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NASA NTRS2022

Life Support Baseline Values and Assumptions Document

The Life Support Baseline Values and Assumptions Document (BVAD) provides analysts, modelers, and other life support researchers with a common set of values and assumptions which can be used as a baseline in their studies. This baseline, in turn, provides a common point of origin from which many studies in the community may depart, making research results easier to compare and providing researchers with reasonable values to assume for areas outside their experience. With the ability to accurately compare different technologies’ performance for the same function, managers will be able to make better decisions regarding technology development.

ECLSS↗

NASA NTRS1993

Unsteady Flow Simulations in Support of the SSME HEX Turning Vane Cracking Investigation with the ATD HPOTP

Unsteady flow computations are being performed with the P&W (ATD) and the Rocketdyne baseline configurations of the SSME LO2 turbine turnaround duct (TAD) and heat exchanger (HEX). The work is in support of the HEX inner turning vane cracking investigation. Fatigue cracking has occurred during hot firings with the P&W configuration on the HEX inner vane, and it appears the fix will involve changes to the TAD splitter vane position and to the TAD inner wall curvature to reduce the dynamic loading on the inner vane. Unsteady flow computations on the P&W baseline and fix and on the Rocketdyne baseline reference follow steady-flow screening computations done by MSFC/ED32 on several trial configurations arriving at the fix. The P&W TAD inlet velocity profile has a strong radial velocity component that directs the flow toward the inner wall and raises the local velocity a factor of two and the dynamic pressure a factor, of four. The fix is intended to redistribute the flow more evenly across the HEX inner and outer vanes like the Rocketdyne baseline reference. Vane buffeting at frequencies around 4,000 Hz is the leading suspected cause of the problem. Our simulations (work in progress) are being done with the USA 2D axisymmetric code approximating the flow as axisymmetric u+v 2D (axial, u, and radial, v, components only). The HEX coils are included in the model to make sure the fix does not adversely affect the HEX environment. Turbulent kinetic energy, k, levels where k = 1/2 v' rms2 are locally as high as 10,000 ft2/sec2 for the P&W baseline at the engine interface (between the TAD and HEX) at the HEX inner vane location. However, k is less than 8,000 on the HEX outer vane and only about 4,500 on the HEX inner vane for the Rocketdyne baseline. Unsteady turbulence intensity, v'rms/v, and pressure, p', are being computed in the present computations to compare with steady-flow Reynolds-averaged computations where p'rms = const (pk) for overall rms random turbulence from 0.1 to 12,000 Hz frequency. Random overall static, p'rms fluctuations as large as 1.7 psi are estimated from k on the HEX inner vane for the P&W baseline configuration but only about 0.7 psi for the Rocketdyne configuration.

Dougherty, N. S.↗

NASA NTRS2007

A Process for Producing Highly Wettable Aluminum 6061 Surfaces Compatible with Hydrazine

NASA's Global Precipitation Measurement (GPM) mission is an ongoing Goddard Space Flight Center (GSFC) project whose basic objective is to improve global precipitation measurements. The space-based portion of the mission architecture consists of a primary or core spacecraft and a constellation of NASA and contributed spacecrafts. The efforts described in this paper refer to the core spacecraft (hereafter referred to as simply GPM) which is to be fabricated at GSFC. It has been decided that the GPM spacecraft is to be a "design-for-demise-spacecraft." This requirement resulted in the need for a propellant tank that would also demise or ablate to an appropriate degree upon re-entry. Composite overwrapped aluminum lined propellant tanks with aluminum propellant management devices (PMD) were shown by analyses to demise and thus became the baseline configuration for GPM. As part of the GPM tank development effort, long term compatibility and wettability testing with hydrazine was performed on Al6061 and 2219 coupons fabricated and cleaned by conventional processes. Long term compatibility was confirmed. However, the wettability of the aluminum as measured by contact angle produced higher than desired angles (greater than 30 deg.) with excessive scatter. The availability of PMD materials exhibiting consistently low contact angles aids in the design of simple PMDs. Two efforts performed by Angeles Crest Engineering and funded by GSFC were undertaken to reduce the risk of using aluminum for the GPM PMD. The goal of the first effort was to develop a cleaning or treatment process to produce consistently low contact angles. The goal of the second effort was to prove via testing that the processed aluminum would retain compatibility with hydrazine and retain low contact angle after long term exposure to hydrazine. Both goals were achieved. This paper describes both efforts and the results achieved.

