Performance of Waterless Concrete

The development of permanent lunar bases is constrained by performance of construction materials and availability of in-situ resources. Concrete seems a suitable construction material for the lunar environment, but water, one of its major components, is an extremely scarce resource on the Moon. This study explores an alternative to hydraulic concrete by replacing the binding mix of concrete (cement and water) with sulfur. Sulfur is a volatile element on the lunar surface that can be extracted from lunar soils by heating. Sulfur concrete mixes were prepared to investigate the effect of extreme environmental conditions on the properties of sulfur concrete. A hypervelocity impact test was conducted, having as its target a 5-cm cubic sample of sulfur concrete. This item consisted of JSC-1 lunar regolith simulant (65%) and sulfur (35%). The sample was placed in the MSFC Impact Test Facility s Micro Light Gas Gun target chamber, and was struck by a 1-mm diameter (~1.4e-03 g) aluminum projectile at 5.85 km/s. In addition, HZTERN code, provided by NASA was used to study the effectiveness of sulfur concrete when subjected to space radiation

MATRIX DESIGN FOR STRATEGICALLY TUNED ABSOLUTELY RESILIENT STRUCTURES (STARS)

ABSTRACT This paper discusses Strategically Tuned Absolutely Resilient Structures (STARS) and steps taken to improve their performance by developing lightweight, high-performance cementitious composites that rely on the interfacial bonding between the aggregate [Poly(vinyl butyral) (PVB)] and reinforcement [Poly(vinyl alcohol) (PVA) fiber]. PVB is selected because it is light weight, adheres well to a variety of surfaces, and has good energy-absorbing characteristics. PVA fiber is used because it has a high tensile strength and bonds well with the cementitious matrix. We show that standard mortar techniques and components can produce relatively high strength flexible mortars without any hard aggregate at all. These mortars are not related to macro defect free cements which are usually prepared with very low w/c ratios and soluble polymers that do not act as aggregates; nor, are these mortars polymer concretes which use a cross linking polymer replacement for Portland cement. A comprehensive trial and error mix design process was followed to arrive at a fiber-free baseline mix having a low density of 1548 kg/m 3 (96.6 lb/ft 3 ) and an average compressive strength of 40 MPa (5800 psi). Mechanical properties such as the compressive strength, flexural strength, ductility, fracture toughness, and impact resistance are evaluated as fibers are added. Results show that the compressive strength decreases slightly with increasing fiber volume fraction whereas flexural strength, ductility, fracture toughness, and impact resistance increase

Mechanical Properties and Durability of "Waterless Concrete"

Waterless concrete consists of molten elementary sulfur and aggregate. The aggregates in lunar environment will be lunar rocks and soil. Sulfur is present on the Moon in Troilite soil (FeS) and by oxidation soil iron and sulfur can be produced. Iron can be used to reinforce the sulfur concrete. Sulfur concrete specimens were cycled between liquid nitrogen (approximately 191 C) and room temperature (approximately 21 C) to simulate exposure to a lunar environment. Cycled and control specimens were subsequently tested in compression at room temperatures (approximately 21 C) and approximately 101 C. Test results showed that due to temperature cycling, compressive strength of cycled specimens was 20% of those non-cycled. Microscopic examination of the fracture surfaces from the cycled samples showed clear de-bonding of the sulfur from the aggregate material whereas it was seen well bonded in those non-cycled. This reduction in strength can be attributed to the large differences in thermal coefficients of expansion of the materials constituting the concrete which promoted cracking. Similar sulfur concrete mixtures were strengthened with short and long glass fibers. The glass fibers from lunar regolith simulant was melted in a 25 cc Pt-Rh crucible in a Sybron Thermoline high temperature MoSi2 furnace at melting temperatures of 1450 to 1600 C for times of 30 min to 1 hour. Glass fibers were cast from the melt into graphite crucibles and were annealed for a couple of hours at 600 C. Glass fibers and small rods were pulled from the melt. The glass melt wets the ceramic rod and long continuous glass fibers were easily hand drawn. The glass fibers were immediately coated with a protective polymer to maintain the mechanical strength. The glass fibers were used to reinforce sulfur concrete plated to improve the flexural strength of the sulfur concrete. Prisms beams strengthened with glass fibers were tested in 4-point bending test. Beams strengthened with glass fiber showed to exhibit an increase in the flexura strength by as much as 45%

