new technology for lightweight and cost effective space instrument structures and mirrors

NASA Astrophysics Data System (ADS)

Devilliers, Christophe; Kroedel, Matthias R.

2005-08-01

For some years Alcatel Space has been interested in the development of a new material to produce lightweight, stiff, stable and cost effective structures and mirrors for space instrument. Cesic from ECM has been selected for its intrinsic properties (high specific modulus, high conductivity, quite low thermal expansion coefficient and high fracture toughness for a ceramic material), added to ample manufacturing capabilities. Under ESA responsibility, a flight representative optical bench of Cesic has been designed, manufactured and tested. The optical bench has been submitted with success to intensive vibration tests up to 80 g on shaker without problem and was tested down to 30 K showing very high stability. Cesic is also envisaged for large and lightweight space telescope mirrors. Coatings on the Cesic substrate have been developed and qualified for the most stringent optical needs. To prove the lightweight capability, a large Cesic mirror D=950 mm with an area mass of less than 25 kg/m2 has been designed, sized again launch loads and WFE performance, and then manufactured. Cesic is also envisaged for large future focal plane holding a large number of detectors assuring high stability thanks to its high thermal conductivity. A full size Cesic focal plane has been already successfully built and tested. Based on these successful results, Alcatel Space is now in position to propose for space projects this technology mastered in common with ECM both for mirrors and structures with new innovative concepts thanks to the manufacturing capabilities of this technology.

Exploring the design of a lightweight, sustainable and comfortable aircraft seat.

PubMed

Kokorikou, A; Vink, P; de Pauw, I C; Braca, A

2016-07-19

Making a lightweight seat that is also comfortable can be contradictory because usually comfort improvement means adding a feature (e.g. headrest, adjustable lumbar support, movable armrests, integrated massage systems, etc.), which makes seats heavier. This paper explores the design of an economy class aircraft seat that aims to be lightweight, comfortable and sustainable. Theory about comfort in seats, ergonomics, lightweight design, Biomimicry and Cradle to cradle was studied and resulted in a list of requirements that the new seat should satisfy. The design process resulted in a new seat that is 36% lighter than the reference seat, which showed that a significant weight reduction can be achieved. This was completed by re-designing the backrest and seat pan and integrating their functions into a reduced number of parts. Apart from the weight reduction that helps in reducing the airplane's environmental impact, the seat also satisfies most of the other sustainability requirements such as the use of recyclable materials, design for disassembly, easy to repair. A user test compared the new seat with a premium economy class aircraft seat and the level of comfort was similar. Strong points of the new design were identified such as the lumbar support and the cushioning material, as well as shortcomings on which the seat needs to be improved, like the seat pan length and the first impression. Long term comfort tests are still needed as the seat is meant for long-haul flights.

Fe-Al-Mn-C lightweight structural alloys: a review on the microstructures and mechanical properties.

PubMed

Kim, Hansoo; Suh, Dong-Woo; Kim, Nack J

2013-02-01

Adding a large amount of light elements such as aluminum to steels is not a new concept recalling that several Fe-Al-Mn-C alloys were patented in 1950s for replacement of nickel or chromium in corrosion resistance steels. However, the so-called lightweight steels or low-density steels were revisited recently, which is driven by demands from the industry where steel has served as a major structural material. Strengthening without loss of ductility has been a triumph in steel research, but lowering the density of steel by mixing with light elements will be another prospect that may support the competitiveness against emerging alternatives such as magnesium alloys. In this paper, we review recent studies on lightweight steels, emphasizing the concept of alloy design for microstructures and mechanical properties. The influence of alloying elements on the phase constituents, mechanical properties and the change of density is critically reviewed. Deformation mechanisms of various lightweight steels are discussed as well. This paper provides a reason why the success of lightweight steels is strongly dependent on scientific achievements even though alloy development is closely related to industrial applications. Finally, we summarize some of the main directions for future investigations necessary for vitalizing this field of interest.

Fe–Al–Mn–C lightweight structural alloys: a review on the microstructures and mechanical properties

PubMed Central

Kim, Hansoo; Suh, Dong-Woo; Kim, Nack J

2013-01-01

Adding a large amount of light elements such as aluminum to steels is not a new concept recalling that several Fe–Al–Mn–C alloys were patented in 1950s for replacement of nickel or chromium in corrosion resistance steels. However, the so-called lightweight steels or low-density steels were revisited recently, which is driven by demands from the industry where steel has served as a major structural material. Strengthening without loss of ductility has been a triumph in steel research, but lowering the density of steel by mixing with light elements will be another prospect that may support the competitiveness against emerging alternatives such as magnesium alloys. In this paper, we review recent studies on lightweight steels, emphasizing the concept of alloy design for microstructures and mechanical properties. The influence of alloying elements on the phase constituents, mechanical properties and the change of density is critically reviewed. Deformation mechanisms of various lightweight steels are discussed as well. This paper provides a reason why the success of lightweight steels is strongly dependent on scientific achievements even though alloy development is closely related to industrial applications. Finally, we summarize some of the main directions for future investigations necessary for vitalizing this field of interest. PMID:27877553

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kelly, Jarod C.; Sullivan, John L.; Burnham, Andrew

This study examines the vehicle-cycle impacts associated with substituting lightweight materials for those currently found in light-duty passenger vehicles. We determine part-based energy use and greenhouse gas (GHG) emission ratios by collecting material substitution data from both the literature and automotive experts and evaluating that alongside known mass-based energy use and GHG emission ratios associated with material pair substitutions. Several vehicle parts, along with full vehicle systems, are examined for lightweighting via material substitution to observe the associated impact on GHG emissions. Results are contextualized by additionally examining fuel-cycle GHG reductions associated with mass reductions relative to the baseline vehiclemore » during the use phase and also determining material pair breakeven driving distances for GHG emissions. The findings show that, while material substitution is useful in reducing vehicle weight, it often increases vehicle-cycle GHGs depending upon the material substitution pair. However, for a vehicle’s total life cycle, fuel economy benefits are greater than the increased burdens associated with the vehicle manufacturing cycle, resulting in a net total life-cycle GHG benefit. The vehicle cycle will become increasingly important in total vehicle life-cycle GHGs, since fuel-cycle GHGs will be gradually reduced as automakers ramp up vehicle efficiency to meet fuel economy standards.« less

Beryllium

Cancer.gov

Learn about beryllium, exposure to which can increase your risk of lung cancer. Beryllium is a naturally occurring, light-weight metal used in products such as aerospace components, transistors, nuclear reactors, and golf clubs. Most exposures occur to workers who produce such products.

Progress in the Phase 0 Model Development of a STAR Concept for Dynamics and Control Testing

NASA Technical Reports Server (NTRS)

Woods-Vedeler, Jessica A.; Armand, Sasan C.

2003-01-01

The paper describes progress in the development of a lightweight, deployable passive Synthetic Thinned Aperture Radiometer (STAR). The spacecraft concept presented will enable the realization of 10 km resolution global soil moisture and ocean salinity measurements at 1.41 GHz. The focus of this work was on definition of an approximately 1/3-scaled, 5-meter Phase 0 test article for concept demonstration and dynamics and control testing. Design requirements, parameters and a multi-parameter, hybrid scaling approach for the dynamically scaled test model were established. The El Scaling Approach that was established allows designers freedom to define the cross section of scaled, lightweight structural components that is most convenient for manufacturing when the mass of the component is small compared to the overall system mass. Static and dynamic response analysis was conducted on analytical models to evaluate system level performance and to optimize panel geometry for optimal tension load distribution.

Development of a lightweight fuel cell vehicle

NASA Astrophysics Data System (ADS)

Hwang, J. J.; Wang, D. Y.; Shih, N. C.

This paper described the development of a fuel cell system and its integration into the lightweight vehicle known as the Mingdao hydrogen vehicle (MHV). The fuel cell system consists of a 5-kW proton exchange membrane fuel cell (PEMFC), a microcontroller and other supported components like a compressed hydrogen cylinder, blower, solenoid valve, pressure regulator, water pump, heat exchanger and sensors. The fuel cell not only propels the vehicle but also powers the supporting components. The MHV performs satisfactorily over a hundred-kilometer drive thus validating the concept of a fuel cell powered zero-emission vehicle. Measurements further show that the fuel cell system has an efficiency of over 30% at the power consumption for vehicle cruise, which is higher than that of a typical internal combustion engine. Tests to improve performance such as speed enhancement, acceleration and fuel efficiency will be conducted in the future work. Such tests will consist of hybridizing with a battery pack.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Luszczek, Piotr R; Tomov, Stanimire Z; Dongarra, Jack J

We present an efficient and scalable programming model for the development of linear algebra in heterogeneous multi-coprocessor environments. The model incorporates some of the current best design and implementation practices for the heterogeneous acceleration of dense linear algebra (DLA). Examples are given as the basis for solving linear systems' algorithms - the LU, QR, and Cholesky factorizations. To generate the extreme level of parallelism needed for the efficient use of coprocessors, algorithms of interest are redesigned and then split into well-chosen computational tasks. The tasks execution is scheduled over the computational components of a hybrid system of multi-core CPUs andmore » coprocessors using a light-weight runtime system. The use of lightweight runtime systems keeps scheduling overhead low, while enabling the expression of parallelism through otherwise sequential code. This simplifies the development efforts and allows the exploration of the unique strengths of the various hardware components.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

MacLeod, Bradley A.; Stanton, Noah J.; Gould, Isaac E.

Lightweight, robust, and flexible single-walled carbon nanotube (SWCNT) materials can be processed inexpensively using solution-based techniques, similar to other organic semiconductors. In contrast to many semiconducting polymers, semiconducting SWCNTs (s-SWCNTs) represent unique one-dimensional organic semiconductors with chemical and physical properties that facilitate equivalent transport of electrons and holes. These factors have driven increasing attention to employing s-SWCNTs for electronic and energy harvesting applications, including thermoelectric (TE) generators. Here we demonstrate a combination of ink chemistry, solid-state polymer removal, and charge-transfer doping strategies that enable unprecedented n-type and p-type TE power factors, in the range of 700 μW m –1 Kmore » –2 at 298 K for the same solution-processed highly enriched thin films containing 100% s-SWCNTs. We also demonstrate that the thermal conductivity appears to decrease with decreasing s-SWCNT diameter, leading to a peak material zT ≈ 0.12 for s-SWCNTs with diameters in the range of 1.0 nm. Here, our results indicate that the TE performance of s-SWCNT-only material systems is approaching that of traditional inorganic semiconductors, paving the way for these materials to be used as the primary components for efficient, all-organic TE generators.« less

Aerospace materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dornheim, M.A.