Moore, N. R.↗

NASA NTRS2017

Thermal Protection for Mars Sample Return Earth Entry Vehicle: A Grand Challenge for Design Methodology and Reliability Verification

Mars Sample Return is our Grand Challenge for the coming decade. TPS (Thermal Protection System) nominal performance is not the key challenge. The main difficulty for designers is the need to verify unprecedented reliability for the entry system: current guidelines for prevention of backward contamination require that the probability of spores larger than 1 micron diameter escaping into the Earth environment be lower than 1 million for the entire system, and the allocation to TPS would be more stringent than that. For reference, the reliability allocation for Orion TPS is closer to 11000, and the demonstrated reliability for previous human Earth return systems was closer to 1100. Improving reliability by more than 3 orders of magnitude is a grand challenge indeed. The TPS community must embrace the possibility of new architectures that are focused on reliability above thermal performance and mass efficiency. MSR (Mars Sample Return) EEV (Earth Entry Vehicle) will be hit with MMOD (Micrometeoroid and Orbital Debris) prior to reentry. A chute-less aero-shell design which allows for self-righting shape was baselined in prior MSR studies, with the assumption that a passive system will maximize EEV robustness. Hence the aero-shell along with the TPS has to take ground impact and not break apart. System verification will require testing to establish ablative performance and thermal failure but also testing of damage from MMOD, and structural performance at ground impact. Mission requirements will demand analysis, testing and verification that are focused on establishing reliability of the design. In this proposed talk, we will focus on the grand challenge of MSR EEV TPS and the need for innovative approaches to address challenges in modeling, testing, manufacturing and verification.

Design and Verification for Reliability↗

NASA NTRS2020

Pterodactyl: Development and Comparison of Control Architectures for a Mechanically Deployed Entry Vehicle

The Pterodactyl project, seeks to advance the current state-of-the-art for entry vehicles by developing novel guidance and control technologies for Deployable Entry Vehicles (DEVs) that can be applied to various entry vehicle configurations. This paper details the efforts on the NASA-funded Pterodactyl project to investigate and implement multiple control techniques for an asymmetric mechanical DEV. We design multiple control architectures for a Pterodactyl Baseline Vehicle (PBV) and evaluate their performance in achieving varying guidance commands during entry. The control architectures studied are (i) propulsive control systems such as reaction control systems and (ii) non-propulsive control systems such as aerodynamic control surfaces and internal moving masses. For each system, state-feedback integral controllers based on linear quadratic regulator (LQR) optimal control methods are designed to track guidance commands of either (i) bank angle or (ii) angle of attack and sideslip angle as determined by the desired guidance trajectory. All control systems are compared for a lunar return reference mission and by providing a comparative analysis of these systems, configurations, and performance, the efforts detailed in this paper and the Pterodactyl project as a whole will help entry vehicle system designers determine suitable control architectures for integration with DEVs and other entry vehicle types.

Okolo, Wendy A.↗

NASA NTRS1984

Determining highly elliptical earth orbits with VLBI and Delta-VLBI

This paper shows the feasibility of using Very Long Baseline Interferometric (VLBI) data acquired by the Deep Space Network to navigate highly elliptical earth orbiting satellites. The planned mission orbit of the Ion Release Module of the Active Magnetospheric Particle Tracer Explorers is used as a reference for developing strategies and provides the first opportunity for a possible flight demonstration with a spacecraft in a highly elliptical orbit. The navigation accuracy improvements achievable with VLBI and Delta-VLBI data types are determined for comparison with the capabilities of a reference Doppler strategy. The results show that strategies using wideband Delta-VLBI measurements taken near periapse perform best, determining apoapse position to an order of magnitude better than conventional Doppler, while also substantially reducing the required antenna support.

