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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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At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Bearing-bypass loading on bolted composite joints

The effects of simultaneous bearing and bypass loading on a graphite-epoxy (T300/5208) laminate were investigated. Onset damage and ultimate strengths were determined for each test case. A finite element stress analysis was conducted for each test case. The computed local stresses were used with appropriate failure criteria to analyze the observed failure modes and strengths. An unexpected interaction of the effect of the bypass and bearing loads was found for the onset of compression reacted bearing damage. The interaction was caused by a decrease in the bolt-hole contact arc and a corresponding increase in the severity of the bearing loads. The amount of bolt-hole contact had a significant effect on local stresses and, thus, on the calculated damage-onset and ultimate strengths. An offset-compression failure mode was identified for laminate failure under compression bearing-bypass loading.

Crews, J. H., Jr.↗
NASA NTRS2018

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing↗
NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite materials were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding of candidate materials to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗
DOE OSTI2022

MPEX High Heat Flux Plasma Dump Design, Manufacture, and Articles Test

Here, the Material Plasma Exposure eXperiment (MPEX) device is a steady-state linear plasma device currently in the final design phase at the Oak Ridge National Laboratory. This device will reach ion fluences up to 10 31 m -2 and will be used to expose neutron-irradiated materials to divertor-relevant plasmas and to study the effects of plasma-material interactions. These studies will elucidate the complex effects of plasmas with divertor candidate materials capable of withstanding high heat flux and high fluences for next-generation fusion devices. Bidirectional plasma will be generated using a high-power (200 kW) helicon source. Plasma will be confined by superconducting magnets. The last plasma-facing component on the upstream side of the MPEX device is the dump, which has been designed to intercept plasma and energetic particles. The dump will have a total heat load of 9.2 kW. A copper alloy (Glidcop AL-15) was selected for use in the water-cooled flange design because of its high thermal conductivity, its retaining strength at elevated temperatures, and its ability to be used in the high-temperature braze joints used in this application. Titanium-zirconium-molybdenum (TZM) tiles are brazed to the Glidcop AL-15 flange using high-temperature braze alloy. External water-cooling channels are used on the dump flange to prevent water leakage inside the vacuum space. This article discusses the details of the high heat flux dump design, including the computational fluid dynamics (CFD) and structural analyses performed to validate the design to meet the operational requirements of the MPEX device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1974

Method of making an explosively welded scarf joint

A method is presented for obtaining a bond joint between thin metal members without the addition of a bonding agent. The method yields bond strengths comparable to the parent metal. The method comprises overlapping the materials at the edges and bonding them by explosive welding while also making use of the explosive force to shape the materials into an essentially planar configuration.

Bement, L. J.↗
NASA NTRS1990

Intercalated graphite fiber composites as EMI shields in aerospace structures

The requirements for electromagnetic interference (EMI) shielding in aerospace structures are complicated over that of ground structures by their weight limitations. As a result, the best EMI shielding materials must blend low density, high strength, and high elastic modulus with high shielding ability. In addition, fabrication considerations including penetrations and joints play a major role. The EMI shielding properties are calculated for shields formed from pristine and intercalated graphite fiber/epoxy composites and compared to preliminary experimental results and to shields made from aluminum. Calculations indicate that EMI shields could be fabricated from intercalated graphite composites which would have less than 12 percent of the mass of conventional aluminum shields, based on mechanical properties and shielding properties alone.

Gaier, James R.↗
NASA NTRS1992

Development of an empirically based dynamic biomechanical strength model

The focus here is on the development of a dynamic strength model for humans. Our model is based on empirical data. The shoulder, elbow, and wrist joints are characterized in terms of maximum isolated torque, position, and velocity in all rotational planes. This information is reduced by a least squares regression technique into a table of single variable second degree polynomial equations determining the torque as a function of position and velocity. The isolated joint torque equations are then used to compute forces resulting from a composite motion, which in this case is a ratchet wrench push and pull operation. What is presented here is a comparison of the computed or predicted results of the model with the actual measured values for the composite motion.

