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Proposed valve employs ferrofluid to make tight seal. Seal requires no precisely machined parts, and hand lapping of valve seats are unnecessary. Magnetic fluid fills gap between shaft and annular pole piece in chamber wall. Precise shaft fit is not necessary.
The feasibility of developing a high temperature capacitor for 1100 F operation which is as small and light as conventional capacitors for normal operating temperatures is discussed. Pyrolyic boron nitride (PBN) was selected for the dielectric. The PBN capacitors were made by slicing and lapping material from thick blocks and then sputtering thin film electrodes. These capacitors had breakdown strengths of 7,000 volts per mil and a dissipation factor of less than 0.001 at 1100 F. Additional processing improvements were made after testing a multi-layer or stacked PBN capacitor for 1,000 hours at 1100 F. Sputter etching the wafers before depositing electrodes resulted in a reduction in dissipation factor. A sputtered boron nitride film applied to the outer electrode surfaces produced a more stable capacitor. A design for a 0.1 mu F capacitor and a summary of PBN wafer fabrication costs are given.
A simple bolted joint was analyzed to calculate bolt clampup relaxation for a graphite/epoxy (T300/5208) laminate. A viscoelastic finite element analysis of a double-lap joint with a steel bolt was conducted. Clampup forces were calculated for various steady-state temperature-moisture conditions using a 20-year exposure duration. The finite element analysis predicted that clampup forces relax even for the room-temperature-dry condition. The relaxations were 8, 13, 20, and 30 percent for exposure durations of 1 day, 1 month, 1 year, and 20 years, respectively. As expected, higher temperatures and moisture levels each increased the relaxation rate. The combined viscoelastic effects of steady-state temperature and moisture appeared to be additive. From the finite-element analysis, a simple equation was developed for clampup force relaxation. This generalized equation was used to calculate clampup forces for the same temperature-moisture conditions as used in the finite-element analysis. The two sets of calculated results agreed well.
Work has progressed in fabrication and characterization of solar cells from ubiquitous crystallization process (UCP) wafers and LASS ribbons. Gettering tests applied to UCP wafers made little change on their performance compared with corresponding baseline data. Advanced processes such as shallow junction (SJ), back surface field (BSF), and multilayer antireflection (MLAR) were also applied. While BSF by Al paste had shunting problems, cells with SJ and BSF by evaporated Al, and MLAR did achieve 14.1% AMI on UCP silicon. The study of LASS material was very preliminary. Only a few cells with SJ, BSR, (no BSF) and MLAR were completed due to mechanical yield problems after lapping the material. Average efficiency was 10.7% AMI with 13.4% AMI for CZ controls. Relatively high minority carrier diffusion lengths were obtained. The lower than expected Jsc could be partially explained by low active area due to irregular sizes.
Sixteen ply, quasi-isotropic laminates of Celanese Celion 6000/PMR-15 and Celion 6000/LARC-160 with a fiber orientation of (0/45/90/-45) sub 2S were evaluated. Tensile and open hole specimens were tested at room temperature to establish laminate tensile strength and net tensile strength at an unloaded bolt hole. Double lap joint specimens with a single 4.83-mm (0.19 in.) diameter bolt torqued to 1.7 N-m (15 lbf-in.) were tested in tension at temperatures of 116 K (-250F), 297 K (75F), and 589 K (600F). The joint ratios of w/d (specimen width to hole diameter) and e/d (edge distance to hole diameter) were varied from 4 to 6 and from 2 to 4, respectively. The effect of joint geometry and temperature on failure mode and joint stresses are shown. Joint stresses calculated at maximum load for each joint geometry and test temperature are reported. Joint strength in net tension, bearing, and shear out at 116 K (-250F), 297 K (75F), and 589 K (600F) are given for the Celion 6000/PMR-15 and Celion 6000/LARC-160 laminates.
The individual sensor system design elements which are the priori components in the registration and rectification process, and the potential impact of error budgets on multitemporal registration and side-lap registration are analyzed. The properties of scanner, MLA, and SAR imaging systems are reviewed. Each sensor displays internal distortion properties which to varying degrees make it difficult to generate on orthophoto projection of the data acceptable for multiple pass registration or meeting national map accuracy standards and is also affected to varying degrees by relief displacements in moderate to hilly terrain. Nonsensor related distortions, associated with the accuracy of ephemeris determination and platform stability, have a major impact on local geometric distortions. Platform stability improvements expected from the new multi mission spacecraft series and improved ephemeris and ground control point determination from the NAVSTAR/global positioning satellite systems are reviewed.