Frauenholz, R. B.↗

NASA NTRS1999

Summary of HEAT 1 Aeroacoustics Installation Effects

A critical part of the NASA High-Speed Research (HSR) program is the demonstration of satisfactory suppression of the jet noise present at low airspeeds. One scheme for reducing jet exhaust noise generated by a future High-Speed Civil Transport (HSCT) is the use of a mixer/ ejector system which would entrain large quantities of ambient air into the exhaust flow from the powerplant in order to cool and slow the jet exhaust before it leaves the tailpipe. Of the variety of factors which can affect the noise suppression characteristics of the mixer/ejector system, the influence of the wing flow field and high-lift devices is not well understood. The effectiveness of the noise suppression device must be evaluated in the presence of the wing/high-lift system before definitive assessments can be made concerning HSCT noise. Of nearly equal importance is the evaluation of the performance of the high-lift system(s) in the presence of realistic propulsion units which feature high ambient flow entrainment rates and jet thrust coefficients. These noise suppressors must provide the required acoustic attenuation while not overly degrading the thrust efficiency of the propulsion system or the lift enhancement of the high-lift devices on the wing. The overall objective of the NASA High-lift Engine Aeroacoustics Technology program is to demonstrate satisfactory interaction between the jet noise suppressor and the high-lift system at airspeeds and angles of attack consistent with takeoff, climb, approach, and landing. In support of this program, an isolated aeroacoustic test of a 13.5%-scale, candidate mixer/ejector nozzle was performed in the Ames' Research Center 40- by 80-Foot Wind Tunnel. The purpose of the test was to measure the baseline aeroacoustic performance characteristics of this nozzle in isolation from the aerodynamic flowfield induced by an HSCT airframe. The test documented the acoustic signature of the nozzles with treated and hardwall ejector surfaces and with changes in the ratio of ejector-duct-to-jet-area over a wide range range of nozzle pressure ratios and freestream Mach numbers. The test also measured the thrust performance, ambient-flow aspiration ratio, and internal and external static pressures on the nozzles. The isolated aeroacoustic performance data has been compared with results obtained with this nozzle installed on a 13.5% Boeing Reference H HSCT configuration, semi-span model. The semi-span, aeroacoustics integration test documented the first-order effects of the airframe flowfield on the acoustic performance of the nozzle and the effect of the nozzle secondary inlet flows on the aerodynamic performance of the wing high-lift systems. This investigation is critical to understanding the mutual installation effects of mixer/ejector nozzles and wing high-lift systems.

Smith, Brian E.↗

NASA NTRS2009

Simulation of an Isolated Tiltrotor in Hover with an Unstructured Overset-Grid RANS Solver

An unstructured overset-grid Reynolds Averaged Navier-Stokes (RANS) solver, FUN3D, is used to simulate an isolated tiltrotor in hover. An overview of the computational method is presented as well as the details of the overset-grid systems. Steady-state computations within a noninertial reference frame define the performance trends of the rotor across a range of the experimental collective settings. Results are presented to show the effects of off-body grid refinement and blade grid refinement. The computed performance and blade loading trends show good agreement with experimental results and previously published structured overset-grid computations. Off-body flow features indicate a significant improvement in the resolution of the first perpendicular blade vortex interaction with background grid refinement across the collective range. Considering experimental data uncertainty and effects of transition, the prediction of figure of merit on the baseline and refined grid is reasonable at the higher collective range- within 3 percent of the measured values. At the lower collective settings, the computed figure of merit is approximately 6 percent lower than the experimental data. A comparison of steady and unsteady results show that with temporal refinement, the dynamic results closely match the steady-state noninertial results which gives confidence in the accuracy of the dynamic overset-grid approach.

