SBIR-STTR Award

We propose an innovative hybrid composite that combines the smart energy-absorbing shear thickening fluids (STF) with validated hard upper torso composite materials to create new STF composite structures with superior impact and damage resistance and self-healing functionality. The proposed innovation directly addresses the subtopic H04.01 need for thin, lightweight composite materials that can be fabricated in complex geometries. STFs are currently being developed by NASA and STF Technologies LLC for use in enhanced puncture and MMOD protective softgoods to improve astronaut survivability. Here, we propose to exploit the unique energy-absorbing properties of shear thickening fluids and prior work by the team, which developed advanced energy absorbing STF materials for sports and military applications, to meet the challenge metrics of a pressure structure composite capable of withstanding 300J of energy in low velocity impact with a structural density of 1.7 g/cm3 or less and thickness of 0.125" or less. The proposed work will combine experiments and modeling to determine the optimal integration of STF with the current best composite materials in the Z-2 suit prototype. The project will leverage the Z-2 suit specific expertise of our partners at UD's Center for Composite Materials (UD-CCM) to develop and test concepts and advance the TRL of new lightweight, damage-tolerant and potentially self-healing hybrid composites. The conformable nature of the STF is amenable to fabrication of complex curved geometries, while the flowable STF within the hybrid laminate can offer healing and leak mitigation after damage. Rapid prototyping, downselection, and validation will be performed in collaboration with UD-CCM, commercialization partners, and NASA scientists and engineers through a combined computational/experimental program with feedback refinement that exploits the unique expertise of all teams.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) The proposed advanced hybrid STF composites are of value for a range of space and ground-based applications. NASA commercial applications of the STF composites include use in the hard upper torso (HUT) of advanced exploration suits. Impact-resistant, damage-tolerant STF hybrid composite materials are directly applicable to the development of a planetary exploration suit (Z-2) that can withstand a variety of operational mishaps, including falling onto rocks or other accidental impact. Additional NASA applications could include use as advanced composites to improve the durability and damage tolerance of storage tanks on vehicles or surface habitats, vehicle components, helmets, or other hard components that can benefit from the combination of lightweight, impact-resistance with the potential leak mitigation mode provided by STF.

Potential NON-NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) The growing market for carbon fiber and fiberglass composites represents a substantial market opportunity for STF composite materials offering improved impact resistance and damage tolerance. The overall glass fiber reinforced panel market is expected to grow to $84 billion globally by 2026 (MarketsAndMarkets, 2015). The carbon fiber reinforced composite market is projected at $20 billion+ in 2024 (Sinha, 2016). Applications include:1.Automotive: an all composite B-pillar was recently demonstrated by researchers at UD CCM under a collaboration with BMW. Carbon fiber composites are also seeing increased demand in automotive due to the desire for increased fuel economy and growing demand for electric vehicles.2.Storage tanks for water, chemical process, oil and gas industries3.Marine4.Aerospace5.Consumer sporting goods -a $2.6 billion dollar market (Grand View Research, 2016) for reinforced composites that includes a number of products that can potentially benefit from improved impact and damage tolerance, such as skis, snowboards, surfboards, bicycle frames, tennis rackets, hockey and lacrosse sticks, helmets, and protective equipment6.Power generation - increasing demand for wind turbine blades is major driver of growth in the fiberglass and carbon fiber reinforced composite market. Composite materials with damage tolerance and tunable damping properties have applications in large- and small-scale generation infrastructure.7.Construction and building materials

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Composites Destructive Testing Fluids Isolation/Protection/Shielding (Acoustic, Ballistic, Dust, Radiation, Thermal) Models & Simulations (see also Testing & Evaluation) Pressure & Vacuum Systems Protective Clothing/Space Suits/Breathing Apparatus Simulation & Modeling Smart/Multifunctional Materials Structures

We propose an innovative hybrid composite material containing shear thickening fluid (STF) Energy Absorbing Layers (SEALs) that provides superior impact protection and novel, self-healing functionality to prevent leakage after impact. The proposed innovation directly addresses the need for thin, lightweight, impact-resistant composite materials that can be fabricated in complex geometries for next-generation space suits. The proposed Phase II research leverages successful Phase I R&D and extensive composite materials and space suit expertise of our partners to advance commercialization and TRL of impact-resistant, damage-tolerant SEAL-composites innovation to produce a prototype suit component suitable for system-level integration and testing. In Phase I it was shown that the SEAL-composites provide significantly improved impact properties and weight savings vs. leading conventional composite materials from the Z-2 prototype. Futhermore, SEAL-composites impart self-healing functionality to mitigate air leakage if damaged. The Phase II objectives and work plan follow a logical sequence to test and downselect improved SEAL-composite materials, to develop and validate a computational model and conduct model-based design optimization, to develop high-fidelity test methods, to refine the manufacturing process to make aerospace-grade SEAL-composites, and to deliver a validated suit prototype component made from SEAL-composites. Further, we will leverage synergistic environmental protection garment (EPG) research being conducted at STF Technologies and the University of Delaware to perform system-level development and optimization of the SEAL-composites combined with emerging, state-of-the-art EPGs. Overall, the proposed Phase II will produce a validated SEAL-composite prototype suit component meeting the needs for improved impact-resistance and damage-tolerance to offer superior astronaut protection in a wide range of future Martian and Lunar surface EVA scenarios.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) The primary target market for the proposed SEAL-composites innovation is in the composite portions of advanced xEMU and mEMU suits for future surface exploration missions. Specifically, the hybrid materials and design of the SEAL-composites provide significant increases in impact-resistance and damage-tolerance as compared to conventional composite materials. Phase I results found that the SEAL-composites tolerate 50% more impact energy without sustaining damage resulting in leakage and were 11% lighter than monolithic designs using the materials developed in the prior Z-2 prototype project. The improved durability and self-healing functionality at reduced weight of the SEAL-composites is useful for increasing the reliability of other composite structures and applications including storage tanks, habitats, or surface exploration vehicle components.



Potential NON-NASA Commercial Applications:
:
(Limit 1500 characters, approximately 150 words) The growing market for carbon fiber and fiberglass composites represents a substantial market opportunity for STF composite materials offering improved impact resistance and damage tolerance. Improvement of out-of-plane impact resistance can potentially improve the durability and utility of composite materials in a wide variety of applications and industries including: 1. Automotive - an all composite B-pillar was recently demonstrated by researchers at UD CCM under a collaboration with BMW. Carbon fiber composites are also seeing increased demand in automotive due to the desire for increased fuel economy and growing demand for electric vehicles. 2. Personal Protective Equipment (PPE), including composite armor and shielding for first responders 3. Storage tanks for water, chemical process, oil and gas industries 4. Aerospace 5. Consumer sporting goods - skis, snowboards, surfboards, bicycle frames, tennis rackets, hockey and lacrosse sticks, helmets, and protective equipment 6. Power generation-increasing demand for wind turbine blades is major driver of growth in the fiberglass and carbon fiber reinforced composite market. Composite materials with damage tolerance and tunable damping properties have applications in large- and small-scale generation infrastructure. 7. Construction and building materials - building cladding, decking 8. Marine

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Characterization Composites Destructive Testing Models & Simulations (see also Testing & Evaluation) Nanomaterials Nondestructive Evaluation (NDE; NDT) Processing Methods Protective Clothing/Space Suits/Breathing Apparatus Smart/Multifunctional Materials Textiles