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Advanced Composites: Mechanical Properties and Hardware Programs for Selected Resin Matrix Materials

This design note presents typical mechanical properties tabulated from industrial and governmental agencies' test programs. All data are correlated to specific products and all of the best known products are presented. The data include six epoxies, eight polyimides and one polyquinoxaline matrix material. Bron and graphite are the fiber reinforcements. Included are forty-two summaries of advanced (resin matrix) composite programs in existence in the United States. It is concluded that the selection of appropriate matrices, the geometric manner in which the fibers are incorporated in the matrix and the durability of the bond between fiber and matrix establish the end properties of the composite material and the performance of the fabricated structure.

Welhart, E. K.↗

Stellar crystal X-ray spectroscopy on OSO-8

The large-area graphite crystal X-ray spectrometer on the OSO-8 satellite is described, and its response to stellar line and continuum radiation is discussed. A high resolution X-ray spectrum of Sco X-1 obtained from a preliminary analysis of quick look data shows a strong, smooth continuum with an absence of emission or absorption features over the energy range 2.2 to 8 keV. Upper limits are set on narrow line emission from highly ionized states of S, Ca, and Fe.

Kestenbaum, H. L.↗

The X-ray polarization experiment on the OSO-8

The OSO-8 satellite, launched on June 21, 1975 contains two X-ray polarimeters. These polarimeters use mosaic crystals of graphite to yield polarization-sensitive Bragg reflection of stellar X-rays. The crystals reflect a narrow energy bandwidth centered at 2.6 and 5.2 keV. The polarimeter background signal is minimized by mounting the crystals on parabolic surfaces which focus the diffracted X-rays onto small-area, beryllium-window proportional counters. This technique permits the observation of low-intensity X-ray sources and reduces the possibility of systematic background effects which could lead to a false signature of polarization. A description of the instrument is given, and the sensitivity to polarization, particularly in regard to binary sources, is discussed. Preliminary results for Cen X-3 and GX5-1 are presented.

Weisskopf, M. C.↗

Investigation of thermal fatigue in fiber composite materials

Graphite-epoxy laminates were thermally cycled to determine the effects of thermal cycles on tensile properties and thermal expansion coefficients of the laminates. Three 12-ply laminate configurations were subjected to up to 5,000 thermal cycles. The cumulative effect of the thermal cycles was determined by destructive inspection (electron micrographs and tensile tests) of samples after progressively larger numbers of cycles. After thermal cycling, the materials' tensile strengths, moduli, and thermal expansion coefficients were significantly lower than for the materials as fabricated. Most of the degradation of properties occurred after only a few cycles. The property degradation was attributed primarily to the progressive development of matrix cracks whose locations depended upon the layup orientation of the laminate.

Fahmy, A. A.↗

Fabrication of polycrystalline solar cells on low-cost substrates

A new method of producing p-n junction semiconductors for solar cells was described; the principal objective of this investigation is to reduce production costs significantly by depositing polycrystalline silicon on a relatively cheap substrate such as metallurgical-grade silicon, graphite, or steel. The silicon layer contains appropriate dopants, and the substrates are coated with a diffusion barrier of silica, borosilicate, phosphosilicate, or mixtures of these compounds.

Chu, T. L.↗

Advanced composites: Environmental effects on selected resin matrix materials

The effects that expected space flight environment has upon the mechanical properties of epoxy and polyimide matrix composites were analyzed. Environmental phenomena covered water immersion, high temperature aging, humidity, lightning strike, galvanic action, electromagnetic interference, thermal shock, rain and sand erosion, and thermal/vacuum outgassing. The technology state-of-the-art for graphite and boron reinforced epoxy and polyimide matrix materials is summarized to determine the relative merit of using composites in the space shuttle program. Resin matrix composites generally are affected to some degree by natural environmental phenomena with polyimide resin matrix materials less affected than epoxies.