Lee-Rausch, Elizabeth M.↗

NASA NTRSDate not supplied

Initial On-Orbit Spectral Calibration of the PACE Ocean Color Instrument

The NASA Plankton, Aerosol, Cloud, and ocean Ecosystem (PACE) mission Project Science Team has used Ocean Color Instrument (OCI) measurements of Fraunhofer lines in spectra of sunlight reflected by the solar diffuser and measurements of atmospheric absorption bands in cloudtop and ocean spectra to characterize the spectral calibration of OCI on orbit. Multiple lines have been analyzed for both the ultraviolet to visible (UVVIS, 340−607 nm) and visible to near-infrared (VISNIR, 597−897 nm) grating spectrographs. The spectrographs yield hyperspectral observations with 5 nm bandwidths and 0.625 nm sampling intervals. The on-orbit observations have been compared with the prelaunch spectral calibration of OCI performed by the Goddard Laser for Absolute Measurement of Radiance (GLAMR) during thermal vacuum testing to track any changes in the calibration since launch. The calibration analyzed the line positions and strengths for the Fraunhofer lines for each spectrograph by comparing the solar spectra measured by OCI with predicted solar spectra derived from the solar reference spectrum and the BRDF of the solar diffuser, convolved with the OCI relative spectral responses. The calibration also compared the line positions of the atmospheric absorption bands with the model transmissions used by the PACE Project. The line position comparisons show that the root mean square (RMS) spectral difference between the measured and predicted spectra is 0.15 nm, the average spectral shift is 0.062 nm, and the residual spectral dispersion over the wavelength range of the Fraunhofer lines is 0.17 nm. All three estimates of the spectral accuracy of OCI meet the instrument functional requirement of a spectral accuracy of 0.5 nm and are well within the 0.625 nm sampling interval of the data. The line strength comparisons between measured and predicted spectra are essentially the same. These results show that the spectral calibration of OCI on orbit has not drifted since the prelaunch calibration of OCI by GLAMR and that the on-orbit spectral calibration of OCI is stable over time. These results also provide a baseline for monitoring the future spectral performance of OCI on orbit.

Radiometric Calibration↗

NASA NTRS1994

Correction to the luni-solar precession from very long baseline interferometry

The redetermination of the luni-solar precession is performed by using Very Long Baseline Interferometry (VLBI) catalogues of extragalactic radio sources containing positions at observation epochs which cover 9 years. The positions of the sources have been determined by the VLBI network of the Crustal Dynamics Project of NASA from measurements covering consecutive half year and one year intervals between 1981 and 1989. In the course of their reduction the International Astronomical Union (IAU) recommended precession terms were applied. On the assumption of an imperfection of the luni-solar precession it is expected that the positions of each source obtained at different epochs but uniformly reduced to the reference system J2000.0 exhibit an apparent proper motion. We attributed this motion tentatively to precession and solved for a correction of the luni-solar precession by making a least squares fit to the position differences between homonymous sources in the set of catalogues. The 18.6 yr terms of nutation entered the process as parameters the values of which were set by choice from the reservoir of recent determinations. Twenty-five sources contributed to the analysis with the effect that the annual and semi-annual catalogues contain 16 sources on the average. The analysis confirmed the slightly overestimated IAU value of the luni-solar precession yielding a mean correction of -3.59 +/- 1.14 mas/yr from the annual and -3.84 +/- 1.16 mas/yr from the semi-annual catalogues. We discuss these secular terms and their dependence on the adopted nutation terms.