1991-04-01

A comprehensive evaluation is made of the development trends in high performance advanced aerospace structural materials applications. It is noted that the anticipated predominance of thermoplastic composite-matrix polymers in the F-22/F-23 ATF propotypes has not materialized, due both to their high materials and processing costs and the emergence of a more tractable high operating temperature thermoset, BMI, whose toughness characteristics are of the order of those associated with thermoplastics. No more than 15 percent of F-22 weight is thermoplastics; the F-23 use of such resins is nill. Throughout the advanced nonmetallics industry, reduced DOD procurements have come to represent slowmore » growth and the prospect of consolidation. Also, such lightweight Al-based metallics as the Al-Li alloys have posed a major market-share challenge to polymeric composites, as in the case of the C-17 airlifter's 6,269 lbs of such Al-Li alloys as 2090, largely in cargo floor and ramp bulkhead structures. The EFA fighter makes frequent use of SPF-DB Ti alloys in combat damage-critical components. Metal-matrix composites employing titanium aluminide matrices will be extensively used in the X-30 hypersonic aircraft program.« less

Ultralight and fire-resistant ceramic nanofibrous aerogels with temperature-invariant superelasticity.

PubMed

Si, Yang; Wang, Xueqin; Dou, Lvye; Yu, Jianyong; Ding, Bin

2018-04-01

Ultralight aerogels that are both highly resilient and compressible have been fabricated from various materials including polymer, carbon, and metal. However, it has remained a great challenge to realize high elasticity in aerogels solely based on ceramic components. We report a scalable strategy to create superelastic lamellar-structured ceramic nanofibrous aerogels (CNFAs) by combining SiO 2 nanofibers with aluminoborosilicate matrices. This approach causes the random-deposited SiO 2 nanofibers to assemble into elastic ceramic aerogels with tunable densities and desired shapes on a large scale. The resulting CNFAs exhibit the integrated properties of flyweight densities of >0.15 mg cm -3 , rapid recovery from 80% strain, zero Poisson's ratio, and temperature-invariant superelasticity to 1100°C. The integral ceramic nature also provided the CNFAs with robust fire resistance and thermal insulation performance. The successful synthesis of these fascinating materials may provide new insights into the development of ceramics in a lightweight, resilient, and structurally adaptive form.

Ultralight and fire-resistant ceramic nanofibrous aerogels with temperature-invariant superelasticity

PubMed Central

Wang, Xueqin; Dou, Lvye; Yu, Jianyong

2018-01-01

Ultralight aerogels that are both highly resilient and compressible have been fabricated from various materials including polymer, carbon, and metal. However, it has remained a great challenge to realize high elasticity in aerogels solely based on ceramic components. We report a scalable strategy to create superelastic lamellar-structured ceramic nanofibrous aerogels (CNFAs) by combining SiO2 nanofibers with aluminoborosilicate matrices. This approach causes the random-deposited SiO2 nanofibers to assemble into elastic ceramic aerogels with tunable densities and desired shapes on a large scale. The resulting CNFAs exhibit the integrated properties of flyweight densities of >0.15 mg cm−3, rapid recovery from 80% strain, zero Poisson’s ratio, and temperature-invariant superelasticity to 1100°C. The integral ceramic nature also provided the CNFAs with robust fire resistance and thermal insulation performance. The successful synthesis of these fascinating materials may provide new insights into the development of ceramics in a lightweight, resilient, and structurally adaptive form. PMID:29719867

Energy conversion system

DOEpatents

Murphy, Lawrence M.

1987-01-01

The energy conversion system includes a photo-voltaic array for receiving solar radiation and converting such radiation to electrical energy. The photo-voltaic array is mounted on a stretched membrane that is held by a frame. Tracking means for orienting the photo-voltaic array in predetermined positions that provide optimal exposure to solar radiation cooperate with the frame. An enclosure formed of a radiation transmissible material includes an inside containment space that accommodates the photo-voltaic array on the stretched membrane, the frame and the tracking means, and forms a protective shield for all such components. The enclosure is preferably formed of a flexible inflatable material and maintains its preferred form, such as a dome, under the influence of a low air pressure furnished to the dome. Under this arrangement the energy conversion system is streamlined for minimizing wind resistance, sufficiently weatherproof for providing protection against weather hazards such as hail, capable of using diffused light, lightweight for low-cost construction, and operational with a minimal power draw.

Energy conversion system

DOEpatents

Murphy, L.M.

1985-09-16

The energy conversion system includes a photo-voltaic array for receiving solar radiation and converting such radiation to electrical energy. The photo-voltaic array is mounted on a stretched membrane that is held by a frame. Tracking means for orienting the photo-voltaic array in predetermined positions that provide optimal exposure to solar radiation cooperate with the frame. An enclosure formed of a radiation transmissible material includes an inside containment space that accommodates the photo-voltaic array on the stretched membrane, the frame and the tracking means, and forms a protective shield for all such components. The enclosure is preferably formed of a flexible inflatable material and maintains its preferred form, such as a dome, under the influence of a low air pressure furnished to the dome. Under this arrangement the energy conversion system is streamlined for minimizing wind resistance, sufficiently weathproof for providing protection against weather hazards such as hail, capable of using diffused light, lightweight for low-cost construction and operational with a minimal power draw.

'NASA Invention of the Year' Controls Noise and Vibration

NASA Technical Reports Server (NTRS)

2007-01-01

Developed at NASA's Langley Research Center, the Macro-Fiber Composite (MFC) is designed to control vibration, noise, and deflections in composite structural beams and panels. Smart Material Corporation specializes in the development of piezocomposite components, and licensed the MFC technology from Langley in 2002. To date, Smart Material Corporation has sold MFCs to over 120 customers, including such industry giants as Volkswagen, Toyota, Honda, BMW, General Electric, and the tennis company, HEAD. The company estimates that its customers have filed at least 100 patents for their various unique uses of the technology. In addition, the company's product portfolio has grown to include piezoceramic fibers and fiber composites, piezoceramic actuators and sensors, and test equipment for these products. It also offers a compact, lightweight power system for MFC testing and validation. Consumer applications already on the market include piezoelectric systems as part of audio speakers, phonograph cartridges and microphones, and recreational products requiring vibration control, such as skis, snowboards, baseball bats, hockey sticks, and tennis racquets.

Ultra-Lightweight Nanocomposite Foams and Sandwich Structures for Space Structure Applications

NASA Technical Reports Server (NTRS)

Tan, Seng

2012-01-01

Microcellular nanocomposite foams and sandwich structures have been created to have excellent electrical conductivity and radiation-resistant properties using a new method that does not involve or release any toxicity. The nanocomposite structures have been scaled up in size to 12 X 12 in. (30 X 30 cm) for components fabrication. These sandwich materials were fabricated mainly from PE, CNF, and carbon fibers. Test results indicate that they have very good compression and compression-after-impact properties, excellent electrical conductivity, and superior space environment durability. Compression tests show that 1000 ESH (equivalent Sun hours) of UV exposure has no effect on the structural properties of the sandwich structures. The structures are considerably lighter than aluminum alloy (= 36 percent lighter), which translates to 36 percent weight savings of the electronic enclosure and its housing. The good mechanical properties of the materials may enable the electronic housing to be fabricated with a thinner structure that further reduces the weight. There was no difficulty in machining the sandwich specimens into electronic enclosure housing.

Effects of Defects in Laser Additive Manufactured Ti-6Al-4V on Fatigue Properties

NASA Astrophysics Data System (ADS)

Wycisk, Eric; Solbach, Andreas; Siddique, Shafaqat; Herzog, Dirk; Walther, Frank; Emmelmann, Claus

Laser Additive Manufacturing (LAM) enables economical production of complex lightweight structures as well as patient individual implants. Due to these possibilities the additive manufacturing technology gains increasing importance in the aircraft and the medical industry. Yet these industries obtain high quality standards and demand predictability of material properties for static and dynamic load cases. However, especially fatigue and crack propagation properties are not sufficiently determined. Therefore this paper presents an analysis and simulation of crack propagation behavior considering Laser Additive Manufacturing specific defects, such as porosity and surface roughness. For the mechanical characterization of laser additive manufactured titanium alloy Ti-6Al-4V, crack propagation rates are experimentally determined and used for an analytical modeling and simulation of fatigue. Using experimental results from HCF tests and simulated data, the fatigue and crack resistance performance is analyzed considering material specific defects and surface roughness. The accumulated results enable the reliable prediction of the defects influence on fatigue life of laser additive manufactured titanium components.

Materials for Stretchable Electronics - Electronic Eyeballs, Brain Monitors and Other Applications

ScienceCinema

Rogers, John A. [University of Illinois, Urbana Champaign, Illinois, United States

2017-12-09

Electronic circuits that involve transistors and related components on thin plastic sheets or rubber slabs offer mechanical properties (e.g. bendability, stretchability) and other features (e.g. lightweight, rugged construction) which cannot be easily achieved with technologies that use rigid, fragile semiconductor wafer or glass substrates.  Device examples include personal or structural health monitors and electronic eye imagers, in which the electronics must conform to complex curvilinear shapes or flex/stretch during use.  Our recent work accomplishes these technology outcomes by use of single crystal inorganic nanomaterials in ‘wavy’ buckled configurations on elastomeric supports.  This talk will describe key fundamental materials and mechanics aspects of these approaches, as well as engineering features of their use in individual transistors, photodiodes and integrated circuits.  Cardiac and brain monitoring devices provide examples of application in biomedicine; hemispherical electronic eye cameras illustrate new capacities for bio-inspired device design.

High Performance MG-System Alloys For Weight Saving Applications: First Year Results From The Green Metallurgy EU Project

NASA Astrophysics Data System (ADS)

D'Errico, Fabrizio; Plaza, Gerardo Garces; Hofer, Markus; Kim, Shae K.

The GREEN METALLURGY Project, a LIFE+ project co-financed by the EU Commission, has just concluded its first year. The Project seeks to set manufacturing processes at a pre-industrial scale for nanostructured-based high-performance Mg-Zn(Y) magnesium alloys. The Project's goal is the reduction of specific energy consumed and the overall carbon-footprint produced in the cradle-to-exit gate phases. Preliminary results addressed potentialities of the upstream manufacturing process pathway. Two Mg-Zn(Y) system alloys with rapid solidifying powders have been produced and directly extruded for 100% densification. Examination of the mechanical properties showed that such materials exhibit strength and elongation comparable to several high performing aluminum alloys; 390 MPa and 440 MPa for the average UTS for two different system alloys, and 10% and 15% elongations for two system alloys. These results, together with the low-environmental impact targeted, make these novel Mg alloys competitive as lightweight high-performance materials for automotive components.