Pandya, A.↗
NASA NTRS2000

Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs

The continual need to reduce airframe cost and the emergence of high speed machining and other manufacturing technologies has brought about a renewed interest in large-scale integral structures for aircraft applications. Applications have been inhibited, however, because of the need to demonstrate damage tolerance, and by cost and manufacturing risks associated with the size and complexity of the parts. The Integral Airframe Structures (IAS) Program identified a feasible integrally stiffened fuselage concept and evaluated performance and manufacturing cost compared to conventional designs. An integral skin/stiffener concept was produced both by plate hog-out and near-net extrusion. Alloys evaluated included 7050-T7451 plate, 7050-T74511 extrusion, 6013-T6511 extrusion, and 7475-T7351 plate. Mechanical properties, structural details, and joint performance were evaluated as well as repair, static compression, and two-bay crack residual strength panels. Crack turning behavior was characterized through panel tests and improved methods for predicting crack turning were developed. Manufacturing cost was evaluated using COSTRAN. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current technology baseline.

Pettit, R. G.↗
NASA NTRS1973

Adhesive-bonded double-lap joints

Explicit analytical solutions are derived for the static load carrying capacity of double-lap adhesive-bonded joints. The analyses extend the elastic solution Volkersen and cover adhesive plasticity, adherend stiffness imbalance and thermal mismatch between the adherends. Both elastic-plastic and bi-elastic adhesive representations lead to the explicit result that the influence of the adhesive on the maximum potential bond strength is defined uniquely by the strain energy in shear per unit area of bond. Failures induced by peel stresses at the ends of the joint are examined. This failure mode is particularly important for composite adherends. The explicit solutions are sufficiently simple to be used for design purposes

Hart-Smith, L. J.↗
NASA NTRS2021

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the-art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts. The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners. However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen Michael Middleton↗
NASA NTRSDate not supplied

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts.1,2 The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners.1 However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen M Middleton↗
DOE OSTI2020

Control of Weld Residual Stress in a Thin Steel Plate through Low Transformation Temperature Welding Consumables

Low transformation temperature welding (LTTW) consumables are characterized by a low martensite start temperature and a large fraction of martensite forming in the weld. It can efficiently reduce the tensile residual stress because the volume expansion associated with the martensitic transformation compensates for the thermal contraction during cooling. In this work, a LTTW wire, designated as EH200B, was created for the arc welding of advanced high-strength steel thin plates. In comparison to conventional ER70S-3 wires, this LTTW wire generated an opposite distortion pattern. Neutron diffraction measurements along the center thickness of the welded plates showed the maximum residual stress along the longitudinal direction (LD) in the weld region, and the heat-affected zone (HAZ) immediately adjacent to the weld region was reduced from ~330 MPa to below 240 MPa by using the LTTW wire. A finite element (FE) model was developed to predict the residual stress distributions of the plates welded under these two wires. The simulation results showed reasonable agreement with the volume-average neutron diffraction data. Compressive residual stress in the weld region using the LTTW wire was predicted by the FE method. Electron backscattered diffraction and x-ray diffraction measurements confirmed ~90% martensite was present in the LTTW weld. The fatigue life of DP980 steel lap joint panels using EH200B wire nearly doubled that of ER70S-3 wire. This improvement was attributed to the high strength and low LD residual stress in the weld and HAZ immediately adjacent to the weld.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Estimating epistemic uncertainty in soil parameters for nonlinear site response analyses: Introducing the Latin Hypercube Sampling technique

