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Report summarizes procedures for design of structural components made of fiber/matrix composite materials and of joints between such components. Summary presented by way of example design cases, using typical numerical values and showing typical results. Simplified form of applicable step-by-step design procedure, suitable for preliminary design, presented for each case. References to detailed descriptions in literature provided.
Minimizing the weight of structural components of the space station launched into orbit in a space shuttle can save cost, reduce the number of space shuttle missions, and facilitate on-orbit fabrication. Traditional manual design of such components, although feasible, cannot represent a minimum weight condition. At NASA Lewis Research Center, a design capability called CometBoards (Comparative Evaluation Test Bed of Optimization and Analysis Routines for the Design of Structures) has been developed especially for the design optimization of such flight components. Two components of the space station - a spacer structure and a support system - illustrate the capability of CometBoards. These components are designed for loads and behavior constraints that arise from a variety of flight accelerations and maneuvers. The optimization process using CometBoards reduced the weights of the components by one third from those obtained with traditional manual design. This paper presents a brief overview of the design code CometBoards and a description of the space station components, their design environments, behavior limitations, and attributes of their optimum designs.
Design and test of advanced structural components and assemblies for space shuttle program
The viability of advanced viscoplastic models for nonlinear finite element analyses of structural components is investigated. Several uniaxial and a multiaxial problem are analyzed using the finite element implementation of Freed's viscoplastic model. Good agreement between the experimental and calculated uniaxial results validates the finite element implementation and gives confidence to apply it to more complex multiaxial problems. A comparison of results for a sample structural component (the cowl lip of a hypersonic engine inlet) with the earlier elastic, elastic-plastic, and elastic-plastic-creep analyses available in the literature shows that the elastic-viscoplastic analyses yield more reasonable stress and strain distributions. Finally, the versatility of the finite-element-based solution technology presented herein is demonstrated by applying it to another viscoplastic model.
Recent analysis of the magnetic correlation function of solar wind fluctuations at 1 AU suggests the existence of two-component structure near the proton-cyclotron scale. Here we use two-and-one-half dimensional and three-dimensional compressible MHD models to look for two-component structure adjacent the proton-cyclotron scale. Our MHD system incorporates both Hall and Finite Larmor Radius (FLR) terms. We find that strong spectral anisotropies appear adjacent the proton-cyclotron scales depending on selections of initial condition and plasma beta. These anisotropies are enhancements on top of related anisotropies that appear in standard MHD turbulence in the presence of a mean magnetic field and are suggestive of one turbulence component along the inertial scales and another component adjacent the dissipative scales. We compute the relative strengths of linear and nonlinear accelerations on the velocity and magnetic fields to gauge the relative influence of terms that drive the system with wave-like (linear) versus turbulent (nonlinear) dynamics.
The previously developed Ko closed-form aging theory has been reformulated into a more compact mathematical form for easier application. A new equivalent loading theory and empirical loading theories have also been developed and incorporated into the revised Ko aging theory for the prediction of a safe operational life of airborne failure-critical structural components. The new set of aging and loading theories were applied to predict the safe number of flights for the B-52B aircraft to carry a launch vehicle, the structural life of critical components consumed by load excursion to proof load value, and the ground-sitting life of B-52B pylon failure-critical structural components. A special life prediction method was developed for the preflight predictions of operational life of failure-critical structural components of the B-52H pylon system, for which no flight data are available.
Tensile properties of protectively coated refractory metals for structural components in high temperature oxidizing environments
NASA missions and space exploration rely on strong, ultra lightweight materials. Such materials are needed for building up past and present space vehicles such as the Sojourner Rover (1997) or the two MERs (2003), but also for a number of components and/or systems including thermal insulators, Solar Sails, Rigid Aeroshells, and Ballutes. The purpose of my internship here at Glenn Research Center is to make dual purpose materials; materials that in addition to being lightweight have electronic, photophysical and magnetic properties and, therefore, act as electronic components and sensors as well as structural components. One type of ultra lightweight material of great interest is aerogels, which have densities ranging from 0.003 g/cc to 0.8 g/cc . However, aerogels are extremely fragile and, as a result, have limited practical applications. Recently, Glenn Research Center has developed a process of nano-casting polymers onto the inorganic network of silica-based aerogels increasing the strength 300 fold while only increasing the density 3 fold. By combining the process of nano-casting polymers with inorganic oxide networks other than silica, we are actively pursuing lightweight dual purpose materials. To date, thirty different inorganic oxide aerogels have been prepared using either standard sol-gel chemistry or a non-alkoxide method involving metal chloride precursors and an epoxide; epichlorohydrin, propylene oxide or trimethylene oxide, as proton scavengers. More importantly, preliminary investigations show that the residual surface hydroxyl groups on each of these inorganic oxide aerogels can be successfully crosslinked with urethane. In addition to characterizing physical and mechanical properties such as density, strength and flexibility, each of these metal oxide aerogels are being characterized for thermal and electronic conductivity and magnetic and optical properties.
