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NASA NTRS2004

Structural Benchmark Testing of Superalloy Lattice Block Subelements Completed

Superalloy lattice block panels, which are produced directly by investment casting, are composed of thin ligaments arranged in three-dimensional triangulated trusslike structures (see the preceding figure). Optionally, solid panel face sheets can be formed integrally during casting. In either form, lattice block panels can easily be produced with weights less than 25 percent of the mass of a solid panel. Inconel 718 (IN 718) and MarM-247 superalloy lattice block panels have been developed under NASA's Ultra-Efficient Engine Technology Project and Higher Operating Temperature Propulsion Components Project to take advantage of the superalloys' high strength and elevated temperature capability with the inherent light weight and high stiffness of the lattice architecture (ref. 1). These characteristics are important in the future development of turbine engine components. Casting quality and structural efficiency were evaluated experimentally using small beam specimens machined from the cast and heat treated 140- by 300- by 11-mm panels. The matrix of specimens included samples of each superalloy in both open-celled and single-face-sheet configurations, machined from longitudinal, transverse, and diagonal panel orientations. Thirty-five beam subelements were tested in Glenn's Life Prediction Branch's material test machine at room temperature and 650 C under both static (see the following photograph) and cyclic load conditions. Surprisingly, test results exceeded initial linear elastic analytical predictions. This was likely a result of the formation of plastic hinges and redundancies inherent in lattice block geometry, which was not considered in the finite element models. The value of a single face sheet was demonstrated by increased bending moment capacity, where the face sheet simultaneously increased the gross section modulus and braced the compression ligaments against early buckling as seen in open-cell specimens. Preexisting flaws in specimens were not a discriminator in flexural, shear, or stiffness measurements, again because of redundant load paths available in the lattice block structure. Early test results are available in references 2 and 3; more complete analyses are scheduled for publication in 2004.

Source record↗

NASA NTRS2012

OVERSMART Reporting Tool for Flow Computations Over Large Grid Systems

Structured grid solvers such as NASA's OVERFLOW compressible Navier-Stokes flow solver can generate large data files that contain convergence histories for flow equation residuals, turbulence model equation residuals, component forces and moments, and component relative motion dynamics variables. Most of today's large-scale problems can extend to hundreds of grids, and over 100 million grid points. However, due to the lack of efficient tools, only a small fraction of information contained in these files is analyzed. OVERSMART (OVERFLOW Solution Monitoring And Reporting Tool) provides a comprehensive report of solution convergence of flow computations over large, complex grid systems. It produces a one-page executive summary of the behavior of flow equation residuals, turbulence model equation residuals, and component forces and moments. Under the automatic option, a matrix of commonly viewed plots such as residual histograms, composite residuals, sub-iteration bar graphs, and component forces and moments is automatically generated. Specific plots required by the user can also be prescribed via a command file or a graphical user interface. Output is directed to the user s computer screen and/or to an html file for archival purposes. The current implementation has been targeted for the OVERFLOW flow solver, which is used to obtain a flow solution on structured overset grids. The OVERSMART framework allows easy extension to other flow solvers.

Kao, David L.↗

NASA NTRS1993

Preconditioned Conjugate Gradient methods for low speed flow calculations

An investigation is conducted into the viability of using a generalized Conjugate Gradient-like method as an iterative solver to obtain steady-state solutions of very low-speed fluid flow problems. Low-speed flow at Mach 0.1 over a backward-facing step is chosen as a representative test problem. The unsteady form of the two dimensional, compressible Navier-Stokes equations are integrated in time using discrete time-steps. The Navier-Stokes equations are cast in an implicit, upwind finite-volume, flux split formulation. The new iterative solver is used to solve a linear system of equations at each step of the time-integration. Preconditioning techniques are used with the new solver to enhance the stability and the convergence rate of the solver and are found to be critical to the overall success of the solver. A study of various preconditioners reveals that a preconditioner based on the lower-upper (L-U)-successive symmetric over-relaxation iterative scheme is more efficient than a preconditioner based on incomplete L-U factorizations of the iteration matrix. The performance of the new preconditioned solver is compared with a conventional line Gauss-Seidel relaxation (LGSR) solver. Overall speed-up factors of 28 (in terms of global time-steps required to converge to a steady-state solution) and 20 (in terms of total CPU time on one processor of a CRAY-YMP) are found in favor of the new preconditioned solver, when compared with the LGSR solver.

