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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Mass and strength analyses and system requirements identified titanium-box-stiffened-skin wall candidate for lightweight fuselage of pressurized vehicle. Photoelastic models of stiffener-to-skin joint used to identify quickly modifications to joint that lowers severity of stress concentration. Results with various photoelastic models cut from polyurethane sheet led to novel diffusion-bond joint with reduced stress concentration.
NASA has been supporting design studies and technology development for fission-based power systems that could provide power to an outpost on the Moon, Mars, or an asteroid. Technology development efforts have included fabrication and evaluation of components used in a Stirling engine power conversion system. This investigation is part of the development of several braze joints crucial for the heat exchanger transfer path from a hot-side heat exchanger to a Stirling engine heat acceptor. Dissimilar metal joints are required to impart both mechanical strength and thermal path integrity for a heater head of interest. Preliminary design work for the heat exchanger involved joints between low carbon stainless steel to Inconel 718, where the 316L stainless steel would contain flowing liquid metal NaK while Inconel 718, a stronger alloy, would be used as structural reinforcement. This paper addressed the long-term microstructural stability of various braze alloys used to join 316L stainless steel heater head to the high conductivity oxygen-free copper acceptor to ensure the endurance of the critical metallic components of this sophisticated heat exchanger. The bonding of the 316L stainless steel heater head material to a copper heat acceptor is required to increase the heat-transfer surface area in contact with flowing He, which is the Stirling engine working fluid.
The development and validation is examined of a dynamic strength model for humans. This model is based on empirical data. The shoulder, elbow, and wrist joints were characterized in terms of maximum isolated torque, or position and velocity, in all rotational planes. This data was reduced by a least squares regression technique into a table of single variable second degree polynomial equations determining torque as a function of position and velocity. The isolated joint torque equations were then used to compute forces resulting from a composite motion, in this case, a ratchet wrench push and pull operation. A comparison of the predicted results of the model with the actual measured values for the composite motion indicates that forces derived from a composite motion of joints (ratcheting) can be predicted from isolated joint measures. Calculated T values comparing model versus measured values for 14 subjects were well within the statistically acceptable limits and regression analysis revealed coefficient of variation between actual and measured to be within 0.72 and 0.80.
The AeroCom BB (Biomass Burning) Experiment AOD (Aerosol Optical Depth) motivation: We have a substantial set of satellite wildfire plume AOD snapshots and injection heights to help calibrate model/inventory performance; We are 1) adding more fire source-strength cases 2) using MISR to improve the AOD constrains and 3) adding 2008 global injection heights; We selected GFED3-daily due to good overall source strength performance, but any inventory can be tested; Joint effort to test multiple, global models, to draw robust BB injection height and emission strength conclusions. We provide satellite-based injection height and smoke plume AOD climatologies.
The dramatic increases in fuel costs and the potential for periods of limited fuel availability provided the impetus to explore technologies to reduce transport aircraft fuel consumption. NASA sponsored the Aircraft Energy Efficiency (ACEE) program beginning in 1976 to develop technologies to improve fuel efficiency. The Lockheed-Georgia Company accomplished under NAS1-16235 Laminar-Flow-Control (LFC) Wing Panel Structural Design and Development (WSSD); design, manufacturing, and testing activities. An in-depth preliminary design of the baseline 1993 LFC wing was accomplished. A surface panel using the Lockheed graphite/epoxy integrated LFC wing box structural concept was designed. The concept was shown by analysis to be structurally efficient and cost effective. Critical details of the surface and surface joint was demonstrated by fabricating and testing complex, concept selection specimens. The Lockheed-Georgia Company accomplishments, Development of LFC Wind Surface Composite Structures (WSCS), are documented. Tests were conducted on two CV2 panels to verify the static tension and fatigue strength of LFC wing surface chordwise joints.