Welhart, E. K.↗

A study to improve the mechanical properties of silicon carbide ribbon fibers

Preliminary deposition studies of SiC ribbon on a carbon ribbon substrate showed that the dominant strength limiting flaws were at the substrate surface. Procedures for making the carbon ribbon substrate from polyimide film were improved, providing lengths up to 450 meters (1,500 ft.) of flat carbon ribbon substrate 1,900 microns (75 mils) wide by 25 microns (1 mil) thick. The flaws on the carbon ribbon were smaller and less frequent than on carbon ribbon used earlier. SiC ribbon made using the improved substrate, including a layer of pyrolytic graphite to reduce further the severity of substrate surface flaws, showed strength levels up to the 2,068 MPa (300 Ksi) target of the program, with average strength levels over 1,700 MPa (250 Ksi) with coefficient of variation as low as 10% for some runs.

Debolt, H. E.↗

Reliability aspects of a composite bolted scarf joint

The design, fabrication, static test, and fatigue test of both tension and compression graphite-epoxy candidates for a wing splice representative of a next-generation transport aircraft was the objective of the reported research program. A single-scarf bolted joint was selected as the design concept. Test specimens were designed and fabricated to represent an upper-surface and a lower-surface panel containing the splice. The load spectrum was a flight-by-flight random-load history including ground-air-ground loads. The results of the fatigue testing indicate that, for this type of joint, the inherent fatigue resistance of the laminate is reflected in the joint behavior and, consequently, the rate of damage accumulation is very slow under realistic fatigue loadings.

Reed, D. L.↗

Structural design of space telescope

Problematic areas are discussed relative to the design of the NASA Large Space Telescope with a view toward showing how these areas are currently being treated so that the primary goals of the program can be met. The discussion covers basic mission, design parameters, metering structural material, and measurements of thermal expansion coefficient and scale testing. Since the test program has not been completed, there are so far no data available to show comparison between the baseline metering structure design and test. However, graphite-epoxy appears very favorable for structural uses, where precise alignment is necessary and a high degree of thermal stability is desired. It is anticipated that there will be a convergence on a straightforward method of arranging the basic structure for the ease of manufacturing and cost savings.

Arnts, G. W., Jr.↗

Direct observation of small cluster mobility and ripening

Direct evidence is reported for the simultaneous occurrence of Ostwald ripening and short-distance cluster mobility during annealing of discontinuous metal films on clean amorphous substrates. The annealing characteristics of very thin particulate deposits of silver on amorphized clean surfaces of single-crystalline thin graphite substrates have been studied by in situ transmission electron microscopy (TEM) under controlled environmental conditions in the temperature range from 25 to 450 C. It was possible to monitor all stages of the experiments by TEM observation of the same specimen area. Slow Ostwald ripening was found to occur over the entire temperature range, but the overriding surface transport mechanism was short-distance cluster mobility. This was concluded from in situ observations of individual particles during annealing and from measurements of cluster size distributions, cluster number densities, area coverages, and mean cluster diameters.

Heinemann, K.↗

Search for X-ray line emission from A0620-00

Measurements of the X-ray spectrum (1.85-7 keV) of A0620-00 obtained on 1975 October 17 and 1976 January 1-9 with the graphite crystal spectrometer on OSO-8 show a smooth continuum with an absence of emission lines. Upper limits are given for line emission from Si and S ions and are used to establish that the source is not optically thin. The results support a dense plasma model.

Kestenbaum, H. L.↗

Measurement of the X-ray polarization of the Crab Nebula

The graphite crystal X-ray polarimeters aboard the OSO-8 satellite were used to observe the Crab Nebula for six days from March 11 through March 17, 1976 (UT). Analysis of 15 orbits of quick-look data shows that the polarization and position angles at 2.6 and 5.2 keV are 15.7%(+ or - 1.5%) at 161.1(+ or - 2.8) deg and 18.3%(+ or - 4.2%) at 155.5(+ or - 6.6) deg, respectively. These results confirm the previous measurement and the hypothesis of synchrotron X-ray emission.