Ajmani, Kumud↗

NASA NTRS1994

A visual detection model for DCT coefficient quantization

The discrete cosine transform (DCT) is widely used in image compression and is part of the JPEG and MPEG compression standards. The degree of compression and the amount of distortion in the decompressed image are controlled by the quantization of the transform coefficients. The standards do not specify how the DCT coefficients should be quantized. One approach is to set the quantization level for each coefficient so that the quantization error is near the threshold of visibility. Results from previous work are combined to form the current best detection model for DCT coefficient quantization noise. This model predicts sensitivity as a function of display parameters, enabling quantization matrices to be designed for display situations varying in luminance, veiling light, and spatial frequency related conditions (pixel size, viewing distance, and aspect ratio). It also allows arbitrary color space directions for the representation of color. A model-based method of optimizing the quantization matrix for an individual image was developed. The model described above provides visual thresholds for each DCT frequency. These thresholds are adjusted within each block for visual light adaptation and contrast masking. For given quantization matrix, the DCT quantization errors are scaled by the adjusted thresholds to yield perceptual errors. These errors are pooled nonlinearly over the image to yield total perceptual error. With this model one may estimate the quantization matrix for a particular image that yields minimum bit rate for a given total perceptual error, or minimum perceptual error for a given bit rate. Custom matrices for a number of images show clear improvement over image-independent matrices. Custom matrices are compatible with the JPEG standard, which requires transmission of the quantization matrix.

Ahumada, Albert J., Jr.↗

NASA NTRS2001

Longtime Durability of PMR-15 Matrix Polymer at 204, 260, 288, and 316 C

Isothermal weight loss studies at the Glenn (Lewis) Research Center were conducted at four temperatures (204, 260, 288, and 316 C) with specimens of varied geometric shapes to investigate the mechanisms involved in the thermal degradation of PMR-15. Both neat resin behavior and composite behaviors were studied. Two points of interest in these studies are the role(s) of oxygen in the mechanisms involved in the thermo-oxidative degradation of these composite materials and the dimensional changes that occur during their useable lifetime. Specimen dimensional changes and surface layer growth were measured and recorded. It was shown that physical and chemical changes take place as a function of time and location in PMR-15 neat resin and composites as aging takes place in air at elevated temperatures. These changes initiate at the outer surfaces of both materials and progress inward following the oxygen as it proceeds by diffusion into the central core of each material. Microstructural changes cause changes in density, material shrinkage (strains), glass transition temperature, dimension, dynamic shear modulus, and compression properties. These changes also occur slowly dividing the polymer material into two distinct parts: a visibly undamaged core section between two visibly damaged surface layers. The surface layer has a significant effect on compression properties of thinner specimens, but the visibly undamaged core material controls these properties for specimens having eight or more plies. It was demonstrated that there are three different mechanisms involved in the degradation of PMR-15 during aging at elevated temperatures. These are a weight gain, a small weight fraction bulk material weight loss, and a large mass fraction weight loss concentrated at the surface of the polymer or composite. At the higher temperatures (260 C and above), the surface loss predominates. Below 260 C, the surface loss and the bulk core loss become more equivalent. Between 175 and 260 C, the initial weight change is due to a weight gain mechanism with a visible lifetime that diminishes as the aging temperature increases.