This study quantifies the effects of epistemic uncertainty in soil parameters on nonlinear (NL) site response analysis (SRA) results, validated against the data recorded at a well-instrumented geotechnical downhole array located in Japan. To this end, a one-dimensional soil column model of the Service Hall Array (SHA) near the Kashiwazaki-Kariwa Nuclear Power Plant (KKNPP) is developed using the finite element (FE) program LS-DYNA. The dynamic stress–strain relationship is characterized by a modified two-stage hyperbolic (MTH) NL backbone curve formulation capable of capturing soil behavior at both small- and large-shear strains. The model is then validated against the ground motion recordings to capture the model bias. The uncertainties associated with the shear-wave velocity profile (a small-strain soil property) and soil shear strength (a large-strain soil property) are incorporated in NL SRA to quantify their separate and joint randomization effects on the results. This study proposes using the Latin Hypercube Sampling (LHS) method as an efficient alternative to commonly used methods, such as Standard Monte Carlo (SMC), to account for uncertainty propagation in such reliability analysis. Both low-intensity and design-level records from the recordings at the SHA are applied to study the contribution of the small- and large-strain NL dynamic soil properties. Results from 46,200 NL FE analyses (23,100 per input motion) are presented. Measured and predicted site response, using recorded ground motions at this downhole array, is compared to assess the significance of soil parameter uncertainty on the observed ground motion dispersions. It is demonstrated that increasing the number of soft realizations and implementing higher level earthquake intensity lead to higher ground motion dispersion. Unlike past studies in randomization of Vs profiles with the SMC method, the LHS method is shown to have no significant effect on the predicted median surface response spectra and amplification factors (AFs) for this case study.

Engineering↗
NASA NTRS1972

Investigation of gold embrittlement in connector solder joints

An investigation was performed to determine to what extent typical flight connector solder joints may be embrittled by the presence of gold. In addition to mapping of gold content in connector solder joints by an electron microprobe analyzer, metallographic examinations and mechanical tests (thermal shock, vibration, impact and tensile strength) were also conducted. A description of the specimens and tests, a discussion of the data, and some conclusions are presented.

Lane, F. L.↗
NASA NTRS1972

Investigation of mounting discrete chip components for hybrid microelectronic applications.

In the assembly of hybrid microcircuits, passive and active discrete chip components are attached by epoxy cements and by solders. This study was initiated to determine the integrity of such attachments. Alumina substrates were subjected to a group of thermal and mechanical test environments defined by test methods in MIL-STD-883. Lot samples of substrates with assembly variations were subjected to separately applied testing and to serial testing. These test methods were applied sequentially to the same lot of substrates. Epoxy cements were generally satisfactory with respect to separate tests, although sequential tests severely degraded epoxy bond strengths of all types. Bond strengths to unglazed substrates were slightly superior to those of the same components on glazed types. Solder joints were vulnerable to catastrophic failure in several environments, especially temperature cycling and thermal shock. Vibration and impact shock also produced solder joint failures.

Caruso, S. V.↗
NASA NTRS1975

Repair of boron/aluminum composites

A program was performed to determine the repairability of boron/aluminum aerospace structural components. During the program, a list of repair guidelines was prepared to aid in determining the proper repair techniques for a given structure. These guidelines included specifying types of repair material and their applicability, corrosion prevention procedures, design criteria, and inspection criteria. Six sets of boron/aluminum structural components were repaired and tested to compare as-fabricated and repaired performance. The specimens included a honeycomb-stiffened panel, elastically buckled tubes, a skin-stringer panel, a tube combining bending and tension, a splice joint specimen, and a tension field panel. All but one set of specimens, when repaired, exceeded the strength of the original specimens. The repairs resulted in an average weight increase per structure of 9% and an average performance increase of 27%. It is concluded that metal-matrix composite material, damaged in service, can be repaired by techniques not very different from those currently in use for conventional materials.

Christian, J. L.↗
NASA NTRS1977

Evaluating of NASA-Langley Research Center explosion seam welding

An explosion bonding technique to meet current fabrication requirements was demonstrated. A test program was conducted on explosion bonded joints, compared to fusion joints in 6061-T6 aluminum. The comparison was made in required fixtures, non-destructive testing, static strength and fatigue strength.

Otto, H. E.↗