Nanotechnology: From Science Fiction to Reality

NASA Technical Reports Server (NTRS)

Siochi, Mia

2016-01-01

Nanotechnology promises unconventional solutions to challenging problems because of expectations that matter can be manipulated at the atomic scale to yield properties that exceed those predicted for bulk materials. The excitement at this possibility has been fueled by significant investments in this technology area. This talk will focus on three examples of where advances are being made to exploit unique properties made possible by nanoscale features for aerospace applications. The first two topics will involve the development of carbon nanotubes for (a) lightweight structural applications and (b) net shape fabricated multifunctional components. The third topic will highlight lessons learned from the demonstration of the effect of nanoengineered surfaces on insect residue adhesion. In all three cases, the approaches used to mature these emerging technologies are based on the acceleration of technology development through multidisciplinary collaborations.

Silicon carbide as a basis for spaceflight optical systems

NASA Astrophysics Data System (ADS)

Curcio, Michael E.

1994-09-01

New advances in the areas of microelectronics and micro-mechanical devices have created a momentum in the development of lightweight, miniaturized, electro-optical space subsystems. The performance improvements achieved and new observational techniques developed as a result, have provided a basis for a new range of Small Explorer, Discovery-class and other low-cost mission concepts for space exploration. However, the ultimate objective of low-mass, inexpensive space science missions will only be achieved with a companion development in the areas of flight optical systems and sensor instrument benches. Silicon carbide (SiC) is currently emerging as an attractive technology to fill this need. As a material basis for reflective, flight telescopes and optical benches, SiC offers: the lightweight and stiffness characteristics of beryllium; glass-like inherent stability consistent with performance to levels of diffraction-limited visible resolution; superior thermal properties down to cryogenic temperatures; and an existing, commercially-based material and processing infrastructure like aluminum. This paper will describe the current status and results of on-going technology developments to utilize these material properties in the creation of lightweight, high- performing, thermally robust, flight optical assemblies. System concepts to be discussed range from an 18 cm aperture, 4-mirror, off-axis system weighing less than 2 kg to a 0.5 m, 15 kg reimager. In addition, results in the development of a thermally-stable, `GOES-like' scan mirror will be presented.

Ultra Lightweight Ballutes for Return to Earth from the Moon

NASA Technical Reports Server (NTRS)

Masciarelli, James P.; Lin, John K. H.; Ware, Joanne S.; Rohrschneider, Reuben R.; Braun, Robert D.; Bartels, Robert E.; Moses, Robert W.; Hall, Jeffery L.

2006-01-01

Ultra lightweight ballutes offer revolutionary mass and cost benefits along with flexibility in flight system design compared to traditional entry system technologies. Under funding provided by NASA s Exploration Systems Research & Technology program, our team was able to make progress in developing this technology through systems analysis and design, evaluation of materials and construction methods, and development of critical analysis tools. Results show that once this technology is mature, significant launch mass savings, operational simplicity, and mission robustness will be available to help carry out NASA s Vision for Space Exploration.

Vehicle Lightweighting: Challenges and Opportunities with Aluminum

NASA Astrophysics Data System (ADS)

Sachdev, Anil K.; Mishra, Raja K.; Mahato, Anirban; Alpas, Ahmet

Rising energy costs, consumer preferences and regulations drive requirements for fuel economy, performance, comfort, safety and cost of future automobiles. These conflicting situations offer challenges for vehicle lightweighting, for which aluminum applications are key. This paper describes product design needs and materials and process development opportunities driven by theoretical, experimental and modeling tools in the area of sheet and castings. Computational tools and novel experimental techniques used in their development are described. The paper concludes with challenges that lie ahead for pervasive use of aluminum and the necessary fundamental R&D that is still needed.

Lightweight protective clothing for the safe handling of high-intensity pressurized lamps

NASA Technical Reports Server (NTRS)

Ewashinka, J. G.

1975-01-01

Five commercially available clothing materials, selected for their high cutting resistance, high strength, light weight and pliability, were tested by exposing them to exploding lamps located less than 60 cm (2 ft) away. Face shield material tested initially was commercial high-strength polycarbonate plastic.

Lightweight blast shield

DOEpatents

Mixon, Larry C.; Snyder, George W.; Hill, Scott D.; Johnson, Gregory L.; Wlodarski, J. Frank; von Spakovsky, Alexis P.; Emerson, John D.; Cole, James M.; Tipton, John P.

1991-01-01

A tandem warhead missile arrangement that has a composite material housing structure with a first warhead mounted at one end and a second warhead mounted near another end of the composite structure with a dome shaped composite material blast shield mounted between the warheads to protect the second warhead from the blast of the first warhead.

Lightweight coaxial cable connector reduces signal loss

NASA Technical Reports Server (NTRS)

Brejcha, A. G., Jr.

1965-01-01

Connectors with milled interface surfaces for perfect electrical contact eliminate secondary- emission discharge and low signal loss in RF coaxial cables. the connectors which contain alignment and centering components for proper joint concentricity are used in communications systems designs.

Lightweight design and analysis of automobile wheel based on bending and radial loads

NASA Astrophysics Data System (ADS)

Jiang, X.; Lyu, R.; Fukushima, Y.; Otake, M.; Ju, D. Y.

2018-06-01

Lightweighting of automobile vehicle is a significant application trends, using magnesium alloy wheels is a valuable way. This article discusses design of a new model of automobile wheel. Then bending test and radial test finite element model were established. Considering three different materials namely magnesium alloy, aluminium alloy and steel, the stress and strain performances of each material can be obtained. Through evaluating and analyzing model in bending test and radial test, we obtained the reasonable and superior results for magnesium alloy wheel. The results of the equivalent stress and deformation were compared, the magnesium alloy wheel practicality has been confirmed. This research predicts the reliability of the structural design, some valuable references are provided for the design and development of magnesium alloy wheel.

Microdesigning of Lightweight/High Strength Ceramic Materials

DTIC Science & Technology

1989-07-31

Continue on reverse if necessary and identiy by block number) FIELD GROUP SUB- GROUP Ceramics, Composite Materials, Colloidal Processing Iii 19. ABSTRACT...to identify key processing parameters that affect the microstructure of the composite material. The second section describes experimental results in...results of the significant theoretical effort made in our group . Theoretical models of particle-particle interaction, particle-polymer interaction

Preliminary Assessment of Potential Habitat Composites' Durability when Exposed to a Long-Term Radiation Environment and Micrometeoroid Impacts

NASA Technical Reports Server (NTRS)

Rojdev, Kristina; Graves, Russell; Golden, John; Atwell, William; O'Rouke, Mary Jane; Hill, Charles; Alred, John

2011-01-01

NASA's exploration goals include extending human presence beyond low earth orbit (LEO). As a result, habitation for crew is a critical requirement for meeting this goal. However, habitats are very large structures that contain a multitude of subsystems to sustain human life over long-durations in space, and one of the key challenges has been keeping weight to a minimum in order to reduce costs. Thus, light-weight and multifunctional structural materials are of great interest for habitation. NASA has started studying polymeric composite materials as potential lightweight and multifunctional structural materials for use in long-duration spaceflight. However, little is known about the survivability of these materials when exposed to the space environment outside of LEO for long durations. Thus, a study has been undertaken to investigate the durability of composite materials when exposed to long-duration radiation. Furthermore, as an addition to the primary study, a secondary preliminary investigation has been started on the micrometeoroid and orbital debris (MMOD) susceptibility of these materials after radiation exposure. The combined effects of radiation and MMOD impacts are the focus of this paper.

Thin-Film Solar Cells on Polymer Substrates for Space Power

NASA Technical Reports Server (NTRS)

Hepps, A. F.; McNatt, Jeremiah; Morel, D. L.; Ferckides, C. S.; Jin, M. H.; Orbey, N.; Cushman, M.; Birkmire, R. W.; Shafarman, W. N.; Newton, R.

2004-01-01

Photovoltaic arrays have played a key role in power generation in space. The current technology will continue to evolve but is limited in the important mass specific power metric (MSP or power/weight ratio) because it is based on bulk crystal technology. Solar cells based on thin-film materials offer the promise of much higher MSP and much lower cost. However, for many space applications, a 20% or greater AM0 efficiency (eta) may be required. The leading thin-film materials, amorphous Si, CuInSe, and CdTe have seen significant advances in efficiency over the last decade but will not achieve the required efficiency in the near future. Several new technologies are herein described to maximize both device eta and MSP. We will discuss these technologies in the context of space exploration and commercialization. One novel approach involves the use of very lightweight polyimide substrates. We describe efforts to enable this advance including materials processing and device fabrication and characterization. Another approach involves stacking two cells on top of each other. These tandem devices more effectively utilize solar radiation by passing through non-absorbed longer wavelength light to a narrow-bandgap bottom cell material. Modeling of current devices in tandem format indicates that AM0 efficiencies near 20% can be achieved with potential for 25% in the near future. Several important technical issues need to be resolved to realize the benefits of lightweight technologies for solar arrays, such as: monolithic interconnects, lightweight array structures, and new ultra-light support and deployment mechanisms. Recent advances will be stressed.

NIAC Phase I Study Final Report on Large Ultra-Lightweight Photonic Muscle Space Structures

NASA Technical Reports Server (NTRS)

Ritter, Joe

2016-01-01

The research goal is to develop new tools support NASA's mission of understanding of the Cosmos by developing cost effective solutions that yield a leap in performance and science data. 'Maikalani' in Hawaiian translates to, "knowledge we gain from the cosmos." Missions like Hubble have fundamentally changed humanity's view of the cosmos. Last year's Nobel prize in physics was a result of astronomical discoveries. $9B class JWST size (6.5 meter diameter) space telescopes, when launched are anticipated to rewrite our knowledge of physics. Here we report on a neoteric meta-material telescope mirror technology designed to enable a factor of 100 or more reduction in areal density, a factor of 100 reduction in telescope production and launch costs as well as other advantages; a leap to enable missions to image the cosmos in unprecedented detail, with the associated gain in knowledge. Whether terahertz, visible or X-ray, reflectors used for high quality electromagnetic imaging require shape accuracy (surface figure) to far better than 1 wavelength (lambda) of the incident photons, more typically lambda/10 or better. Imaging visible light therefore requires mirror surfaces that approximate a desired curve (e.g. a sphere or paraboloid) with smooth shape deviation of th less than approximately 1/1000 the diameter of a human hair. This requires either thick high modulus material like glass or metal, or actuators to control mirror shape. During Phase I our team studied a novel solution to this systems level design mass/shape tradespace requirement both to advance the innovative space technology concept and also to help NASA and other agencies meet current operational and future mission requirements. Extreme and revolutionary NASA imaging missions such as Terrestrial Planet Imager (TPI) require lightweight mirrors with minimum diameters of 20 to 40 meters. For reference, NASA's great achievement; the Hubble space telescope, is only 2.4 meters in diameter. What is required is a way to make large inexpensive deployable mirrors where the cost is measured in millions, not billions like current efforts. For example we seek an interim goal within 10 years of a Hubble size (2.4m) primary mirror weighing 1 pound at a cost of 10K in materials. Described here is a technology using thin ultra lightweight materials where shape can be controlled simply with a beam of light, allowing imaging with incredibly low mass yet precisely shaped mirrors. These " Photonic Muscle" substrates will eventually make precision control of giant s p a c e apertures (mirrors) possible. OCCAM substrates make precision control of giant ultra light-weight mirror apertures possible. This technology is posed to create a revolution in remote sensing by making large ultra lightweight space telescopes a fiscal and material reality over the next decade.