Bowles, Kenneth J.↗

NASA NTRS1995

A simulated RTM process for fabricating polyimide (AMB-21) carbon fiber composites

An experimental polyimide matrix, AMB-21 - supplied by NASA/LeRC, was especially formulated to be non-carcinogenic. It was also expected to be amenable to a Resin Transfer Molding Process (RTM). AMB-21 is a solid at room temperature and must be heated to a very high temperature to obtain a fluid state. However, even after heating it to a realistic high temperature, it was found to be too viscous for use in a RTM process. As a result, a promising approach was experimented leading to the introduction of the resin into a solvent solution in order to obtain a viscosity suitable for RTM. A mixture of methanol and tetrahydroferone was found to be a suitable solvent mixture. The matrix solution was introduced into carbon-fiber preform using two techniques: (1) injection of matrix into a Resin Transfer Mold after positioning the preform into the 'mold cavity', and (2) infiltration of matrix into the preform using the 'autoclave through-the-thickness transfer process'. After completing the resin transfer (infiltration) process, the 'filled' preform was heated to 300 F for one hour to reduce the solvent content. The temperature was then increased to 400 F under a vacuum to complete the solvent evaporation and to remove volatile products of the polyimide imidization. The impregnated preform was removed from the mold and press-cured at 200 psi and 600 FF for two hours. The resulting panel was found to be of reasonably good quality. This observation was based on the results obtained from short beam shear strength (700-8000 psi) tests and microscopic examination of the cross-section indicating a very low level of porosity. Further, the flash around the molded panels from the compression molding was free of porosity indicating the removal of volatiles, solvents, and other imidization products. Based on these studies, a new RTM mold containing a diaphragm capable of applying 200 psi at 600 F has been designed and constructed with the expectation that it will allow the incorporation of all of the above processing steps, including the consolidation with the preform in the mold cavity. Moreover, the new diaphragm design will enable to process larger preform panels. Processing studies with the diaphragm mold are being initiated.

Avva, V. Sarma↗

NASA NTRS2006

Mechanical Properties of T650-35/AFR-PE-4 at Elevated Temperatures for Lightweight Aeroshell Designs

Considerable efforts have been underway to develop multidisciplinary technologies for aeroshell structures that will significantly increase the allowable working temperature for the aeroshell components, and enable the system to operate at higher temperatures while sustaining performance and durability. As part of these efforts, high temperature polymer matrix composites and fabrication technologies are being developed for the primary load bearing structure (heat shield) of the spacecraft. New high-temperature resins and composite material manufacturing techniques are available that have the potential to significantly improve current aeroshell design. In order to qualify a polymer matrix composite (PMC) material as a candidate aeroshell structural material, its performance must be evaluated under realistic environments. Thus, verification testing of lightweight PMC's at aeroshell entry temperatures is needed to ensure that they will perform successfully in high-temperature environments. Towards this end, a test program was developed to characterize the mechanical properties of two candidate material systems, T650-35/AFR-PE-4 and T650-35/RP46. The two candidate high-temperature polyimide resins, AFR-PE-4 and RP46, were developed at the Air Force Research Laboratory and NASA Langley Research Center, respectively. This paper presents experimental methods, strength, and stiffness data of the T650-35/AFR-PE-4 material as a function of elevated temperatures. The properties determined during the research test program herein, included tensile strength, tensile stiffness, Poisson s ratio, compressive strength, compressive stiffness, shear modulus, and shear strength. Unidirectional laminates, a cross-ply laminate and two eight-harness satin (8HS)-weave laminates (4-ply and 10-ply) were tested according to ASTM standard methods at room and elevated temperatures (23, 316, and 343 C). All of the relevant test methods and data reduction schemes are outlined along with mechanical data. These data contribute to a database of material properties for high-temperature polyimide composites that will be used to identify the material characteristics of potential candidate materials for aeroshell structure applications.