Ultrasonic metal welding (UMW) is a solid-state joining technique with varied industrial applications. Despite of its numerous advantages, UMW has a relative narrow operating window and is sensitive to variations in process conditions. As such, it is imperative to quantitatively characterize the influence of welding parameters on the resulting joint quality. The quantification model can be subsequently used to optimize the parameters. Conventional response surface methodology (RSM) usually employs linear or polynomial models, which may not be able to capture the intricate, nonlinear input-output relationships in UMW. Furthermore, some UMW applications call for simultaneous optimization of multiple quality indices such as peel strength, shear strength, electrical conductivity, and thermal conductivity. To address these challenges, this paper develops a machine learning (ML)-based RSM to model the input-output relationships in UMW and jointly optimize two quality indices, namely, peel and shear strengths. The performance of various ML methods including spline regression, Gaussian process regression (GPR), support vector regression (SVR), and conventional polynomial regression models with different orders is compared. A case study using experimental data shows that GPR with radial basis function (RBF) kernel and SVR with RBF kernel achieve the best prediction accuracy. The obtained response surface models are then used to optimize a compound joint strength indicator that is defined as the average of normalized shear and peel strengths. In addition, the case study reveals different patterns in the response surfaces of shear and peel strengths, which has not been systematically studied in the literature. While developed for the UMW application, the method can be extended to other manufacturing processes.
A concept in manipulator development to overcome the 'weak wrist syndrome', a triple-axis common-pivot arm wrist (TACPAW), is presented. It contains torque motors for actuation, tachometers for measuring rate, and resolvers for position measurements. Furthermore, it provides three degrees of freedom, i.e., pitch, yaw, and roll, in a single manipulator joint. The advantages of this development are increased strength, compactness, and simplification of controls. Designed to be compatible with the protoflight manipulator arm, the joints of TACPAW are back-driveable with + or - 45 deg rotation in pitch, + or - 45 deg in yaw and continuous roll in either direction while delivering 20.5 N-m (15 ft-lb) torque in each of the three movements.
This work investigated the role of interface, adherend, and adhesive in adhesively-bonded metal-metal, metal-CFRTP, and CFRTP-CFRTP combinations with plasma-treated surfaces under shear deformation. To this end, aluminum alloys (AA5052 and AA6061) and short-carbon-fiber-reinforced polyamide 66 (CFRPA66) were used as examples and performed through single lap shear testing. The results showed that air plasma surface treatment can improve the shear behavior of adhesively-bonded AA5052-CFRPA66 and CFRPA66-CFRPA66 joints with about 20% enhanced lap shear strength compared to non-treated cases. Failure surface morphology of plasma-treated CFRPA66 adherend confirmed this improvement by showing an increased amount of adhesive failure than interfacial failure between CFRPA66 and adhesive. But this is not true for AA5052-AA6061 joints with plasma-treated surfaces exhibiting almost no enhanced lap shear strength. This study also showed the importance of selecting a proper surface modification method for the enhancement of adhesive-bonded structures under shear deformation through the analysis of the results in this study and in the literature. For fiber-reinforced polymers (FRPs), improving FRP/adhesive interface may be prioritized via different surface modification methods (e.g., plasma, chemical coating, etc.) than adhesive modification methods. However, for surface-cleaned metals, toughening adhesive via different enhancement methods (e.g., nano-particles, chemical enhancement, etc.) may be more important than improving metal/adhesive interface. These insightful results are valuable in the area of multi-materials joining.
The effective weight reduction in the automotive industry by the wide adoption of lightweight magnesium (Mg) alloys demands high-quality joint between magnesium alloys and massively-used steels in order to wring the excess weight with strength and safety assurance. However, Mg-steel joint is difficult to achieve because there is no mutual solubility between magnesium and steel and huge disparity in physical properties. An impact-based welding method recently showed successful Mg-steel joining. In this work, the characteristics of Mg-steel interface joined by the impact welding method were investigated. Synchrotron high-energy X-ray computed tomography and diffraction were applied to characterize the microstructure across Mg-steel interface. Results revealed a deposit layer formed at the joint interface where Fe-rich particles spread deep into the Mg matrix. High-resolution 3D morphology of Mg-steel interface demonstrated the trapped pores and cracks inside the deposit layer. Finally, the formation of the deposit layer and the void/cracking evolution were analyzed by using finite element models. These findings provide insights into the immiscible Mg-steel joining process.
