Ultra-lightweight Core Materials

Closeout Summary: Two of the here vendors were able to produce 1 sq. ft. metallic nanolattice (HRL) and carbon nanotube composite honeycomb (Orbital) core panels (flat and curved) which were furnished to NASA for testing. These vendors also furnished sandwich panels from these cores (not required in the contact). While not all of the KPPs were met, significant advancement of the technology was made. Orbital and HRL were able to produce core materials with mechanical properties that exceed those of 3 lb/ft3 aluminum honeycomb (KPPs based upon 6 lb/ft3. TRL elevated to 4. The objective of this project was to develop and mature high payoff nanotechnologies for future NASA mission with a focus on technologies that could lead to significant reductions in vehicle weight and improvements in performance. The project successfully developed high strength carbon nanotube composites and, for the first time, demonstrated them in a load-bearing component (composite overwrap pressure vessel) that was flight tested on a sounding rocket as part of a cold-gas thruster system. The project also developed polyimide aerogel insulation for electrical wiring that is 90% lighter than conventional polymer insulation and carbon nanotube and metal nanolattice cores for composite sandwich structures with properties that exceeded those of conventional aluminum honeycomb cores at the same density.