Future NASA missions and space explorations rely on the use of materials that are strong ultra lightweight and able to withstand extreme temperatures. Aerogels are low density (0.01-0.5 g/cu cm) high porosity materials that contain a glass like structure formed through standard sol-gel chemistry. As a result of these structural properties, aerogels are excellent thermal insulators and are able to withstand temperatures in excess of l,000 C. The open structure of aerogels, however, renders these materials extremely fragile (fracturing at stress forces less than 0.5 N/sq cm). The goal of NASA Glenn Research Center is to increase the strength of these materials by templating polymers and metals onto the surface of an aerogel network facilitating the use of this material for practical applications such as structural components of space vehicles used in exploration. The work this past year focused on two areas; (1) the research and development of new templated aerogels materials and (2) process development for future manufacturing of structural components. Research and development occurred on the production and characterization of new templating materials onto the standard silica aerogel. Materials examined included polymers such as polyimides, fluorinated isocyanates and epoxies, and, metals such as silver, gold and platinum. The final properties indicated that the density of the material formed using an isocyanate is around 0.50 g/cc with a strength greater than that of steel and has low thermal conductivity. The process used to construct these materials is extremely time consuming and labor intensive. One aspect of the project involved investigating the feasibility of shortening the process time by preparing the aerogels in the templating solvent. Traditionally the polymerization used THF as the solvent and after several washes to remove any residual monomers and water, the solvent around the aerogels was changed to acetonitrile for the templating step. This process took a couple of days. It was experimentally determined that the polymerization reaction could be done in acetonitrile instead of THF with no detrimental effects to the properties of the resulting aerogel. Other changes in the time needed to crosslink the gels in the isocyanate solution as well as changes to the subsequent washing procedure could also shorten the processing time with no effect on the properties. Processing methods were also developed that allowed a variety of shapes as well as sizes of these materials to be formed.
The advantages of the use of composite materials in structural applications have been identified in numerous engineering studies. Technology development programs are underway to correct known deficiencies and to provide needed improvements. However, in the final analysis, flight service programs are necessary to develop broader acceptance of, and confidence in, any new class of materials such as composites. Such flight programs, initiated by NASA Langley Research Center, are reviewed. These programs which include the selectively reinforced metal and the all-composite concepts applied to both secondary and primary aircraft structural components, are described and current status is indicated.
The advantages of the use of composite materials in structural applications have been identified in numerous engineering studies. Technology development programs are underway to correct known deficiencies and to provide needed improvements. However, in the final analysis, flight service programs are necessary to develop broader acceptance of, and confidence in, any new class of materials such as composites. Such flight programs, initiated by NASA Langley Research Center, will be reviewed in the proposed paper. These programs, which include the selectively reinforced metal and the all-composite concepts applied to both secondary and primary aircraft structural components, will be described and current status will be indicated.