Walter, H. G.↗

NASA NTRS1996

A Comparison of Structurally Connected and Multiple Spacecraft Interferometers

Structurally connected and multiple spacecraft interferometers are compared in an attempt to establish the maximum baseline (referred to as the "cross-over baseline") for which it is preferable to operate a single-structure interferometer in space rather than an interferometer composed of numerous, smaller spacecraft. This comparison is made using the total launched mass of each configuration as the comparison metric. A framework of study within which structurally connected and multiple spacecraft interferometers can be compared is presented in block diagram form. This methodology is then applied to twenty-two different combinations of trade space parameters to investigate the effects of different orbits, orientations, truss materials, propellants, attitude control actuators, onboard disturbance sources, and performance requirements on the cross-over baseline. Rotating interferometers and the potential advantages of adding active structural control to the connected truss of the structurally connected interferometer are also examined. The minimum mass design of the structurally connected interferometer that meets all performance-requirements and satisfies all imposed constraints is determined as a function of baseline. This minimum mass design is then compared to the design of the multiple spacecraft interferometer. It is discovered that the design of the minimum mass structurally connected interferometer that meets all performance requirements and constraints in solar orbit is limited by the minimum allowable aspect ratio, areal density, and gage of the struts. In the formulation of the problem used in this study, there is no advantage to adding active structural control to the truss for interferometers in solar orbit. The cross-over baseline for missions of practical duration (ranging from one week to thirty years) in solar orbit is approximately 400 m for non-rotating interferometers and 650 m for rotating interferometers.

Surka, Derek M.↗

NASA NTRS2004

The Stellar Imager (SI)"Vision Mission"

The Stellar Imager (SI) is a "Vision" mission in the Sun-Earth Connection (SEC) Roadmap, conceived for the purpose of understanding the effects of stellar magnetic fields, the dynamos that generate them, and the internal structure and dynamics of the stars in which they exist. The ultimate goal is to achieve the best possible forecasting of solar/stellar magnetic activity and its impact on life in the Universe. The science goals of SI require an ultra-high angular resolution, at ultraviolet wavelengths, on the order of 100 micro-arcsec and thus baselines on the order of 0.5 km. These requirements call for a large, multi-spacecraft (less than 20) imaging interferometer, utilizing precision formation flying in a stable environment, such as in a Lissajous orbit around the Sun-Earth L2 point. SI's resolution will make it an invaluable resource for many other areas of astrophysics, including studies of AGN s, supernovae, cataclysmic variables, young stellar objects, QSO's, and stellar black holes. ongoing mission concept and technology development studies for SI. These studies are designed to refine the mission requirements for the science goals, define a Design Reference Mission, perform trade studies of selected major technical and architectural issues, improve the existing technology roadmap, and explore the details of deployment and operations, as well as the possible roles of astronauts and/or robots in construction and servicing of the facility.

Carpenter, Ken↗

NASA NTRS2016

NASA Phase2 Unlimited Rights Final Report Research and Technology for Aerospace Propulsion Systems (RTAPS) Task Order: ERA Advanced Core Compressor Technology Program

As part of the NASA Integrated Systems Research Program (ISRP), Environmentally Responsible Aviation (ERA) Project, NASA GRC and GE Aviation have partnered to investigate the technology barriers associated with improved fuel economy of large gas turbine engines. Crucial to improving fuel economy is the increase in pressure ratio (PR) of the core high pressure compressor (HPC). A key enabler to increasing HPC pressure ratios are new technology front stage airfoil designs that have higher efficiency, higher pressure ratios and improvements in front stage part-power operability. The purpose of this work is to design and test two high pressure ratio, high efficiency front block designs. The baseline design, hereafter referred to as Build 1, is similar to what would be found in a high efficiency 30:1 PR class HPC. A redesigned front block with improved blading will also be tested and hereafter be referred to as Build 2. The goal of Build 2 is to increase stage aero loading (increase stage pressure ratio) beyond Build 1 while maintaining equivalent efficiency and stall margin. The detailed inter-stage and traverse data from the two builds will be used to improve understanding of the complex flow physics at high-speed and part-speed conditions that impact performance and operability. By addressing, understanding and solving the challenges associated with aerodynamic losses and stage matching better design strategies can be incorporated in future core compressors with higher efficiency, thereby enabling improvement in mission fuel burn while still meeting operability requirements.

