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At least 325 records · Page 18

Study of advanced composite structural design concepts for an arrow wing supersonic cruise configuration

Based on estimated graphite and boron fiber properties, allowable stresses and strains were established for advanced composite materials. Stiffened panel and conventional sandwich panel concepts were designed and analyzed, using graphite/polyimide and boron/polyimide materials. The conventional sandwich panel was elected as the structural concept for the modified wing structure. Upper and lower surface panels of the arrow wing structure were then redesigned, using high strength graphite/polyimide sandwich panels, retaining the titanium spars and ribs from the prior study. The ATLAS integrated analysis and design system was used for stress analysis and automated resizing of surface panels. Flutter analysis of the hybrid structure showed a significant decrease in flutter speed relative to the titanium wing design. The flutter speed was increased to that of the titanium design by selective increase in laminate thickness and by using graphite fibers with properties intermediate between high strength and high modulus values.

Turner, M. J.↗

Improved, Low-Stress Economical Submerged Pipeline

A preliminary study has shown that the use of a high-strength composite fiber cloth material may greatly reduce fabrication and deployment costs of a subsea offshore pipeline. The problem is to develop an inexpensive submerged pipeline that can safely and economically transport large quantities of fresh water, oil, and natural gas underwater for long distances. Above-water pipelines are often not feasible due to safety, cost, and environmental problems, and present, fixed-wall, submerged pipelines are often very expensive. The solution is to have a submerged, compliant-walled tube that when filled, is lighter than the surrounding medium. Some examples include compliant tubes for transporting fresh water under the ocean, for transporting crude oil underneath salt or fresh water, and for transporting high-pressure natural gas from offshore to onshore. In each case, the fluid transported is lighter than its surrounding fluid, and thus the flexible tube will tend to float. The tube should be ballasted to the ocean floor so as to limit the motion of the tube in the horizontal and vertical directions. The tube should be placed below 100-m depth to minimize biofouling and turbulence from surface storms. The tube may also have periodic pumps to maintain flow without over-pressurizing, or it can have a single pump at the beginning. The tube may have periodic valves that allow sections of the tube to be repaired or maintained. Some examples of tube materials that may be particularly suited for these applications are non-porous composite tubes made of high-performance fibers such as Kevlar, Spectra, PBO, Aramid, carbon fibers, or high-strength glass. Above-ground pipes for transporting water, oil, and natural gas have typically been fabricated from fiber-reinforced plastic or from more costly high-strength steel. Also, previous suggested subsea pipeline designs have only included heavy fixed-wall pipes that can be very expensive initially, and can be difficult and expensive to deploy for long distances. A much less expensive Kevlar pipeline can be coiled up on a ship s deck and deployed in the water as the ship moves. Support ships can be used to drop sand into conduits below the uninflated tube, so that the tube remains in place when more buoyant fresh water later fills the tubes.

Jones, Jack A.↗

Composite impact strength improvement through a fiber/matrix interphase

Research was conducted to improve the impact strength and toughness of fiber/resin composites by means of a fiber coating interphase. Graphite fiber/epoxy resin composites were fabricated with four different fiber coating systems introduced in a matrix-fiber interphase. Two graphite fibers, a high strength and a high modulus type, were studied with the following coating systems: chemical vapor deposited boron, electroless nickel, a polyamide-imide resin and a thermoplastic polysulfone resin. Evaluation methods included the following tests: Izod, flexure, shear fracture toughness, longitudinal and transverse tensile, and transverse and longitudinal compression. No desirable changes could be effected with the high strength fiber, but significant improvements in impact performance were observed with the polyamide-imide resin coated high modulus fiber with no loss in composite modulus.

Cavano, P. J.↗

An oxide dispersion strengthened Ni-W-Al alloy with superior high temperature strength

An experimental oxide dispersion strengthened (ODS) alloy, WAZ-D, derived from the WAZ-20 composition was produced by the mechanical alloying process. Cast WAZ-20 is strengthened by both a high refractory metal content, and 70 volume percent of gamma prime. The ODS alloy WAZ-D was responsive to variables of alloy content, of attritor processing, of consolidation by extrusion, and of heat treatment. The best material produced had large highly elongated grains. It exhibited tensile strengths generally superior to a comparable cast alloy. The ODS alloy exhibited high temperature stress rupture life considerably superior to any known cast superalloy. Tensile and rupture ductility were low, as was intermediate temperature rupture life. Very low creep rates were noted and some specimens failed with essentially no third stage creep. Also the benefit derived from the oxide dispersion, far out-weighed that from the elongated microstructure alone.