The evaluation, selection, and demonstration of structural adhesive systems for supersonic cruise research applications, and establishment of environmental durability of selected systems for up to 20,000 hours is described. Ten candidate adhesives were initially evaluated. During screening and evaluation, these candidates were narrowed to three of the most promising for environmental durability testing. The three adhesives were LARC-13, PPQ, and NR056X. The LARC-13 was eliminated because of a lack of stability at 505 K. The NRO56X was removed from the market. The LARC-TPI was added after preliminary evaluation and an abbreviated screening test. Only PPQ and LARC-TPI remained as the reasonable candidates late into the durability testing. Large area bond panels were fabricated to demonstrate the processibility of the selected systems. Specifications were prepared to assure control over critical material and process parameters. Surface characterization concentrated primarily upon titanium surface treatments of 10 volt chronic acid anodize, 5 volt chromic acid anodize and PASA-JELL. Failure analysis was conducted on lap shear adhesive bond failures which occurred in PPQ and LARC-13 test specimens after 10,000 hours at 505 K.
When an adhesively bonded joint is undergoing cyclic loading, one of the possible damage modes that occurs is called cyclic debonding - progressive separation of the adherends by failure of the adhesive bond under cyclic loading. In most practical structures, both peel and shear stresses exist in the adhesive bonding during cyclic loading. The results of an experimental and analytical study to determine the role of peel stresses on cyclic debonding in a mixed mode specimen are presented. Experimentally, this was done by controlling the forces that create the peel stresses by applying a clamping force to oppose the peel stresses. Cracked lap shear joints were chosen for this study. A finite element analysis was developed to assess the effect of the clamping force on the strain energy release rates due to shear and peel stresses. The results imply that the peel stress is the principal stress causing cyclic debonding.
Previously developed computer programs for analyzing stepped-lap adhesive-bonded joints and doublers have been modified to permit the inclusion of variable adhesives as well as nonuniform adherends. The new version of the analysis program is described with reference to examples illustrating the effects of load redistribution around flaws and porosity. The loss of strength associated with pinched-off edges is illustrated, and the benefits of deliberately thickening the adhesive layer in the immediate vicinity of the ends of the overlap are demonstrated. The changes in shear load transfer due to softening of some of the adhesive by moisture absorption while the remainder either has never been soaked or has dried out locally are discussed.
Digital system automatically guides welding torch to produce squarebutt, V-groove and lap-joint weldments within tracking accuracy of +0.2 millimeter. Television camera observes and traverses weld joint, carrying welding torch behind. Image of joint digitized, and resulting data used to derive control signals that enable torch to track joint.
The molecular understanding of the role which the surface oxide layer of the adherend plays in titanium bonding is studied. The effects of Ti6-4 adherends pretreatment, bonding conditions, and thermal aging of the lap shear specimens were studied. The use of the SEM/EDAX and ESCA techniques to study surface morphology and surface composition was emphasized. In addition, contact angles and both infrared and visible reflection spectroscopy were used in ancillary studies.
The use of mixed solvents and of modified monomeric ester reactants was investigated as a means of improving the tack and drape retention characteristics of PMR-15 polyimide prepreg. Methanol, ethanol, 1-propanol and 1-butanol were used to prepare the esters, prepreg solutions, and T-300 graphite fabric and Celion 6000 unidirectional fiber prepregs. The tack retention characteristics of the T-300 fabric prepreg after exposure to simulated use conditions were determined using a simple lap shear test. Drape was qualitatively assessed by visually monitoring the deformability of the prepreg. Thermo-oxidative stability and mechanical properties retention of the Celion 6000 grahite fiber composites were determined as a function of exposure time in air at 600 F.
The effects of simulated lightning strikes and currents on aircraft bonded joints and access/inspection panels were investigated. Both metallic and composite specimens were tested. Tests on metal fuel feed through elbows in graphite/epoxy structures were evaluated. Sparking threshold and residual strength of single lap bonded joints and sparking threshold of access/inspection panels and metal fuel feed through elbows are reported.