Bending, Free Vibration, and Buckling Analysis of Functionally Graded Porous Micro-Plates Using a General Third-Order Plate Theory

Static bending, free vibration and buckling of functionally graded porous micro-plates are investigated using a general third order plate theory. In addition, analytical solutions are obtained using the Navier method. The effect of the material length scale factor and the variation of material property through the thickness direction of plates are considered as well as porosity effects. Three different porosity distributions are considered and the effects of porosity variations are examined in the framework of a general third order plate theory. Numerical results show that the effect of each distribution of porosity is distinguished due to coupling between the heterogeneity of the material properties and the variation of porosity

Sulfur "Concrete" for Lunar Applications - Sublimation Concerns

Melting sulfur and mixing it with an aggregate to form "concrete" is commercially well established and constitutes a material that is particularly well-suited for use in corrosive environments. Discovery of the mineral troilite (FeS) on the moon poses the question of extracting the sulfur for use as a lunar construction material. This would be an attractive alternative to conventional concrete as it does not require water. However, the viability of sulfur concrete in a lunar environment, which is characterized by lack of an atmosphere and extreme temperatures, is not well understood. Here it is assumed that the lunar ore can be mined, refined, and the raw sulfur melded with appropriate lunar regolith to form, for example, bricks. This study evaluates pure sulfur and two sets of small sulfur concrete samples that have been prepared using JSC-1 lunar stimulant and SiO2 powder as aggregate additions. Each set was subjected to extended periods in a vacuum environment to evaluate sublimation issues. Results from these experiments are presented and discussed within the context of the lunar environment

Fatigue Stress-Life Model of RC Beams Based on an Accelerated Fatigue Method

Several standard fatigue testing methods are used to determine the fatigue stress-life prediction model (S-N curve) and the endurance limit of Reinforced Concrete (RC) beams, including the application of constant cyclic tension-tension loads at different stress or strain ranges. The standard fatigue testing methods are time-consuming and expensive to perform, as a large number of specimens is needed to obtain valid results. The purpose of this paper is to examine a fatigue stress-life predication model of RC beams that are developed with an accelerated fatigue approach. This approach is based on the hypothesis of linear accumulative damage of the Palmgren–Miner rule, whereby the applied cyclic load range is linearly increased with respect to the number of cycles until the specimen fails. A three-dimensional RC beam was modeled and validated using ANSYS software. Numerical simulations were performed for the RC beam under linearly increased cyclic loading with different initial loading conditions. A fatigue stress-life model was developed that was based on the analyzed data of three specimens. The accelerated fatigue approach has a higher rate of damage accumulations than the standard testing approach. All of the analyzed specimens failed due to an unstable cracking of concrete. The developed fatigue stress-life model fits the upper 95% prediction band of RC beams that were tested under constant amplitude cyclic loading

Modeling Damage in Concrete Pavements and Bridges

Sponsoring Agency Code Supplementary Notes Abstract This project focused on micromechanical modeling of damage in concrete under general, multi-axial loading. A continuum-level, three-dimensional constitutive model based on micromechanics was developed. The model accounts for damage in concrete by statistically averaging the response (opening and shear) of an ensemble of microcracks under a three-dimensional stress state. The model is implemented in ABAQUS analysis code and can be utilized by ALDOT engineers to make an informed assessment of the damage in concrete pavements and bridges. 17

Lunar Contour Crafting: A Novel Technique for ISRU-Based Habitat Development

As the nation prepares to return to the Moon, it is apparent that the viability of long duration visits with appropriate radiation shielding/crew protection, hinges on the development of Lunar structures, preferably in advance of a manned landing, and preferably utilizing in-situ resources. Contour Crafting is a USC-patented technique for automated development of terrestrial concrete-based structures. The process is relatively fast, completely automated, and supports the incorporation of various infrastructure elements such as plumbing and electrical wiring. This paper will present a conceptual design of a Lunar Contour Crafting system designed to autonomously fabricate integrated structures on the Lunar surface using high-strength concrete based on Lunar regolith, including glass reinforcement rods or fibers fabricated from melted regolith. Design concepts will be presented, as well as results of initial tests aimed at concrete and glass production using Lunar regolith simulant. Key issues and concerns will be presented, along with design concepts for an LCC testbed to be developed at MSFC's Prototype Development Laboratory (PDL)