Glasgow, T. K.↗

Androgynous Fasteners for Robotic Structural Assembly

We describe the design and analysis of an androgynous fastener for autonomous robotic assembly of high performance structures. The design of these fasteners aims to prioritize ease of assembly through simple actuation with large driver positioning tolerance requirements, while producing a reversible mechanical connection with high strength and stiffness per mass. This can be applied to high strength to weight ratio structural systems, such as discrete building block based systems that offer reconfigurability, scalability, and system lifecycle efficiency. Such periodic structures are suitable for navigation and manipulation by relatively small mobile robots. The integration of fasteners, which are lightweight and can be robotically installed, into a high performance robotically managed structural system is of interest to reduce launch energy requirements, enable higher mission adaptivity, and decrease system life-cycle costs.

Formoso, Olivia↗

Factors affecting the strength of multipass low-alloy steel weld metal

The mechanical properties of multipass high-strength steel weld metals depend upon several factors, among the most important being: (1) The interaction between the alloy composition and weld metal cooling rate which determines the as-deposited microstructure; and (2) the thermal effects of subsequent passes on each underlying pass which alter the original microstructure. The bulk properties of a multipass weld are therefore governed by both the initial microstructure of each weld pass and its subsequent thermal history. Data obtained for a high strength low alloy steel weld metal confirmed that a simple correlation exists between mechanical properties and welding conditions if the latter are in turn correlated as weld cooling rate.

Krantz, B. M.↗

Energy Absorbing Protective Shroud

The present invention is a dissipating protection energy system designed to receive and safely dissipate the kinetic energy from high energy fragments. The energy dissipation system dissipates energy transferred to it by the incremental and progressive rupturing at an approximately constant force of strategically placed sacrificial stitching applied to a number of high strength straps, such as an aromatic polyimide fiber of extremely high tensile strength. Thus, the energy dissipation system provides a lightweight device for controlling and dissipating the dangerous and destructive energy stored in high strength fragments released by catastrophic failures of machinery minimizing damage to other critical components.

Schneider, William C.↗

An oxide dispersion strengthened Ni-W-Al alloy with superior high temperature strength

Oxide dispersion strengthened alloys based on the WAZ-20 nickel-base alloy were prepared by the mechanical alloying process described by Benjamin (1973), and evaluated. The results of microstructural examinations and mechanical property determinations are discussed. It is shown that WAZ-20, a high gamma-prime fraction alloy having a high gamma-prime solvus temperature, can be effectively dispersion strengthened. The strengths obtained were outstanding, especially at 1150 and 1205 C. The strength is attributed to a combination of highly alloyed matrix, elongated grain structure, and hard phase dispersion. Tensile ductility can be improved by post-recrystallization heat treatment. The new alloy shows some potential for low stress post-extrusion forming.

Glasgow, T. K.↗

Mechanical Testing of IN718 Lattice Block Structures

Lattice block construction produces a flat, structurally rigid panel composed of thin ligaments of material arranged in a three-dimensional triangulated truss-like structure. Low-cost methods of producing cast metallic lattice block panels are now available that greatly expand opportunities for using this unique material system in today's high-performance structures. Additional advances are being made in NASA's Ultra Efficient Engine Technology (UEET) program to extend the lattice block concept to superalloy materials. Advantages offered by this combination include high strength, light weight, high stiffness, and elevated temperature capabilities. Recently under UEET, the nickel-based superalloy Inconel 718 (IN718) was investment cast into lattice block panels with great success. To evaluate casting quality and lattice block architecture merit, individual ligaments, and structural subelement specimens were extracted from the panels. Tensile tests, structural compression, and bending strength tests were performed on these specimens. Fatigue testing was also completed for several bend test specimens. This paper first presents metallurgical and optical microscopy analysis of the castings. This is followed by mechanical test results for the tensile ligament tests and the subelement compression and bending strength tests, as well as for the fatigue tests that were performed. These tests generally showed comparable properties to base IN718 with the same heat treatment, and they underscored the benefits offered by lattice block materials. These benefits might be extended with improved architecture such as face sheets.