A Look Inside Argonne's Center for Nanoscale Materials

ScienceCinema

Divan, Ralu; Rosenthal, Dan; Rose, Volker; Wai Hla

2018-05-23

At a very small, or "nano" scale, materials behave differently. The study of nanomaterials is much more than miniaturization - scientists are discovering how changes in size change a material's properties. From sunscreen to computer memory, the applications of nanoscale materials research are all around us. Researchers at Argonne's Center for Nanoscale Materials are creating new materials, methods and technologies to address some of the world's greatest challenges in energy security, lightweight but durable materials, high-efficiency lighting, information storage, environmental stewardship and advanced medical devices.

Towards intelligent microstructural design of Nanocomposite Materials. Lightweight, high strength structural/armor materials for service in extreme environments

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mara, Nathan Allan; Bronkhorst, Curt Allan; Beyerlein, Irene Jane

2015-12-21

The intent of this research effort is to prove the hypothesis that: Through the employment of controlled processing parameters which are based upon integrated advanced material characterization and multi-physics material modeling, bulk nanolayered composites can be designed to contain high densities of preferred interfaces that can serve as supersinks for the defects responsible for premature damage and failure.

Thin combiner optics utilizing volume holographic optical elements (vHOEs) using Bayfol HX photopolymer film

NASA Astrophysics Data System (ADS)

Bruder, Friedrich-Karl; Fäcke, Thomas; Hagen, Rainer; Hansen, Sven; Manecke, Christel; Orselli, Enrico; Rewitz, Christian; Rölle, Thomas; Walze, Günther

2017-06-01

The main function of any augmented reality system is to seamlessly merge the real world perception of a viewer with computer generated images and information. Besides real-time head-tracking and room-scanning capabilities the combiner optics, which optically merge the natural with the artificial visual information, represent a key component for those systems. Various types of combiner optics are known to the industry, all with their specific advantages and disadvantages. Beside the well-established solutions based on refractive optics or surface gratings, volume Holographic Optical Elements (vHOEs) are a very attractive alternative in this field. The unique characteristics of these diffractive grating structures - being lightweight, thin, flat and invisible in Off Bragg conditions - make them perfectly suitable for their use in integrated and compact combiners. For any consumer application it is paramount to build unobtrusive and lightweight augmented reality displays, for which those volume holographic combiners are ideally suited. Due to processing challenges of (historic) holographic recording materials mass production of vHOE holographic combiners was not possible. Therefore vHOE based combiners found use in military applications only by now. The new Bayfol® HX instant developing holographic photopolymer film provides an ideal technology platform to optimize the performance of vHOEs in a wide range of applications. Bayfol® HX provides full color capability and adjustable diffraction efficiency as well as an unprecedented optical clarity when compared to classical holographic recording materials like silver halide emulsions (AgHX) or dichromated gelatin (DCG). Bayfol® HX film is available in industrial scale and quality. Its properties can be tailored for various diffractive performances and integration methods. Bayfol® HX film is easy to process without any need for chemical or thermal development steps, offering simplified contact-copy mass production schemes.

On a high-potential variable flexural stiffness device

NASA Astrophysics Data System (ADS)

Henke, Markus; Gerlach, Gerald

2013-05-01

There are great efforts in developing effective composite structures for lightweight constructions for nearly every field of engineering. This concerns for example aeronautics and spacecrafts, but also automotive industry and energy harvesting applications. Modern concepts of lightweight components try to make use of structures with properties which can be adjusted in a controllable was. However, classic composite materials can only slightly adapt to varying environmental conditions because most materials, like carbon or glass-fiber composites show properties which are time-constant and not changeable. This contribution describes the development, the potential and the limitations of novel smart, self-controlling structures which can change their mechanical properties - e.g. their flexural stiffness - by more then one order of magnitude. These structures use a multi-layer approach with a 10-layer stack of 0.75 mm thick polycarbonate. The set-up is analytically described and its mechanical behavior is predicted by finite element analysis done with ABAQUS. The layers are braided together by an array of shape memory alloy (SMA) wires, which can be activated independently. Depending on the temperature applied by the electrical current flowing through the wires and the corresponding contraction the wires can tightly clamp the layers so that they cannot slide against each other due to friction forces. In this case the multilayer acts as rigid beam with high stiffness. If the friction-induced shear stress is smaller than a certain threshold, then the layers can slide over each other and the multilayer becomes compliant under bending load. The friction forces between the layers and, hence, the stiffness of the beam is controlled by the electrical current through the wires. The more separate parts of SMA wires the structure has the larger is the number of steps of stiffness changes of the flexural beam.

Lightweight, flexible, high-performance carbon nanotube cables made by scalable flow coating

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mirri, Francesca; Orloff, Nathan D.; Forser, Aaron M.

Coaxial cables for data transmission are ubiquitous in telecommunications, aerospace, automotive, and robotics industries. Yet, the metals used to make commercial cables are unsuitably heavy and stiff. These undesirable traits are particularly problematic in aerospace applications, where weight is at a premium and flexibility is necessary to conform with the distributed layout of electronic components in satellites and aircraft. The cable outer conductor (OC) is usually the heaviest component of modern data cables; therefore, exchanging the conventional metallic OC for lower weight materials with comparable transmission characteristics is highly desirable. Carbon nanotubes (CNTs) have recently been proposed to replace themore » metal components in coaxial cables; however, signal attenuation was too high in prototypes produced so far. Here, we fabricate the OC of coaxial data cables by directly coating a solution of CNTs in chlorosulfonic acid (CSA) onto the cable inner dielectric. This coating has an electrical conductivity that is approximately 2 orders of magnitude greater than the best CNT OC reported in the literature to date. In conclusion, this high conductivity makes CNT coaxial cables an attractive alternative to commercial cables with a metal (tin-coated copper) OC, providing comparable cable attenuation and mechanical durability with a 97% lower component mass.« less

Lightweight, flexible, high-performance carbon nanotube cables made by scalable flow coating

DOE PAGES

Mirri, Francesca; Orloff, Nathan D.; Forser, Aaron M.; ...

2016-01-21

Coaxial cables for data transmission are ubiquitous in telecommunications, aerospace, automotive, and robotics industries. Yet, the metals used to make commercial cables are unsuitably heavy and stiff. These undesirable traits are particularly problematic in aerospace applications, where weight is at a premium and flexibility is necessary to conform with the distributed layout of electronic components in satellites and aircraft. The cable outer conductor (OC) is usually the heaviest component of modern data cables; therefore, exchanging the conventional metallic OC for lower weight materials with comparable transmission characteristics is highly desirable. Carbon nanotubes (CNTs) have recently been proposed to replace themore » metal components in coaxial cables; however, signal attenuation was too high in prototypes produced so far. Here, we fabricate the OC of coaxial data cables by directly coating a solution of CNTs in chlorosulfonic acid (CSA) onto the cable inner dielectric. This coating has an electrical conductivity that is approximately 2 orders of magnitude greater than the best CNT OC reported in the literature to date. In conclusion, this high conductivity makes CNT coaxial cables an attractive alternative to commercial cables with a metal (tin-coated copper) OC, providing comparable cable attenuation and mechanical durability with a 97% lower component mass.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sabau, Adrian

Joining carbon fiber composites and aluminum for lightweight cars and other multi-material high-end products could become less expensive and the joints more robust because of a new method that harnesses a laser’s power and precision.

Hot Rolling Scrap Reduction through Edge Cracking and Surface Defects Control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Beaudoin, Armand

2016-05-29

The design of future aircraft must address the combined demands for fuel efficiency, reduced emissions and lower operating costs. One contribution to these goals is weight savings through the development of new alloys and design techniques for airframe structures. This research contributes to the light-weighting through fabrication of monolithic components from advanced aluminum alloys by making a link between alloy processing history and in-service performance. Specifically, this research demonstrates the link between growing cracks with features of the alloy microstructure that follow from thermo-mechanical processing. This is achieved through a computer model of crack deviation. The model is validated againstmore » experimental data from production scale aluminum alloy plate, and demonstration of the effect of changes in processing history on crack growth is made. The model is cast in the open-source finite element code WARP3D, which is freely downloadable and well documented. This project provides benefit along several avenues. First, the technical contribution of the computer model offers the materials engineer a critical means of providing guidance both upstream, to process tuning to achieve optimal properties, and downstream, to enhance fault tolerance. Beyond the fuel savings and emissions reduction inherent in the light-weighting of aircraft structures, improved fault tolerance addresses demands for longer inspection intervals over baseline, and a lower life cycle cost.« less

NASA Tech Briefs, August 2004

NASA Technical Reports Server (NTRS)

2004-01-01

Topics covered include: Data Relay Board with Protocol for High-Speed, Free-Space Optical Communications; Software and Algorithms for Biomedical Image Data Processing and Visualization; Rapid Chemometric Filtering of Spectral Data; Prioritizing Scientific Data for Transmission; Determining Sizes of Particles in a Flow from DPIV Data; Faster Processing for Inverting GPS Occultation Data; FPGA-Based, Self-Checking, Fault-Tolerant Computers; Ultralow-Power Digital Correlator for Microwave Polarimetry; Grounding Headphones for Protection Against ESD; Lightweight Stacks of Direct Methanol Fuel Cells; Highly Efficient Vector-Inversion Pulse Generators; Estimating Basic Preliminary Design Performances of Aerospace Vehicles; Framework for Development of Object-Oriented Software; Analyzing Spacecraft Telecommunication Systems; Collaborative Planning of Robotic Exploration; Tools for Administration of a UNIX-Based Network; Preparing and Analyzing Iced Airfoils; Evaluating Performance of Components; Fuels Containing Methane of Natural Gas in Solution; Direct Electrolytic Deposition of Mats of MnxOy Nanowires; Bubble Eliminator Based on Centrifugal Flow; Inflatable Emergency Atmospheric-Entry Vehicles; Lightweight Deployable Mirrors with Tensegrity Supports; Centrifugal Adsorption Cartridge System; Ultrasonic Apparatus for Pulverizing Brittle Material; Transplanting Retinal Cells using Bucky Paper for Support; Using an Ultrasonic Instrument to Size Extravascular Bubbles; Coronagraphic Notch Filter for Raman Spectroscopy; On-the-Fly Mapping for Calibrating Directional Antennas; Working Fluids for Increasing Capacities of Heat Pipes; Computationally-Efficient Minimum-Time Aircraft Routes in the Presence of Winds; Liquid-Metal-Fed Pulsed Plasma Thrusters; Personal Radiation Protection System; and Attitude Control for a Solar-Sail Spacecraft.