Axial Compressors↗

NASA NTRSDate not supplied

Updated Human Mars Ascent Vehicle Concept in Support of NASA’s Strategic Analysis Cycle 2021

The NASA Artemis program has brought significant change to the agency’s human exploration strategy over the last several years. The human exploration of Mars remains an ultimate objective of the overall human exploration strategy. However, how the agency intends to execute initial human exploration of Mars has shifted to better align with current policy. These changes find their way into the design of key architecture elements, such as the Mars Ascent Vehicle (MAV). Of the numerous changes in the conceptual human Mars architecture, two in particular have had significant impact on the design of the human MAV: the desire for minimal surface infrastructure for initial human Mars missions, and technology investment timelines in support of initial human missions to Mars. The first leads to a surface mission architecture targeting a 30-day surface duration with two crewmembers. The second drives out in-situ resource utilization (ISRU) from the initial sortie. As a result, the reference MAV design for initial human Mars missions in the Human Exploration and Operations Mission Directorate’s Strategic Analysis Cycle 2021 (SAC21) is based around supporting the return of 2 crew from the surface of Mars, without surface ISRU. This has led to several design changes since 2019, when details of a reference human MAV were last published. The MAV concept for SAC21 consists of a two-stage vehicle capable of supporting two crew for 84 hours. This duration is derived from a baseline ascent trajectory targeting an apoapsis rendezvous with the habitation element in a nominal 5-sol Mars aggregation orbit. With the goal of minimizing technology investments for the initial surface sortie removing ISRU from the trade space, the MAV must now be landed either fully loaded with propellant, or with some portion of the propellant off-loaded. Landing a partially-fueled MAV will require additional surface assets to perform robotic propellant transfer on the surface of Mars from a pre-emplaced propellant depot. Furthermore, cryogenic fluid management and storage for extended duration with no losses represents additional technology investment that would have to be made to support cryogenic-based propellant concepts that have been the baseline in past architectures. As a result, the SAC21 architecture utilizes a storable propellant-based MAV propulsion system to minimize these potential technology investments incurred by cryogenic-based propulsion systems. Recent efforts also focused on evaluating the sensitivity of key design parameters, such as landing site latitude, elevation, and local atmospheric conditions. All play a large role in determining the predicted propellant requirements of the MAV. Understanding their potential impacts is important because of the rippling effects of changes to the MAV design on other architecture elements, such as entry, descent, landing, and transportation systems. Results indicate up to +2% to -4% wet mass variation due to landing site latitude, with higher latitudes greater than 70 degrees North resulting in greater than 6% wet mass increases. The MAV saw reduced impact due to atmospheric design parameters, which only accounting for -0.6% to +0.4% wet mass variation.

Douglas J. Trent↗

NASA NTRS2005

Solar Electric and Chemical Propulsion for a Titan Mission

Systems analyses were performed for a Titan Explorer Mission characterized by Earth-Saturn transfer stages using solar electric power generation and propulsion systems for primary interplanetary propulsion, and chemical propulsion for capture at Titan. An examination of a range of system factors was performed to determine their effect on the payload delivery capability to Titan. The effect of varying launch vehicle type, solar array power level, ion thruster number, specific impulse, trip time, and Titan capture stage chemical propellant choice was investigated. The major purpose of the study was to demonstrate the efficacy of applying advanced ion propulsion system technologies like NASA's Evolutionary Xenon Thruster (NEXT), coupled with state-of-the-art (SOA) and advanced chemical technologies to a Flagship class mission. This study demonstrated that a NASA Design Reference Mission (DRM) payload of 406 kg could be successfully delivered to Titan using the baseline advanced ion propulsion system in conjunction with SOA chemical propulsion for Titan capture. In addition, the SEPS/Chemical system of this study is compared to an all- chemical NASA DRM mission. Results showed that the NEXT- based SEPS/Chemical system was able to deliver the required payload to Titan in 5 years less transfer time and on a smaller launch vehicle than the SOA chemical option.