Krause, David L.↗

Energy efficient engine high-pressure turbine detailed design report

The energy efficient engine high-pressure turbine is a single stage system based on technology advancements in the areas of aerodynamics, structures and materials to achieve high performance, low operating economics and durability commensurate with commercial service requirements. Low loss performance features combined with a low through-flow velocity approach results in a predicted efficiency of 88.8 for a flight propulsion system. Turbine airfoil durability goals are achieved through the use of advanced high-strength and high-temperature capability single crystal materials and effective cooling management. Overall, this design reflects a considerable extension in turbine technology that is applicable to future, energy efficient gas-turbine engines.

Thulin, R. D.↗

Polyarylene Ethers with Improved Properties

This invention relates to novel polyarylene ethers which possess the combination of high strength, toughness, and high use temperature with ease of extrusion and formation into complex objects. These polyarylene ethers are suitable for use in adhesives, coatings, films, membranes, and composite matrices. The polyarylene ethers of this invention are the polycondensation products from the reaction of either 1,3-bis (4-chloro or fluorobenzoyl) benzene with any one of the following bisphenolic compounds: bis (3-hydroxyphenyl) methane; bis (4-hydroxyphenyl) methane; 1,1-dimethyl-bis (4-hydroxyphenyl)methane, or 9,9-bis (4-hydroxyphenyl) fluorene. Random and block copolymers are also comprehended.

Hergenrother, P. M.↗

Evaluation and ranking of candidate ceramic wafer engine seal materials

Modern engineered ceramics offer high temperature capabilities not found in even the best superalloy metals. The high temperature properties of several selected ceramics including aluminum oxide, silicon carbide, and silicon nitride are reviewed as they apply to hypersonic engine seal design. A ranking procedure is employed to objectively differentiate among four different monolithic ceramic materials considered, including: a cold-pressed and sintered aluminum oxide; a sintered alpha-phase silicon carbide; a hot-isostatically pressed silicon nitride; and a cold-pressed and sintered silicon nitride. This procedure is used to narrow the wide range of potential ceramics considered to an acceptable number for future detailed and costly analyses and tests. The materials are numerically scored according to their high temperature flexural strength; high temperature thermal conductivity; resistance to crack growth; resistance to high heating rates; fracture toughness; Weibull modulus; and finally according to their resistance to leakage flow, where materials having coefficients of thermal expansion closely matching the engine panel material resist leakage flow best. The cold-pressed and sintered material (Kyocera SN-251) ranked the highest in the overall ranking especially when implemented in engine panels made of low expansion rate materials being considered for the engine, including Incoloy and titanium alloys.

Steinetz, Bruce M.↗

Advanced composite materials and processes

Composites are generally defined as two or more individual materials, which, when combined into a single material system, results in improved physical and/or mechanical properties. The freedom of choice of the starting components for composites allows the generation of materials that can be specifically tailored to meet a variety of applications. Advanced composites are described as a combination of high strength fibers and high performance polymer matrix materials. These advanced materials are required to permit future aircraft and spacecraft to perform in extended environments. Advanced composite precursor materials, processes for conversion of these materials to structures, and selected applications for composites are reviewed.

Baucom, Robert M.↗

New textile composite materials development, production, application

New textile composite materials development, production, and application are discussed. Topics covered include: super-high-strength, super-high-modulus fibers, filaments, and materials manufactured on their basis; heat-resistant and nonflammable fibers, filaments, and textile fabrics; fibers and textile fabrics based on fluorocarbon poylmers; antifriction textile fabrics based on polyfen filaments; development of new types of textile combines and composite materials; and carbon filament-based fabrics.

Mikhailov, Petr Y.↗

Comparison of Graphite Fabric Reinforced PMR-15 and Avimid N Composites After Long Term Isothermal Aging at Various Temperatures