A highly reliable, fully digital, closed circuit television optical, type automatic weld seam tracking control system was developed. This automatic tracking equipment is used to reduce weld tooling costs and increase overall automatic welding reliability. The system utilizes a charge injection device digital camera which as 60,512 inidividual pixels as the light sensing elements. Through conventional scanning means, each pixel in the focal plane is sequentially scanned, the light level signal digitized, and an 8-bit word transmitted to scratch pad memory. From memory, the microprocessor performs an analysis of the digital signal and computes the tracking error. Lastly, the corrective signal is transmitted to a cross seam actuator digital drive motor controller to complete the closed loop, feedback, tracking system. This weld seam tracking control system is capable of a tracking accuracy of + or - 0.2 mm, or better. As configured, the system is applicable to square butt, V-groove, and lap joint weldments.
Eight different Ti-6Al-4V surface treatments were investigated for each of 10 candidate resins. Primers (two for each resin) were studied for appropriate cure and thickness and initial evaluation of bond joints began using various combinations of the adhesive resins and surface treatments. Surface failure areas of bonded titanium coupons were analyzed by electron microscopy and surface chemical analysis techniques. Results of surface characterization and failure analysis are described for lap shear bond joints occurring with adhesive systems consisting of: (1) LARC-13 adhesive, Pasa jell surface treatment; (2) LARC-13 adhesive, 10 volt CAA treatment; (3) PPQ adhesive, 10 volt CAA treatment; and (4) PPQ adhesive, 5 volt CAA treatment. The failure analysis concentrated on the 10,000 hr 505K (450 F) exposed specimens which exhibited adhesive failure. Environmental exposure data being generated on the PPQ-10 volt CAA and the LARC-TPI-10 volt CAA adhesive systems is included.
An experimental program was conducted to quantify instability-induced imbedded delamination growth. Static tests on double cantilever beam (DCB) specimens yielded the critical mode 1 strain energy release rate (G sub 1 C) for T300/5208 graphite/epoxy. Static tests on mixed mode cracked lap shear (CLS) specimens, and a nonlinear finite element analysis (NFEA) of the CLS specimen to separate mode 1 and mode 2 effects, yielded the critical mode 2 strain energy release rate (G sub 2 C) for T300/5208. Constant amplitude fatigue tests on DCB and CLS specimens, along with the NFEA results on CLS specimens, quantified mode 1 and mode 2 contributions to delamination growth rate. Fatigue tests were conducted at a frequency (omega) of 10 Hertz, maintaining the minimum to maximum cyclic load ratio (R) at 0.05. Static compression and constant amplitude compression fatigue tests were also conducted on specimens with imbedded through the width (ITTW) delaminations. Kapton imbeddments were located below 3, 4 or 6 plies in a 64-ply laminate, during layup, to simulate ITTW delaminations.
X ray photoelectron spectroscopy and contact angle measurements on graphite fiber composites pretreated in a number of different ways including mechanical, chemical, and light irradiation were analyzed. Data acquired on surface contamination as a result of fabrication techniques provides answers to the strength and durability of adhesively bonded composites. These techniques were shown to provide valuable information on surface analysis of pretreated composites prior to adhesive bonding and following lap shear fracture.
The installation of a composite skin panel on the cargo ramp of a CH-530 marine helicopter is discussed. The composite material is of Kevlar/Epoxy (K/E) which replaces aluminum outer skins on the aft two bays of the ramp. The cargo ramp aft region was selected as being a helicopter airframe surface subjected to possible significant field damage and would permit an evaluation of the long term durability of the composite skin panel. A structural analysis was performed and the skin shears determined. Single lap joints of K/E riveted to aluminum were statically tested. The joint tests were used to determine bearing allowables and the required K/E skin gage. The K/E skin panels riveted to aluminum edge members were tested in a shear fixture to confirm the allowable shear and bearing strengths. Impact tests were conducted on aluminum skin panels to determine energy level and damage relationship. The K/E skin panels of various ply orientations and laminate thicknesses were then impacted at similar energy levels. The results of the analysis and tests were used to determine the required K/E skin gages in each of the end two bays of the ramp.