Cupples, Michael↗

NASA NTRS2008

A Gyroless Safehold Control Law Using Angular Momentum as an Inertial Reference Vector

A novel safehold control law was developed for the nadir-pointing Vegetation Canopy Lidar (VCL) spacecraft, necessitated by a challenging combination of constraints. The instrument optics did not have a recloseable cover to protect them form potentially catastrophic damage if they were exposed to direct sunlight. The baseline safehold control law relied on a single-string inertial reference unit. A gyroless safehold law was developed to give a degree of robustness to gyro failures. Typical safehold solutions were not viable; thermal constraints made spin stabilization unsuitable, and an inertial hold based solely on magnetometer measurements wandered unaceptably during eclipse. The novel approach presented here maintains a momentum bias vector not for gyroscopic stiffness, but to use as an inertial reference direction during eclipse. The control law design is presented. The effect on stability of the rank-deficiency of magnetometer-based rate derivation is assessed. The control law's performance is evaluated by simulation.

Stoneking, Eric↗

NASA NTRS2008

A Gyroless Safehold Control Law using Angular Momentum as an Inertial Reference Vector

A novel safehold control law was developed for the nadir-pointing Vegetation Canopy Lidar (VCL) spacecraft, necessitated by a challenging combination of constraints. The instrument optics did not have a reclosable cover to protect them from potentially catastrophic damage if they were exposed to direct sunlight. The baseline safehold control law relied on a single-string inertial reference unit. A gyroless safehold law was developed to give a degree of rebustness to gyro failures. Typical safehold solutions were not viable; thermal constraints made spin stabilization unsuitable, and an inertial hold based solely on magnetometer measurements wandered unacceptably during eclipse. The novel approach presented here maintains a momentum bias vector not for gyroscopic stiffness, but to use as an inertial reference direction during eclipse. The control law design is presented. The effect on stability of the rate-deficiency of magnetometer-based rate derivation is assessed. The control law's performance is evaluated by simulation.

Stoneking, Eric↗

NASA NTRS2024

Offset-Stoichiometric Reflowable Composite Bonding Method with Adhesive for Mitigating Strict Faying Surface Tolerances

Inherent susceptibility of adhesive bonds to miniscule quantities of contamination can cause undetectable weakened bonds. For this reason, the Federal Aviation Administration (FAA) places strict regulations on adhesively bonded joints in primary aircraft structures. To meet certification requirements aircraft manufactures resort to redundant load paths in the form of fasteners which inherently add weight to the structure and increase manufacturing time. In prior work, a secondary bonding technique called AERoBOND was developed, which utilized off-stoichiometric epoxymatrix resins to facilitate reflow and diffusion of the resin within the joint interface during a secondary bonding/cure process, thus achieving a bond similar to a co-cured joint. However, the AERoBOND process required tight spatial tolerances between the two parts being joined. This study examined the utilization of conventional adhesive with the AERoBOND method to act as a filler in the joint line, effectively reducing the need for tight tolerances on the joining parts and serving as a flexible alternative for existing manufacturing processes. Ultrasonic inspection, optical microscopy, and ASTM International standard tests were performed to analyze the joints for defects and to quantify the mode-I and mode-II interlaminar fracture toughness and short beam strength of the proposed methodology with varying manufacturing parameters. The comprehensive results indicate that the AERoBOND+ method with and without surface preparation performs comparably to co-cured and conventional, adhesively bonded joints when secondary cured in an autoclave with 791 kPa of pressure. As an example, the AERoBOND+ panel without surface preparation bonded with 791 kPa of pressure (referred to as AB+3 throughout paper) had a mode-I fracture toughness (G Ic ) of 0.643 kJ/m 2 and a mode-II fracture toughness (G IIc ) of 4.000 kJ/m 2 in the non-precracked condition and 4.218 kJ/m 2 in the precracked condition at the adhesive-to-prepreg interface. These results were 96%, 142%, and 217%, respectively, of a co-cured baseline panel (referred to as C1 throughout paper).

Composites↗