Background The integration of dissimilar materials poses a significant challenge in engineering, necessitating innovative solutions for robust and reliable joining. Interlocking metasurfaces (ILMs) are a new joining technology comprising arrays of autogenous features patterned across two surfaces that interlock to form robust structural joints. Objective Here, this study elucidates the factors influencing the tensile performance of ILM joints formed between dissimilar materials. Methods We employed parametric optimization to identify optimal unit cell geometries for maximal yield strength based on the hypothesis that the elastic tensile properties of the materials are the primary determinants of tensile performance. Experimental validation was performed by mechanically testing the theorized optimal ILM geometry and a range of ILM geometries to capture the overall behavior trends of joints between two additively manufactured polymers, VeroPureWhite (VW) and RGDA8430-DM (8430). Results Experimental validation of optimized designs revealed that additional factors, e.g. flexural strength and localized plasticity, also strongly influenced the tensile performance of T-slot ILMs joining dissimilar materials. The proposed optimal design remained the best performer. Conclusions This study demonstrates the viability of ILMs as a joining method for dissimilar materials. ILMs can join dissimilar materials with no loss in joint yield strength compared to joints composed solely of the weaker of the two constitutive materials. ILMs demonstrated their potential as a versatile and effective joining technology in diverse engineering applications.
Continuum mechanics solutions are derived for the static load-carrying capacity of scarf and stepped-lap adhesive-bonded joints. The analyses account for adhesive plasticity and adherend stiffness imbalance and thermal mismatch. The scarf joint solutions include a simple algebraic formula which serves as a close lower bound, within a small fraction of a per cent of the true answer for most practical geometries and materials. Digital computer programs were developed and, for the stepped-lap joints, the critical adherend and adhesive stresses are computed for each step. The scarf joint solutions exhibit grossly different behavior from that for double-lap joints for long overlaps inasmuch as that the potential bond shear strength continues to increase with indefinitely long overlaps on the scarf joints. The stepped-lap joint solutions exhibit some characteristics of both the scarf and double-lap joints. The stepped-lap computer program handles arbitrary (different) step lengths and thickness and the solutions obtained have clarified potentially weak design details and the remedies. The program has been used effectively to optimize the joint proportions.
The results of initial experiments show that high-strength void-free bonds can be formed by vacuum brazing of stainless steels using copper and nickel-based filler metals. In Nitronic 40, brazed joints have been formed with strengths in excess of the yield strength of the parent metal, and even at liquid nitrogen temperatures the excellent mechanical properties of the parent metal are only slightly degraded. The poor toughness of 15-5 P.H. stainless steel at cryogenic temperatures is lowered even further by the presence of the brazed bonds investigated. It is highly unlikely that the technique would be used for any critical areas of aerofoil models intended for low-temperature service. Nevertheless, the potential advantages of this simplified method of construction still have attractions for use at ambient temperatures.
The major emphasis was to develop erectable joints for large aerobrake support trusses. The truss joints must be able to withstand the large forces experienced by the truss during the aero-pass, as well as be easily assembled and disassembled on orbit by astronauts or robots. Other important design considerations include; strength, stiffness, and allowable error in strut length. Six mechanical joint designs, as well as a seventh joint design, where a high strength epoxy is injected to make the connection rigid, are presented.
At the lunar south pole, solar arrays elevated by truss towers are exposed to near continuous sunlight since the sun remains near the horizon. Recent studies suggest that tower heights on the order of 50 m are needed to meet the power requirements to support a sustained lunar presence. While eventually towers may be constructed using materials sourced in-situ, initially structural elements will likely be brought from the Earth, deployed, and assembled. Thermoplastic composites offer the benefit of high specific stiffness and strength properties along with welding for assembly joints, and therefore represent a promising material system for this application. The focus of this paper is on the structural sizing of such towers. A set of expressions based on beam theory are presented for preliminary sizing of the truss tower structure for strength and buckling. The loading condition that drives sizing is base excitation resulting from moonquakes. A point design, developed through finite element analysis, verifies the analytical sizing routine and shows the importance of joints. The results show a viable point design and highlight the factors most significant in the structural sizing.