CeSiCò - a new technology for lightweight and cost effective space instruments structures and mirrors

NASA Astrophysics Data System (ADS)

Devilliers, Christophe; Krödel, Matthias

2017-11-01

Alcatel Alenia Space and ECM have jointly developed a new ceramic material to produce lightweight, stiff, stable and cost effective structures and mirrors for space instrument the CesicÒ. Its intrinsic properties, added to ample manufacturing capabilities allow to manufacture stiff and lightweight cost effective mirrors and structure for space instruments. Different scale 1 flight representative CesicÒ optical structures have been manufactured and successfully tested under very strong dynamic environment and cryogenic condition down to 30K CesicÒ is also envisaged for large and lightweight space telescopes mirrors, a large CesicÒ 1 meter class mirror with an area mass of less than 25 Kg/m2 has been sized again launch loads and WFE performance and manufactured. CesicÒ applicability for large focal plane have been demonstrated through different scale 1 breadboards. Based on these successful results, AlcatelAleniaSpace and ECM are now in position to propose for space this technology with new innovative concepts thanks to the CesicÒ manufacturing capabilities. CesicÒ has therefore been selected for the structure and mirrors parts of a flight instrument payload and the manufacturing of the flight hardware is already underway. An high temperature high gain lightweight antenna breadboard is also under manufacturing for Bepi colombo mission. CesicÒ is therefore a good candidate for future challenging space instruments and is currently proposed for Japan and US space projects.

Low Cost Manufacturing Approach of High Temperature PMC Components

NASA Technical Reports Server (NTRS)

Kannmacher, Kevin

1997-01-01

The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

Experimental Investigation of the Effect of Manufactured Sand and Lightweight Sand on the Properties of Fresh and Hardened Self-Compacting Lightweight Concretes.

PubMed

Zhu, Yiyun; Cui, Hongzhi; Tang, Waiching

2016-08-29

Self-compacting lightweight concrete (SCLC) is a promising construction material for building applications, but most SCLCs today are made with river sand (RS). There is an increasing demand for environmental protection, as well as materials with a high strength/density ratio. The manufactured sand (MS) and lightweight sand (LS) as fine aggregates in cement-based composite materials have been receiving more attention among researchers. However, there is not much information about the effects of MS and LS on the properties of the fresh and hardened SCLCs. In this paper, the properties of fresh and hardened SCLC made with MS and LS were investigated by a series of experiments. SCLCs made with RS served as the control in this study. The test results show that increasing the sand ratio (from 0.40-0.50) decreased the filling ability and led to an increased T 50 time, which is the time spent for the concrete to reach the 500 mm spread circle, for all of the fresh SCLCs. Although the passing ability of MS-SCLCs and LS-SCLCs is not as good as RS-SCLCs, their results are still within an acceptable range. The ratio of mechanical properties to density was found to increase with an increase of the sand ratio for all of the hardened SCLCs. MS-SCLCs presented the highest compressive strength among all of the SCLCs studied. Although the mean compressive strength of LS-SCLCs is lower than those of the other two SCLCs by 8%, their strength to density ratio is higher than others by 15%, and the ratio increases remarkably with the increase of the sand ratio. Permeability test results showed that the permeability coefficient of MS-SCLC is remarkably lower than that of LS-SCLC, but slightly higher than that of RS-SCLC.

Experimental Investigation of the Effect of Manufactured Sand and Lightweight Sand on the Properties of Fresh and Hardened Self-Compacting Lightweight Concretes

PubMed Central

Zhu, Yiyun; Cui, Hongzhi; Tang, Waiching

2016-01-01

Self-compacting lightweight concrete (SCLC) is a promising construction material for building applications, but most SCLCs today are made with river sand (RS). There is an increasing demand for environmental protection, as well as materials with a high strength/density ratio. The manufactured sand (MS) and lightweight sand (LS) as fine aggregates in cement-based composite materials have been receiving more attention among researchers. However, there is not much information about the effects of MS and LS on the properties of the fresh and hardened SCLCs. In this paper, the properties of fresh and hardened SCLC made with MS and LS were investigated by a series of experiments. SCLCs made with RS served as the control in this study. The test results show that increasing the sand ratio (from 0.40–0.50) decreased the filling ability and led to an increased T50 time, which is the time spent for the concrete to reach the 500 mm spread circle, for all of the fresh SCLCs. Although the passing ability of MS-SCLCs and LS-SCLCs is not as good as RS-SCLCs, their results are still within an acceptable range. The ratio of mechanical properties to density was found to increase with an increase of the sand ratio for all of the hardened SCLCs. MS-SCLCs presented the highest compressive strength among all of the SCLCs studied. Although the mean compressive strength of LS-SCLCs is lower than those of the other two SCLCs by 8%, their strength to density ratio is higher than others by 15%, and the ratio increases remarkably with the increase of the sand ratio. Permeability test results showed that the permeability coefficient of MS-SCLC is remarkably lower than that of LS-SCLC, but slightly higher than that of RS-SCLC. PMID:28773857

21. VIEW OF THE SUPERCOMPACTOR. THE SUPERCOMPACTOR WAS USED TO ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

21. VIEW OF THE SUPERCOMPACTOR. THE SUPERCOMPACTOR WAS USED TO REDUCE THE VOLUME OF MISCELLANEOUS PLUTONIUM CONTAMINATED MATERIALS SUCH AS GLOVES, PAPER, AND LIGHTWEIGHT METALS. THESE MATERIALS WERE COMPACTED INTO A DRUM FOR DISPOSAL. (4/4/91) - Rocky Flats Plant, Plutonium Fabrication, Central section of Plant, Golden, Jefferson County, CO

Flexible Composite-Material Pressure Vessel

NASA Technical Reports Server (NTRS)

Brown, Glen; Haggard, Roy; Harris, Paul A.

2003-01-01

A proposed lightweight pressure vessel would be made of a composite of high-tenacity continuous fibers and a flexible matrix material. The flexibility of this pressure vessel would render it (1) compactly stowable for transport and (2) more able to withstand impacts, relative to lightweight pressure vessels made of rigid composite materials. The vessel would be designed as a structural shell wherein the fibers would be predominantly bias-oriented, the orientations being optimized to make the fibers bear the tensile loads in the structure. Such efficient use of tension-bearing fibers would minimize or eliminate the need for stitching and fill (weft) fibers for strength. The vessel could be fabricated by techniques adapted from filament winding of prior composite-material vessels, perhaps in conjunction with the use of dry film adhesives. In addition to the high-bias main-body substructure described above, the vessel would include a low-bias end substructure to complete coverage and react peak loads. Axial elements would be overlaid to contain damage and to control fiber orientation around side openings. Fiber ring structures would be used as interfaces for connection to ancillary hardware.

Progress on high-performance rapid prototype aluminum mirrors

NASA Astrophysics Data System (ADS)

Woodard, Kenneth S.; Myrick, Bruce H.

2017-05-01

Near net shape parts can be produced using some very old processes (investment casting) and the relatively new direct metal laser sintering (DMLS) process. These processes have significant advantages for complex blank lightweighting and costs but are not inherently suited for producing high performance mirrors. The DMLS process can provide extremely complex lightweight structures but the high residual stresses left in the material results in unstable mirror figure retention. Although not to the extreme intricacy of DMLS, investment casting can also provide complex lightweight structures at considerably lower costs than DMLS and even conventional wrought mirror blanks but the less than 100% density for casting (and also DMLS) limits finishing quality. This paper will cover the progress that has been made to make both the DMLS and investment casting processes into viable near net shape blank options for high performance aluminum mirrors. Finish and figure results will be presented to show performance commensurate with existing conventional processes.

Vibration behaviour of foamed concrete floor with polypropylene and rise husk ash fibre

NASA Astrophysics Data System (ADS)

Azaman, N. A. Mohd; Ghafar, N. H. Abd; Ayub, N.; Ibrahim, M. Z.

2017-11-01

In the history of the construction industry, lightweight concrete or foamed concrete is a special concrete which can very useful in the construction sector because it is very lightweight and it can compact by itself at each angle of foamwork. Foamed concrete is one of lightweight concrete which widely used for floor construction due to its light weight and economic. The significant challenges in the floor design process are considering the vibration that needs improvements for the poor dynamic behaviour insulation. An alternative material to replace sand with certain amount of rice husk ash (RHA) and polypropylene was introduced. Research was determine the dynamic behavior of foam-polypropylene and foam-RHA concrete by using impact hammer test. The natural frequency for normal foamed concrete, 0.5 % of Polypropylene and 15% of RHA is 29.8 Hz, 29.3 Hz and 29.5 Hz respectively.

Structurally Integrated Antenna Concepts for HALE UAVs

NASA Technical Reports Server (NTRS)

Cravey, Robin L.; Vedeler, Erik; Goins, Larry; Young, W. Robert; Lawrence, Roland W.

2006-01-01

This technical memorandum describes work done in support of the Multifunctional Structures and Materials Team under the Vehicle Systems Program's ITAS (Integrated Tailored Aero Structures) Project during FY 2005. The Electromagnetics and Sensors Branch (ESB) developed three ultra lightweight antenna concepts compatible with HALE UAVs (High Altitude Long Endurance Unmanned Aerial Vehicles). ESB also developed antenna elements that minimize the interaction between elements and the vehicle to minimize the impact of wing flexure on the EM (electromagnetic) performance of the integrated array. In addition, computer models were developed to perform phase correction for antenna arrays whose elements are moving relative to each other due to wing deformations expected in HALE vehicle concepts. Development of lightweight, conformal or structurally integrated antenna elements and compensating for the impact of a lightweight, flexible structure on a large antenna array are important steps in the realization of HALE UAVs for microwave applications such as passive remote sensing and communications.

Opto-thermal analysis of a lightweighted mirror for solar telescope.

PubMed

Banyal, Ravinder K; Ravindra, B; Chatterjee, S

2013-03-25

In this paper, an opto-thermal analysis of a moderately heated lightweighted solar telescope mirror is carried out using 3D finite element analysis (FEA). A physically realistic heat transfer model is developed to account for the radiative heating and energy exchange of the mirror with surroundings. The numerical simulations show the non-uniform temperature distribution and associated thermo-elastic distortions of the mirror blank clearly mimicking the underlying discrete geometry of the lightweighted substrate. The computed mechanical deformation data is analyzed with surface polynomials and the optical quality of the mirror is evaluated with the help of a ray-tracing software. The thermal print-through distortions are further shown to contribute to optical figure changes and mid-spatial frequency errors of the mirror surface. A comparative study presented for three commonly used substrate materials, namely, Zerodur, Pyrex and Silicon Carbide (SiC) is relevant to vast area of large optics requirements in ground and space applications.