Weisskopf, M. C.↗

Chemistry of primitive solar material

The paper reviews chemical processes that occurred in the cooler outer regions of the primitive solar nebula (PSN) at the time of intimate chemical contact between the preplanetary condensate and the nebular gas. The elemental composition of the PSN is discussed, the 15 most abundant elements in it are listed, and numerical models of it are examined. Various condensation models are described and tested against observed properties of the planets, their satellites, and the asteroids. The chemistry of abundant volatile elements in the PSN is investigated along with stability limits of graphite in a solar-composition gas, regions of dominance of the most abundant carbon-containing gas species in the same gas, and implications of the moon's composition for its origin. Some theories that have been proposed as alternatives to the condensation models are noted.

Barshay, S. S.↗

Inexpensive silicon sheets for solar cells

Technique of producing silicon sheets by drawing gridlike or porous graphite gauze through silicon melt is readily adaptable to mass production, making process applicable to inexpensive manufacture of solar cell arrays.

Ciszek, T. F.↗

Stress concentration factors around a circular hole in laminated composites

Stress concentration factors around a circular hole in a composite laminate are determined. The specific case investigated is a four layer (-45/45/45/-45 degs) graphite epoxy laminate. The factors are determined experimentally by means of electrical resistance strain gages, and analytically by using a hybrid finite element analysis.

Ueng, C. E. S.↗

Advanced composite rudders for DC-10 aircraft: Design, manufacturing, and ground tests

Design synthesis, tooling and process development, manufacturing, and ground testing of a graphite epoxy rudder for the DC-10 commercial transport are discussed. The composite structure was fabricated using a unique processing method in which the thermal expansion characteristics of rubber tooling mandrels were used to generate curing pressures during an oven cure cycle. The ground test program resulted in certification of the rudder for passenger-carrying flights. Results of the structural and environmental tests are interpreted and detailed development of the rubber tooling and manufacturing process is described. Processing, tooling, and manufacturing problems encountered during fabrication of four development rudders and ten flight-service rudders are discussed and the results of corrective actions are described. Non-recurring and recurring manufacturing labor man-hours are tabulated at the detailed operation level. A weight reduction of 13.58 kg (33 percent) was attained in the composite rudder.

Lehman, G. M.↗

PMR polyimide/graphite fiber composite fan blades

Ultrahigh speed fan blades, designed in accordance with the requirements of an ultrahigh tip speed blade axial flow compressor, were fabricated from a high strength graphite fiber tow and a PMR polyimide resin. The PMR matrix was prepared by combining three monomeric reactants in methyl alcohol, and the solution was applied directly to the reinforcing fiber for subsequent in situ polymerization. Some of the molded blades were completely finished by secondary bonding of root pressure pads and an electroformed nickel leading edge sheath prior to final machining. The results of the spin testing of nine PMR fan blades are given. Prior to blade fabrication, heat resin tensile properties of the PMR resin were examined at four formulated molecular weight levels. Additionally, three formulated molecular weight levels were investigated in composite form with both a high modulus and a high strength fiber, both as-molded and postcured, in room temperature and 232 C transverse tensile, flexure and short beam shear. Mixed fiber orientation panels simulating potential blade constructions were also evaluated. Flexure tests, short beam shear tests, and tensile tests were conducted on these angle-plied laminates.

Cavano, P. J.↗

Preliminary evaluation of fiber composite reinforcement of truck frame rails

The use of graphite fiber/resin matrix composite to effectively reinforce a standard steel truck frame rail is studied. A preliminary design was made and it was determined that the reinforcement weight could be reduced by a factor of 10 when compared to a steel reinforcement. A section of a 1/3 scale reinforced rail was fabricated to demonstrate low cost manufacturing techniques. The scale rail section was then tested and increased stiffness was confirmed. No evidence of composite fatigue was found after 500,000 cycles to a fiber stress of 34,000 psi. The test specimen failed in bending in a static test at a load 50 percent greater than that predicted for a non-reinforced rail.

Faddoul, J. R.↗

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