At the lunar south pole, solar arrays elevated by truss towers are exposed to near continuous sunlight since the sun remains near the horizon. Recent studies suggest that tower heights on the order of 50 m are needed to meet the power requirements to support a sustained lunar presence. While eventually towers may be constructed using materials sourced in-situ, initially structural elements will likely be brought from the Earth, deployed, and assembled. Thermoplastic composites offer the benefit of high specific stiffness and strength properties along with welding for assembly joints, and therefore represent a promising material system for this application. The focus of this paper is on the structural sizing of such towers. A set of expressions based on beam theory are presented for preliminary sizing of the truss tower structure for strength and buckling. The loading condition that drives sizing is base excitation resulting from moonquakes. A point design, developed through finite element analysis, verifies the analytical sizing routine and shows the importance of joints. The results show a viable point design and highlight the factors most significant in the structural sizing.
At the lunar south pole, solar arrays elevated by truss towers are exposed to near continuous sunlight since the sun remains near the horizon. Recent studies suggest that tower heights on the order of 50 m are needed to meet the power requirements to support a sustained lunar presence. While eventually towers may be constructed using materials sourced in-situ, initially structural elements will likely be brought from the Earth, deployed, and assembled. Thermoplastic composites offer the benefit of high specific stiffness and strength properties along with welding for assembly joints, and therefore represent a promising material system for this application. The focus of this paper is on the structural sizing of such towers. A set of expressions based on beam theory are presented for preliminary sizing of the truss tower structure for strength and buckling. The loading condition that drives sizing is base excitation resulting from moonquakes. A point design, developed through finite element analysis, verifies the analytical sizing routine and shows the importance of joints. The results show a viable point design and highlight the factors most significant in the structural sizing.
Vacuum brazing is a viable process to achieve strong permanent and hermetic joints in space. As in any joining process, brazed Joints have various imperfections and defects. It is important to understand the impact that flaws have on the load carrying capacity and performance of the brazed joints. This study focuses on the behavior of lap shear joints due to their engineering importance in brazed aerospace structures. In Part 1 an average shear strength capabilitY and failure modes of the single lap joints are explored. Specimens comprised of 0.090 inch thick 347 stainless steel sheet brazed with pure silver are tested in accordance with the AWS C3.2 standard. Comparison of the measured loads and average shear stresses at failure with the Finite Element Analysis (FEA) of the same specimens as a function of the overlap lengths shows excellent correlation between the experimental and calculated values for the defect-free lap joints. In Part 2, various flaws will be introduced in the test specimens to simulate lack of braze coverage in the lap joints. Mechanical testing and FEA will be performed on these joints to verify if behavior of ductile ]appoints containing flaws is similar to the joints with the reduced braze area. Finally, in Part 3, the results obtained in Part 1 and 2 will be applied to the brazed assembly to evaluate a load carrying capability of the structural lap joint containing defects.
Abstract Superwood is a densified wood product that shows promise as a lightweight and renewable alternative for metallic materials. In order for this high-performance new material to be used in multi-material products, it must be able to be joined with other major materials. For example, joining superwood to aluminum would provide a key enabling technology for its use in automotive components since aluminum is presently a major lightweight material for such applications. In this paper, a methacrylate-based adhesive has been identified to provide high lap shear strength (7.5 MPa) for aluminum-to-superwood joints. The aluminum-to-superwood samples were prepared with different amounts of pre-polishing to create openings to the pores in the superwood so adhesive could penetrate into them and create a mechanical interlock, in addition to the hydrogen/chemical bonding at the surface between the methyl methacrylate (MMA) in methacrylate-based adhesive and the cellulose in superwood. For aluminum samples, a thin layer (typically a few nanometers) of oxide film on the surfaces provides hydrogen/chemical bond to MMA structure in the adhesive layer. The failure strength of the superwood-to-aluminum joint sample is about 50% higher than that of natural wood to natural wood joint sample and comparable to that of aluminum-to-aluminum joint sample.