An overview of carbon materials for flexible electrochemical capacitors.

PubMed

He, Yongmin; Chen, Wanjun; Gao, Caitian; Zhou, Jinyuan; Li, Xiaodong; Xie, Erqing

2013-10-07

Under the background of the quick development of lightweight, flexible, and wearable electronic devices in our society, a flexible and highly efficient energy management strategy is needed for their counterpart energy-storage systems. Among them, flexible electrochemical capacitors (ECs) have been considered as one of the most promising candidates because of their significant advantages in power and energy densities, and unique properties of being flexible, lightweight, low-cost, and environmentally friendly compared with current energy storage devices. In a common EC, carbon materials play an irreplaceable and principal role in its energy-storage performance. Up till now, most progress towards flexible ECs technologies has mostly benefited from the continuous development of carbon materials. As a result, in view of the dual remarkable highlights of ECs and carbon materials, a summary of recent research progress on carbon-based flexible EC electrode materials is presented in this review, including carbon fiber (CF, consisting of carbon microfiber-CMF and carbon nanofiber-CNF) networks, carbon nanotube (CNT) and graphene coatings, CNT and/or graphene papers (or films), and freestanding three-dimensional (3D) flexible carbon-based macroscopic architectures. Furthermore, some promising carbon materials for great potential applications in flexible ECs are introduced. Finally, the trends and challenges in the development of carbon-based electrode materials for flexible ECs and their smart applications are analyzed.

Amine terminated bisaspartimide polymer

NASA Technical Reports Server (NTRS)

Kumar, D. (Inventor); Fohlen, G. M. (Inventor); Parker, J. A. (Inventor)

1986-01-01

Novel amine terminated bisaspartimides are prepared by a Michael-type reaction of an aromatic bismalteimide and an aromatic diamine in an aprotic solvent. These bisaspartimides are thermally polymerized to yield tough, resinous polymers cross-lined through -NH- groups. Such polymers are useful in applications requiring materials with resistance to change at elevated temperatures, e.g., as lightweight laminates with graphite cloth, molding material prepregs, adhesives and insulating material.

Analysis of Lightweight Materials for the AM2 System

DTIC Science & Technology

2014-06-01

and fatigue behavior in magnesium alloys . Materials Science & Engineering A (Structural Materials: Properties , Microstructure and Processing ), v 434...Table 7. Tensile properties of the alloys AA2024 or the T3 and T81 temper designations (Kuo et al . 2005...using a powder metallurgy technique, such as a standard cold compacting press and sintering process . However, the fatigue life of the liquid-based

2016 Summer Series - Kenneth Cheung: Building Blocks for Aerospace Structures

NASA Image and Video Library

2016-06-16

Strong, ultra-lightweight materials are expected to play a key role in the design of future aircraft and space vehicles. Lower structural mass leads to improved performance, maneuverability, efficiency, range and payload capacity. Dr. Kenneth Cheung is developing cellular composite building blocks, or digital materials, to create transformable aerostructures. In his presentation, Dr. Cheung will discuss the implications of the digital materials and morphing structures.

A Method for Optimizing Lightweight-Gypsum Design Based on Sequential Measurements of Physical Parameters

NASA Astrophysics Data System (ADS)

Vimmrová, Alena; Kočí, Václav; Krejsová, Jitka; Černý, Robert

2016-06-01

A method for lightweight-gypsum material design using waste stone dust as the foaming agent is described. The main objective is to reach several physical properties which are inversely related in a certain way. Therefore, a linear optimization method is applied to handle this task systematically. The optimization process is based on sequential measurement of physical properties. The results are subsequently point-awarded according to a complex point criterion and new composition is proposed. After 17 trials the final mixture is obtained, having the bulk density equal to (586 ± 19) kg/m3 and compressive strength (1.10 ± 0.07) MPa. According to a detailed comparative analysis with reference gypsum, the newly developed material can be used as excellent thermally insulating interior plaster with the thermal conductivity of (0.082 ± 0.005) W/(m·K). In addition, its practical application can bring substantial economic and environmental benefits as the material contains 25 % of waste stone dust.

Superlight, Mechanically Flexible, Thermally Superinsulating, and Antifrosting Anisotropic Nanocomposite Foam Based on Hierarchical Graphene Oxide Assembly.

PubMed

Peng, Qingyu; Qin, Yuyang; Zhao, Xu; Sun, Xianxian; Chen, Qiang; Xu, Fan; Lin, Zaishan; Yuan, Ye; Li, Ying; Li, Jianjun; Yin, Weilong; Gao, Chao; Zhang, Fan; He, Xiaodong; Li, Yibin

2017-12-20

Lightweight, high-performance, thermally insulating, and antifrosting porous materials are in increasing demand to improve energy efficiency in many fields, such as aerospace and wearable devices. However, traditional thermally insulating materials (porous ceramics, polymer-based sponges) could not simultaneously meet these demands. Here, we propose a hierarchical assembly strategy for producing nanocomposite foams with lightweight, mechanically flexible, superinsulating, and antifrosting properties. The nanocomposite foams consist of a highly anisotropic reduced graphene oxide/polyimide (abbreviated as rGO/PI) network and hollow graphene oxide microspheres. The hierarchical nanocomposite foams are ultralight (density of 9.2 mg·cm -3 ) and exhibit ultralow thermal conductivity of 9 mW·m -1 ·K -1 , which is about a third that of traditional polymer-based insulating materials. Meanwhile, the nanocomposite foams show excellent icephobic performance. Our results show that hierarchical nanocomposite foams have promising applications in aerospace, wearable devices, refrigerators, and liquid nitrogen/oxygen transportation.

Carbon Fiber Mirror for a CubeSat Telescope

NASA Astrophysics Data System (ADS)

Kim, Young-Soo; Jang, Jeong Gyun; Kim, Jihun; Nam, Uk Won

2017-08-01

Telescope mirrors made by carbon fibers have been increasingly used especially for space applications, and they may replace the traditional glass mirrors. Glass mirrors are easy to fabricate, but needed to be carefully handled as they are brittle. Other materials have also been considered for telescope mirrors, such as metals, plastics, and liquids even. However glass and glass ceramics are still commonly and dominantly used.Carbon fiber has mainly been used for mechanical supports like truss structure and telescope tubes, as it is stiff and light-weight. It can also be a good material for telescope mirrors, as it has additional merits of non-brittle and very low thermal expansion. Therefore, carbon fiber mirror would be suitable for space telescopes which should endure the harsh vibration conditions during launch.A light-weight telescope made by carbon fiber has been designed for a small satellite which would have much less weight than conventional ones. In this poster, mirror materials are reviewed, and a design of carbon fiber telescope is presented and discussed.

Light-weight sandwich panel honeycomb core with hybrid carbon-glass fiber composite skin for electric vehicle application

NASA Astrophysics Data System (ADS)

Cahyono, Sukmaji Indro; Widodo, Angit; Anwar, Miftahul; Diharjo, Kuncoro; Triyono, Teguh; Hapid, A.; Kaleg, S.

2016-03-01

The carbon fiber reinforced plastic (CFRP) composite is relative high cost material in current manufacturing process of electric vehicle body structure. Sandwich panels consisting polypropylene (PP) honeycomb core with hybrid carbon-glass fiber composite skin were investigated. The aim of present paper was evaluate the flexural properties and bending rigidity of various volume fraction carbon-glass fiber composite skins with the honeycomb core. The flexural properties and cost of panels were compared to the reported values of solid hybrid Carbon/Glass FRP used for the frame body structure of electric vehicle. The finite element model of represented sandwich panel was established to characterize the flexural properties of material using homogenization technique. Finally, simplified model was employed to crashworthiness analysis for engine hood of the body electric vehicle structure. The good cost-electiveness of honeycomb core with hybrid carbon-glass fiber skin has the potential to be used as a light-weight alternative material in body electric vehicle fabricated.

RF beam transmission of x-band PAA system utilizing large-area, polymer-based true-time-delay module developed using imprinting and inkjet printing

NASA Astrophysics Data System (ADS)

Pan, Zeyu; Subbaraman, Harish; Zhang, Cheng; Li, Qiaochu; Xu, Xiaochuan; Chen, Xiangning; Zhang, Xingyu; Zou, Yi; Panday, Ashwin; Guo, L. Jay; Chen, Ray T.

2016-02-01

Phased-array antenna (PAA) technology plays a significant role in modern day radar and communication networks. Truetime- delay (TTD) enabled beam steering networks provide several advantages over their electronic counterparts, including squint-free beam steering, low RF loss, immunity to electromagnetic interference (EMI), and large bandwidth control of PAAs. Chip-scale and integrated TTD modules promise a miniaturized, light-weight system; however, the modules are still rigid and they require complex packaging solutions. Moreover, the total achievable time delay is still restricted by the wafer size. In this work, we propose a light-weight and large-area, true-time-delay beamforming network that can be fabricated on light-weight and flexible/rigid surfaces utilizing low-cost "printing" techniques. In order to prove the feasibility of the approach, a 2-bit thermo-optic polymer TTD network is developed using a combination of imprinting and ink-jet printing. RF beam steering of a 1×4 X-band PAA up to 60° is demonstrated. The development of such active components on large area, light-weight, and low-cost substrates promises significant improvement in size, weight, and power (SWaP) requirements over the state-of-the-art.

Composite Materials for Low-Temperature Applications

NASA Technical Reports Server (NTRS)

2008-01-01

Composite materials with improved thermal conductivity and good mechanical strength properties should allow for the design and construction of more thermally efficient components (such as pipes and valves) for use in fluid-processing systems. These materials should have wide application in any number of systems, including ground support equipment (GSE), lunar systems, and flight hardware that need reduced heat transfer. Researchers from the Polymer Science and Technology Laboratory and the Cryogenics Laboratory at Kennedy Space Center were able to develop a new series of composite materials that can meet NASA's needs for lightweight materials/composites for use in fluid systems and also expand the plastic-additive markets. With respect to thermal conductivity and physical properties, these materials are excellent alternatives to prior composite materials and can be used in the aerospace, automotive, military, electronics, food-packaging, and textile markets. One specific application of the polymeric composition is for use in tanks, pipes, valves, structural supports, and components for hot or cold fluid-processing systems where heat flow through materials is a problem to be avoided. These materials can also substitute for metals in cryogenic and other low-temperature applications. These organic/inorganic polymeric composite materials were invented with significant reduction in heat transfer properties. Decreases of 20 to 50 percent in thermal conductivity versus that of the unmodified polymer matrix were measured. These novel composite materials also maintain mechanical properties of the unmodified polymer matrix. These composite materials consist of an inorganic additive combined with a thermoplastic polymer material. The intrinsic, low thermal conductivity of the additive is imparted into the thermoplastic, resulting in a significant reduction in heat transfer over that of the base polymer itself, yet maintaining most of the polymer's original properties. Normal polymer processing techniques can turn these composite materials into unique, custom parts for ground support, Shuttle, and Constellation needs. We fabricated test specimens of the composite and base materials for thermal and mechanical characterization and found that the strength of the composite material at nominal-percentage loading remained relatively unchanged from the base material.