The objective of this two-year project was to develop and deliver to the NASA-Glenn Research Center a two-dimensional higher-order theory, and related computer codes, for the analysis and design of cylindrical functionally graded materials/structural components for use in advanced aircraft engines (e.g., combustor linings, rotor disks, heat shields, brisk blades). To satisfy this objective, two-dimensional version of the higher-order theory, HOTCFGM-2D, and four computer codes based on this theory, for the analysis and design of structural components functionally graded in the radial and circumferential directions were developed in the cylindrical coordinate system r-Theta-z. This version of the higher-order theory is a significant generalization of the one-dimensional theory, HOTCFGM-1D, developed during the FY97 for the analysis and design of cylindrical structural components with radially graded microstructures. The generalized theory is applicable to thin multi-phased composite shells/cylinders subjected to steady-state thermomechanical, transient thermal and inertial loading applied uniformly along the axial direction such that the overall deformation is characterized by a constant average axial strain. The reinforcement phases are uniformly distributed in the axial direction, and arbitrarily distributed in the radial and circumferential direction, thereby allowing functional grading of the internal reinforcement in the r-Theta plane. The four computer codes fgmc3dq.cylindrical.f, fgmp3dq.cylindrical.f, fgmgvips3dq.cylindrical.f, and fgmc3dq.cylindrical.transient.f are research-oriented codes for investigating the effect of functionally graded architectures, as well as the properties of the multi-phase reinforcement, in thin shells subjected to thermomechanical and inertial loading, on the internal temperature, stress and (inelastic) strain fields. The reinforcement distribution in the radial and circumferential directions is specified by the user. The thermal and inelastic properties of the individual phases can vary with temperature. The inelastic phases are presently modeled by the power-law creep model generalized to multi-directional loading (within fgmc3dq.cylindrical.f and fgmc3dq.cylindrical.transient.f for steady-state and transient thermal loading, respectively), and incremental plasticity and GVIPS unified viscoplasticity theories (within the steady-state loading versions fgmp3dq.cylindrical.f and fgmgvips3dq.cylindrical.f).
Jet engine combustor liners were tested in the structural component response facility at NASA Lewis. In this facility combustor liners were thermally cycled to simulate a flight envelope of takeoff, cruise, and return to idle. Temperatures were measured with both thermocouples and an infrared thermal imaging system. A conventional stacked-ring louvered combustor liner developed a crack at 1603 cycles. This test was discontinued after 1728 cycles because of distortion of the liner. A segmented or float wall combustor liner tested at the same heat flux showed no significant change after 1600 cycles. Changes are being made in the facility to allow higher temperatures.
An engineering approach for the application of textile composites to a structural component is addressed. The main objective is to improve impact resistance of composite blades by using some form of 3-D reinforcement. Project goals, results, and conclusions are discussed.
A more accurate procedure was developed for the determination of the inelastic behavior of structural components. The actual stress-strain curve for the mathematical of the structure was utilized to generate the force-deformation relationships for the structural elements, rather than using simplified models such as elastic-plastic, bilinear and trilinear approximations. relationships were generated for beam elements with various types of cross sections. In the generational of these curves, stress or load reversals, kinematic hardening and hysteretic behavior were taken into account. Intersections between loading and unloading branches were determined through an iterative process. Using the inelastic properties obtained, the plastic static response of some simple structural systems composed of beam elements was computed. Results were compared with known solutions, indicating a considerable improvement over response predictions obtained by means of simplified approximations used in previous investigations.
Formal approaches are summarized to evaluate design concepts and perform sensitivity analyses on design parameters of composite structural components for vehicles. The formal approaches include structural analyses coupled with composite micromechanics to assess the structural response of beams made from various intraply hybrids, finite element analysis in conjunction with composite mechanics to assess the structural response of panels made from strip hybrids, and sensitivity analysis through optimization to assess the effects of various design parameters on the optimum design of a panel made from angleplied composite laminates. Results obtained from these approaches are presented in graphical and tabular form to illustrate parametric studies and acceptable ranges of various design parameters.
A theory is developed for predicting the hydrothermomechanical response of advanced composite structural components. The combined hydrothermal effects on the mechanical properties of unidirectional composites loaded along the material axis and off-axis, and of angleplied laminates are also evaluated. The materials investigated consist of neat PR-288 epoxy matrix resin and an AS-type graphite fiber/PR-288 resin unidirectional composite.
This paper presents a model for predicting the life of laminated composite structural components subjected to fatigue induced microstructural damage. The model uses the concept of continuum damage mechanics, wherein the effects of microcracks are incorporated into a damage dependent lamination theory instead of treating each crack as an internal boundary. Internal variables are formulated to account for the effects of both matrix cracks and internal delaminations. Evolution laws for determining the damage variables as functions of ply stresses are proposed, and comparisons of predicted damage evolution are made to experiment. In addition, predicted stiffness losses, as well as ply stresses are shown as functions of damage state for a variety of stacking sequences.