Extensive effort is currently being expended to demonstrate the feasibility of using high-performance, polymer-matrix composites as engine structural materials over the expected operating lifetime of the aircraft, which can extend from 18,000 to 30,000 hr. The goal is to develop light-weight, high-strength, and high-modulus materials for use in higher temperature sections of advanced 21 st century aircraft propulsion systems. To accomplish this goal, it is necessary to pursue the development of thermal and mechanical durability models for graphite-fiber-reinforced, polymer-matrix composites. Numerous investigations have been reported regarding the thermo-oxidative stability (TOS) of the polyimide PMR-15 (1-5). A significant amount of this work has been directed at edge and geometry effects, reinforcement fiber influences, and empirical modeling of high-temperature weight loss behavior. It is yet to be determined if the information obtained from the PMR-15 composite tests is applicable to other polyimide-matrix composites. The condensation-curing polymer Avimid N is another advanced composite material often considered for structural applications at high temperatures. Avimid N has better thermo-oxidative stability than PMR-15 (6), but the latter is more easily processed. The most comprehensive study of the thermo-oxidative stability of Avimid N neat resin and composites at 371 (infinity)C is found in Salin and Seferis (7). The purposes of the work described herein were to compare the thermal aging behavior of these two matrix polymers and to determine the reasons for and the consequences of the difference in thermal durability. These results might be of some use in improving future polymer development through the incorporation of the desirable characteristics of both polyimides.

Bowles, Kenneth J.↗

Advances in Space Transportation Technology Toward the NASA Goals

NASA has set goals to increase safety by one hundred times while reducing cost tenfold over the next decade. This dramatic increase in safety will come by departing from a past emphasis on cost and performance to a new paradigm of safety and reliability, which, in turn, will drive down cost. To accomplish this, vehicle systems must be inherently reliable, functionally redundant wherever practical and designed to minimize or eliminate catastrophic failure modes. Over the next twenty-five years, NASA has set goals to increase safety ten thousand times while reducing cost one hundred fold. Safety will increase towards today's airline safety and the low price per flight has the potential to enable a 15-fold increase in the size of the current projected space launch market. This level of improvement is comparable to the developments in the 1970s in the computer microprocessor when microchips went from hundreds of thousands to tens of thousands of dollars - hailing the era of the personal computer. In order to achieve such ambitious cost goals, today's partial and fully expendable rockets must be replaced by fully reusable systems. A RLV can eliminate assembly and checkout of the large number of complex interfaces on today's Space Shuttle. Full reusability will eliminate the necessity to throw away expensive hardware and the need for on-going production. Systems in ten years will have to accommodate 50 to 100 missions per year and could be commercially certified for hundreds of flights. In twenty-five years, the number of flights per year could jump to over 1,000, which will require certification for thousands of flights. The large increase in flights per year will demand that current operations and maintenance procedures be revolutionized. Unlike the current shuttle, which requires several thousand personnel over five months to process, the next generation system must be turned around in one week with less than one hundred personnel. In contrast to the rigorous disassembly and inspections required for the Space Shuttle's subsystems, the next generation vehicle's on-board health monitoring systems will could tell the ground crews which systems need replacement before landing. In twenty-five years, vehicles will be re-flown within one with crews numbering less than one hundred. Fully automated ground processing systems must require only a handful of personnel to launch the vehicle. Due to the increased intelligence of on-board systems, only cursory walk-around inspections would be required between flights An assessment of the progress in breakthrough technologies toward these goals by the NASA Advanced Space Transportation Program is presented. These breakthrough technologies include combined rocket and air breathing propulsion, high strength lightweight structures, high temperature materials, vehicle health management, and flight operations.

Lyles, Garry M.↗

Friction-Stir Welding of Aluminum For the Space Program

The Marshall Space Flight Center is developing and characterizing the friction stir welding process for the Space Shuttle and other space programs. This revolutionary process, invented and patented by The Weld Institute in England, offers tremendous advantages for joining aluminum for high performance applications. It is particularly suited for advanced aluminum-lithium alloys, such as 2195, the primary structural alloy used in the External Tank. The friction stir welding process joins metals with minimal heat input, resulting in high-strength joints with high ductility. It is a simple process to demonstrate using a common milling machine for sample parts, but relatively expensive to implement on large-scale hardware, due to the high cost of tooling needed to handle the high forging pressures characteristic of the process. Recent developments at the Marshall Space Flight Center have demonstrated friction stir welding on linear joints up to 5 meters (15 ft.), with material thickness ranging between 2.5 mm and 16.5 mm (0.100" to 0.650"). High efficiency weld joints have been produced in aluminum from the 2000, 5000, and 6000 series alloy systems. A "retractable pin tool" system was patented by MSFC that allows use of friction stir welding for joints with changing material thickness, and with less rigid tooling than previously considered. This presentation will describe the details of alloys welded to-date and technical advances under development at MSFC. These developments could have substantial benefit to industrial applications for welding aluminum.

Jones, Clyde S.↗