U.S. Army Technology Collaboration Briefing

DTIC Science & Technology

2012-09-11

engine boosting ( turbo chargers and super chargers), homogeneous charged compression, direct injection, etc. • Advanced light-weight materials...mitigation, recycling, and supply chain development. • Alternative fuels including biofuels, hydrogen, electricity, diesel , etc. • Vehicle

An Assessment of Technology for Turbojet Engine Rotor Failures

NASA Technical Reports Server (NTRS)

Witmer, E. A. (Editor)

1977-01-01

Design considerations, objectives, and approaches used in containing rotor burst debris are discussed. Methods are given for determining the fracture resistance of various materials used in providing lightweight shielding from fragment impact.

Physico-chemical characterization of mortars as a tool in studying specific hydraulic components: application to the study of ancient Naxos aqueduct

NASA Astrophysics Data System (ADS)

Maravelaki-Kalaitzaki, P.; Galanos, A.; Doganis, I.; Kallithrakas-Kontos, N.

2011-07-01

Mortars and plasters from the ancient aqueduct on the island of Naxos, Greece, were studied with regard to mineralogical and chemical composition, grain size distribution, raw materials and hydraulic properties, in order to assess their characteristics and design compatible repair mortars. The authentic materials contained lime, crushed-brick, siliceous and calcitic aggregates, in different proportions according to mortar type. Crushed-bricks fired at low temperatures and lightweight volcanic aggregates contained amorphous phases, which upon reaction with lime yielded hydraulic components capable of protecting the construction from the continuous presence of water. Hydraulic calcium silicate/aluminate hydrates, the proportions and the perfect packing of the raw materials, along with the diligent application justify the longevity and durability of the studied samples. The hydraulic properties of samples were pointed out through (a) the well-established CO2/H2O ratio derived from the thermogravimetric analysis and (b) by introducing two powerful indices issued from the chemical analysis, namely CaOhydr and soluble SiO2 hydr. These indices improved the clustering of hydraulic mortars and provided better correlation between mortars, plasters and their binders. By comparing grain size distribution and hydraulicity indices it was possible to distinguish among the construction phases. Based on this study, repair mortars were formulated by hydraulic lime, siliceous sand, calcareous and crushed-brick aggregates, with the optimal water content, ensuring optimum workability and compatible appearance with the authentic ones.

NEUTRON SHIELDING STRUCTURE

DOEpatents

Mattingly, J.T.

1962-09-25

A lightweight neutron shielding structure comprises a honeycomb core which is filled with a neutron absorbing powder. The honeycomb core is faced with parallel planar facing sheets to form a lightweight rigid unit. Suitable absorber powders are selected from among the following: B, B/sub 4/C, B/sub 2/O/ sub 3/, CaB/sub 6/, Li/sub 2/CO3, LiOH, LiBO/sub 2/, Li/s ub 2/O. The facing sheets are constructed of a neutron moderating material, so that fast neutrons will be moderated while traversing the facing sheets, and ultimately be absorbed by the absorber powder in the honeycomb. Beryllium is a preferred moderator material for use in the facing sheets. The advantage of the structure is that it combines the rigidity and light weight of a honeycomb construction with the neutron absorption properties of boron and lithium. (AEC)

NBL Pistol Grip Tool for Underwater Training of Astronauts

NASA Technical Reports Server (NTRS)

Liszka, Michael; Ashmore, Matthew; Behnke, Mark; Smith, Walter; Waterman, Tod

2011-01-01

A document discusses a lightweight, functional mockup of the Pistol Grip Tool for use during underwater astronaut training. Previous training tools have caused shoulder injuries. This new version is more than 50 percent lighter [in water, weight is 2.4 lb (=1.1 kg)], and can operate for a six-hour training session after 30 minutes of prep for submersion. Innovations in the design include the use of lightweight materials (aluminum and Delrin(Registered TradeMark)), creating a thinner housing, and the optimization of internal space with the removal of as much excess material as possible. This reduces tool weight and maximizes buoyancy. Another innovation for this tool is the application of a vacuum that seats the Orings in place and has shown to be reliable in allowing underwater usage for up to six hours.

Performance of lightweight large C/SiC mirror

NASA Astrophysics Data System (ADS)

Yui, Yukari Y.; Goto, Ken; Kaneda, Hidehiro; Katayama, Haruyoshi; Kotani, Masaki; Miyamoto, Masashi; Naitoh, Masataka; Nakagawa, Takao; Saruwatari, Hideki; Suganuma, Masahiro; Sugita, Hiroyuki; Tange, Yoshio; Utsunomiya, Shin; Yamamoto, Yasuji; Yamawaki, Toshihiko

2017-11-01

Very lightweight mirror will be required in the near future for both astronomical and earth science/observation missions. Silicon carbide is becoming one of the major materials applied especially to large and/or light space-borne optics, such as Herschel, GAIA, and SPICA. On the other hand, the technology of highly accurate optical measurement of large telescopes, especially in visible wavelength or cryogenic circumstances is also indispensable to realize such space-borne telescopes and hence the successful missions. We have manufactured a very lightweight Φ=800mm mirror made of carbon reinforced silicon carbide composite that can be used to evaluate the homogeneity of the mirror substrate and to master and establish the ground testing method and techniques by assembling it as the primary mirror into an optical system. All other parts of the optics model are also made of the same material as the primary mirror. The composite material was assumed to be homogeneous from the mechanical tests of samples cut out from the various areas of the 800mm mirror green-body and the cryogenic optical measurement of the mirror surface deformation of a 160mm sample mirror that is also made from the same green-body as the 800mm mirror. The circumstance and condition of the optical testing facility has been confirmed to be capable for the highly precise optical measurements of large optical systems of horizontal light axis configuration. Stitching measurement method and the algorithm for analysis of the measurement is also under study.

Polyimide/Glass Composite High-Temperature Insulation

NASA Technical Reports Server (NTRS)

Pater, Ruth H.; Vasquez, Peter; Chatlin, Richard L.; Smith, Donald L.; Skalski, Thomas J.; Johnson, Gary S.; Chu, Sang-Hyon

2009-01-01

Lightweight composites of RP46 polyimide and glass fibers have been found to be useful as extraordinarily fire-resistant electrical-insulation materials. RP46 is a polyimide of the polymerization of monomeric reactants (PMR) type, developed by NASA Langley Research Center. RP46 has properties that make it attractive for use in electrical insulation at high temperatures. These properties include high-temperature resistance, low relative permittivity, low dissipation factor, outstanding mechanical properties, and excellent resistance to moisture and chemicals. Moreover, RP46 contains no halogen or other toxic materials and when burned it does not produce toxic fume or gaseous materials. The U. S. Navy has been seeking lightweight, high-temperature-resistant electrical-insulation materials in a program directed toward reducing fire hazards and weights in ship electrical systems. To satisfy the requirements of this program, an electrical-insulation material must withstand a 3-hour gas-flame test at 1,600 F (about 871 C). Prior to the development reported here, RP46 was rated for use at temperatures from -150 to +700 F (about -101 to 371 C), and no polymeric product - not even RP46 - was expected to withstand the Navy 3-hour gas-flame test.

Designing optimized ultra-lightweighted mirror structures made of Cesic for space and ground based applications

NASA Astrophysics Data System (ADS)

Hofbauer, Peter; Krödel, Matthias R.

2010-07-01

Today's space applications increasingly utilize lightweighted construction concepts, motivated by the demands of manufacturing and functionality, and by economics. Particularly for space optics, mirror stability and stiffness need to be maximized, while mass needs to be minimized. Therefore, mirror materials must possess, besides high material strength and manufacturing versatility, high thermal conductivity combined with low heat capacity and long-term stability against varying thermal loads. Additionally, optical surfaces need to be compatible with reflective coating materials. In order to achieve these requirements, the interplay between material properties and mirror design on one hand, and budgetary constraints on the other must be considered. In this paper, we address these issues by presenting an FEM design study of open and closed-back mirror structures with extremely thin reinforcing ribs, with the goal of obtaining optimal physical and optical characteristics. Furthermore, we show that ECM's carbon-fiber reinforced SiC composite, Cesic®, and its newly developed, HB-Cesic® , with their low CTE, low density, and high stiffness, are not only excellent mirror materials, but allow the rapid manufacturing of complex monolithic optical structures at reasonable cost.

Investigation of Flat Clinching Process Combined with Material Forming Technology for Aluminum Alloy.

PubMed

Chen, Chao; Zhao, Shengdun; Han, Xiaolan; Wang, Yongfei; Zhao, Xuzhe

2017-12-15

In recent years, the use of aluminum alloy has tended to increase for building lightweight automobiles to reduce their automotive weight, which is helpful to save energy and protect the environment. In order to join aluminum alloy, a flat-clinching process combined with material forming technology was investigated to join aluminum alloy sheets using an experimental and a numerical method. Al1060 was chosen as the material of the sheet, and DEFORM-2D software was used to build the numerical model. After the numerical model was validated by the experimental results, the influences of punch diameter and holder force on the materials deforming behavior of the clinched joint were analyzed using the numerical model. Then, the material flow, joining ability, and joining quality were investigated to assess the clinched joint. The results showed that an increase in punch diameter could give rise to an increase in neck thickness and interlocking length, while an increase in blank holder force induced a decrease in interlocking length and an increase in neck thickness. The joining quality could be increased by increasing the forming force. It can be concluded that a clinched joint has better joining quality for joining light-weight sheets onto automotive structures.

Impact Resistance of Lightweight Hybrid Structures for Gas Turbine Engine Fan Containment Applications

NASA Technical Reports Server (NTRS)

Hebsur, Mohan G.; Noebe, Ronald D.; Revilock, Duane M.

2003-01-01

The ballistic impact resistance of hybrid composite sandwich structures was evaluated with the ultimate goal of developing new materials or structures for potential gas turbine engine fan containment applications. The sandwich structures investigated consisted of GLARE-5 laminates as face sheets with lightweight cellular metallic materials such as honeycomb, foam, and lattice block as a core material. The impact resistance of these hybrid sandwich structures was compared to GLARE-5 laminates and 2024-T3 Al sheet, which were tested as a function of areal weight (material thickness). The GLARE-5 laminates exhibited comparable impact properties to that of 2024-T3 Al at low areal weights, even though there were significant differences in the static tensile properties of these materials. The GLARE-5, however, did have a greater ballistic limit than straight aluminum sheet at higher areal weights. Furthermore, there is up to a 25% advantage in ballistic limit for the GLARE-5/foam sandwich structures compared to straight 2024-T3 Al. But no advantage in ballistic limit was observed between any of the hybrid sandwich structures and thicker versions of GLARE-5. Recommendations for future work are provided, based on these preliminary data.

Photonic Bandgap (PBG) Shielding Technology

NASA Technical Reports Server (NTRS)

Bastin, Gary L.

2007-01-01

Photonic Bandgap (PBG) shielding technology is a new approach to designing electromagnetic shielding materials for mitigating Electromagnetic Interference (EM!) with small, light-weight shielding materials. It focuses on ground planes of printed wiring boards (PWBs), rather than on components. Modem PSG materials also are emerging based on planar materials, in place of earlier, bulkier, 3-dimensional PBG structures. Planar PBG designs especially show great promise in mitigating and suppressing EMI and crosstalk for aerospace designs, such as needed for NASA's Constellation Program, for returning humans to the moon and for use by our first human visitors traveling to and from Mars. Photonic Bandgap (PBG) materials are also known as artificial dielectrics, meta-materials, and photonic crystals. General PBG materials are fundamentally periodic slow-wave structures in I, 2, or 3 dimensions. By adjusting the choice of structure periodicities in terms of size and recurring structure spacings, multiple scatterings of surface waves can be created that act as a forbidden energy gap (i.e., a range of frequencies) over which nominally-conductive metallic conductors cease to be a conductor and become dielectrics. Equivalently, PBG materials can be regarded as giving rise to forbidden energy gaps in metals without chemical doping, analogous to electron bandgap properties that previously gave rise to the modem semiconductor industry 60 years ago. Electromagnetic waves cannot propagate over bandgap regions that are created with PBG materials, that is, over frequencies for which a bandgap is artificially created through introducing periodic defects

Carbon Nanotube Coatings as Used in Strain Sensors for Composite Tanks

NASA Technical Reports Server (NTRS)

Trigwell, Steve; Snyder, Sarah; Hatfield, Walt; Dervishi, Enkeleda; Biris, Alexandru S.

2011-01-01

The next generation of cryogenic fuel tanks, crew habitats and other components for future spacecraft will focus on the usc of lightweight carbon fiber composite materials. A critical issue in the design and optimization of such tanks and structures will bc in structural health monitoring, however, current strain sensors have limitations. In this study, a novel carbon nanotube thin film was applied to carbon fiber composites for structural monitoring. Applying a load using a 3-point bend test to simulate bowing of a tank wall, induced significant increases in the film's electrical resistance at small deflections. Upon release of the load, the resistance returned to its approximate start value and was reproducible over multiple tests. The results show that a carbon nanotube thin film has great potential for the health monitoring of composite structures.

Reducing Weight for Transportation Applications: Technology Challenges and Opportunities

NASA Astrophysics Data System (ADS)

Taub, Alan I.

Today's land, sea and air transportation industries — as a business necessity — are focused on technology solutions that will make vehicles more sustainable in terms of energy, the environment, safety and affordability. Reducing vehicle weight is a key enabler for meeting these challenges as well as increasing payload and improving performance. The potential weight reductions from substituting lightweight metals (advanced high-strength steels, aluminum, magnesium and titanium alloys) are well established. For magnesium castings, weight savings of 60% have been reported [1]. The value of weight reduction depends on the transportation sector and ranges from about 5/kg saved for automobiles to over 500/kg saved for aircraft [2]. The challenge is to optimize the material properties and develop robust, high volume, manufacturing technologies and the associated supply chain to fabricate components and subsystems at the appropriate cost for each application.

Technology development program for an advanced microsheet glass concentrator

NASA Technical Reports Server (NTRS)

Richter, Scott W.; Lacy, Dovie E.

1990-01-01

Solar Dynamic Space Power Systems are candidate electrical power generating systems for future NASA missions. One of the key components in a solar dynamic power system is the concentrator which collects the sun's energy and focuses it into a receiver. In 1985, the NASA Lewis Research Center initiated the Advanced Solar Dynamic Concentrator Program with funding from NASA's Office of Aeronautics and Space Technology (OAST). The objectives of the Advanced Concentrator Program is to develop the technology that will lead to lightweight, highly reflective, accurate, scaleable, and long lived (7 to 10 years) space solar dynamic concentrators. The Advanced Concentrator Program encompasses new and innovative concepts, fabrication techniques, materials selection, and simulated space environmental testing. The Advanced Microsheet Glass Concentrator Program, a reflector concept, that is currently being investigated both in-house and under contract is discussed.

Development of Metal Matrix Composites for NASA's Advanced Propulsion Systems

NASA Technical Reports Server (NTRS)

Lee, J.; Elam, S.

2001-01-01

The state-of-the-art development of several Metal Matrix Composites (MMC) for NASA's advanced propulsion systems will be presented. The goal is to provide an overview of NASA-Marshall Space Flight Center's on-going activities in MMC components for advanced liquid rocket engines such as the X-33 vehicle's Aerospike engine and X-34's Fastrac engine. The focus will be on lightweight, low cost, and environmental compatibility with oxygen and hydrogen of key MMC materials, within each of NASA's new propulsion application, that will provide a high payoff for NASA's Reusable Launch Vehicles and space access vehicles. In order to fabricate structures from MMC, effective joining methods must be developed to join MMC to the same or to different monolithic alloys. Therefore, a qualitative assessment of MMC's welding and joining techniques will be outlined.

Mechanical performance and parameter sensitivity analysis of 3D braided composites joints.

PubMed

Wu, Yue; Nan, Bo; Chen, Liang

2014-01-01

3D braided composite joints are the important components in CFRP truss, which have significant influence on the reliability and lightweight of structures. To investigate the mechanical performance of 3D braided composite joints, a numerical method based on the microscopic mechanics is put forward, the modeling technologies, including the material constants selection, element type, grid size, and the boundary conditions, are discussed in detail. Secondly, a method for determination of ultimate bearing capacity is established, which can consider the strength failure. Finally, the effect of load parameters, geometric parameters, and process parameters on the ultimate bearing capacity of joints is analyzed by the global sensitivity analysis method. The results show that the main pipe diameter thickness ratio γ, the main pipe diameter D, and the braided angle α are sensitive to the ultimate bearing capacity N.

A Comparison of Brayton and Stirling Space Nuclear Power Systems for Power Levels from 1 Kilowatt to 10 Megawatts

NASA Technical Reports Server (NTRS)

Mason, Lee S.

2000-01-01

An analytical study was conducted to assess the performance and mass of Brayton and Stirling nuclear power systems for a wide range of future NASA space exploration missions. The power levels and design concepts were based on three different mission classes. Isotope systems, with power levels from 1 to 10 kW, were considered for planetary surface rovers and robotic science. Reactor power systems for planetary surface outposts and bases were evaluated from 10 to 500 kW. Finally, reactor power systems in the range from 100 kW to 10 mW were assessed for advanced propulsion applications. The analysis also examined the effect of advanced component technology on system performance. The advanced technologies included high temperature materials, lightweight radiators, and high voltage power management and distribution.

X-Aerogels for Structural Components and High Temperature Applications

NASA Technical Reports Server (NTRS)

2005-01-01

Future NASA missions and space explorations rely on the use of materials that are strong ultra lightweight and able to withstand extreme temperatures. Aerogels are low density (0.01-0.5 g/cu cm) high porosity materials that contain a glass like structure formed through standard sol-gel chemistry. As a result of these structural properties, aerogels are excellent thermal insulators and are able to withstand temperatures in excess of l,000 C. The open structure of aerogels, however, renders these materials extremely fragile (fracturing at stress forces less than 0.5 N/sq cm). The goal of NASA Glenn Research Center is to increase the strength of these materials by templating polymers and metals onto the surface of an aerogel network facilitating the use of this material for practical applications such as structural components of space vehicles used in exploration. The work this past year focused on two areas; (1) the research and development of new templated aerogels materials and (2) process development for future manufacturing of structural components. Research and development occurred on the production and characterization of new templating materials onto the standard silica aerogel. Materials examined included polymers such as polyimides, fluorinated isocyanates and epoxies, and, metals such as silver, gold and platinum. The final properties indicated that the density of the material formed using an isocyanate is around 0.50 g/cc with a strength greater than that of steel and has low thermal conductivity. The process used to construct these materials is extremely time consuming and labor intensive. One aspect of the project involved investigating the feasibility of shortening the process time by preparing the aerogels in the templating solvent. Traditionally the polymerization used THF as the solvent and after several washes to remove any residual monomers and water, the solvent around the aerogels was changed to acetonitrile for the templating step. This process took a couple of days. It was experimentally determined that the polymerization reaction could be done in acetonitrile instead of THF with no detrimental effects to the properties of the resulting aerogel. Other changes in the time needed to crosslink the gels in the isocyanate solution as well as changes to the subsequent washing procedure could also shorten the processing time with no effect on the properties. Processing methods were also developed that allowed a variety of shapes as well as sizes of these materials to be formed.

Broadband low-frequency sound isolation by lightweight adaptive metamaterials

NASA Astrophysics Data System (ADS)

Liao, Yunhong; Chen, Yangyang; Huang, Guoliang; Zhou, Xiaoming

2018-03-01

Blocking broadband low-frequency airborne noises is highly desirable in lots of engineering applications, while it is extremely difficult to be realized with lightweight materials and/or structures. Recently, a new class of lightweight adaptive metamaterials with hybrid shunting circuits has been proposed, demonstrating super broadband structure-borne bandgaps. In this study, we aim at examining their potentials in broadband sound isolation by establishing an analytical model that rigorously combines the piezoelectric dynamic couplings between adaptive metamaterials and acoustics. Sound transmission loss of the adaptive metamaterial is investigated with respect to both the frequency and angular spectrum to demonstrate their sound-insulation effects. We find that efficient sound isolation can indeed be pursued in the broadband bi-spectrum for not only the case of the small resonator's periodicity where only one mode relevant to the mass-spring resonance exists, but also for the large-periodicity scenario, so that the total weight can be even lighter, in which the multiple plate-resonator coupling modes appear. In the latter case, the negative spring stiffness provided by the piezoelectric stack has been utilized to suppress the resonance-induced high acoustic transmission. Such kinds of adaptive metamaterials could open a new approach for broadband noise isolation with extremely lightweight structures.