Whitley, Karen S.↗

NASA NTRS2012

Processing and Damage Tolerance of Continuous Carbon Fiber Composites Containing Puncture Self-Healing Thermoplastic Matrix

Research at NASA Langley Research Center (NASA LaRC) has identified several commercially available thermoplastic polymers that self-heal after ballistic impact and through-penetration. One of these resins, polybutadiene graft copolymer (PB(sub g)), was processed with unsized IM7 carbon fibers to fabricate reinforced composite material for further evaluation. Temperature dependent characteristics, such as the degradation point, glass transition (T(sub g)), and viscosity of the PBg polymer were characterized by thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and dynamic parallel plate rheology. The PBg resin was processed into approximately equal to 22.0 cm wide unidirectional prepreg tape in the NASA LaRC Advanced Composites Processing Research Laboratory. Data from polymer thermal characterization guided the determination of a processing cycle used to fabricate quasi-isotropic 32-ply laminate panels in various dimensions up to 30.5cm x 30.5cm in a vacuum press. The consolidation quality of these panels was analyzed by optical microscopy and acid digestion. The process cycle was further optimized based on these results and quasi-isotropic, [45/0/-45/90]4S, 15.24cm x 15.24cm laminate panels were fabricated for mechanical property characterization. The compression strength after impact (CAI) of the IM7/pBG composites was measured both before and after an elevated temperature and pressure healing cycle. The results of the processing development effort of this composite material as well as the results of the mechanical property characterization are presented in this paper.

Grimsley, Brian W.↗

NASA NTRS1999

Development of Curved-Plate Elements for the Exact Buckling Analysis of Composite Plate Assemblies Including Transverse-Shear Effects

The analytical formulation of curved-plate non-linear equilibrium equations including transverse-shear-deformation effects is presented. A unified set of non-linear strains that contains terms from both physical and tensorial strain measures is used. Linearized, perturbed equilibrium equations (stability equations) that describe the response of the plate just after buckling occurs are derived. These equations are then modified to allow the plate reference surface to be located a distance z(sub c) from the centroidal surface. The implementation of the new theory into the VICONOPT exact buckling and vibration analysis and optimum design computer program is described. The terms of the plate stiffness matrix using both classical plate theory (CPT) and first-order shear-deformation plate theory (SDPT) are presented. The effects of in-plane transverse and in-plane shear loads are included in the in-plane stability equations. Numerical results for several example problems with different loading states are presented. Comparisons of analyses using both physical and tensorial strain measures as well as CPT and SDPT are made. The computational effort required by the new analysis is compared to that of the analysis currently in the VICONOPT program. The effects of including terms related to in-plane transverse and in-plane shear loadings in the in-plane stability equations are also examined. Finally, results of a design-optimization study of two different cylindrical shells subject to uniform axial compression are presented.

McGowan, David M.↗

NASA NTRS1997

Visibility of wavelet quantization noise

The discrete wavelet transform (DWT) decomposes an image into bands that vary in spatial frequency and orientation. It is widely used for image compression. Measures of the visibility of DWT quantization errors are required to achieve optimal compression. Uniform quantization of a single band of coefficients results in an artifact that we call DWT uniform quantization noise; it is the sum of a lattice of random amplitude basis functions of the corresponding DWT synthesis filter. We measured visual detection thresholds for samples of DWT uniform quantization noise in Y, Cb, and Cr color channels. The spatial frequency of a wavelet is r 2-lambda, where r is display visual resolution in pixels/degree, and lambda is the wavelet level. Thresholds increase rapidly with wavelet spatial frequency. Thresholds also increase from Y to Cr to Cb, and with orientation from lowpass to horizontal/vertical to diagonal. We construct a mathematical model for DWT noise detection thresholds that is a function of level, orientation, and display visual resolution. This allows calculation of a "perceptually lossless" quantization matrix for which all errors are in theory below the visual threshold. The model may also be used as the basis for adaptive quantization schemes.

NASA Center ARC↗

NASA NTRS1978

Effect of impact damage on the compression strength of filamentary-composite hat-stiffened panels

An experimental investigation was conducted to evaluate the effect of low-velocity impact damage on the compression strength of filamentary-composite hat-stiffened panels. Twenty-four specimens of three design configurations fabricated from graphite-epoxy and boron-epoxy materials were tested. All three design configurations met the design buckling requirements in the undamaged condition. The impact damage was caused by firing aluminum spheres at the panels to simulate impact on aircraft from runway stones. Panels were damaged by impact in the hat cap or in the skin beneath the hat cap (regions of high axial stiffness) and in the skin between stiffeners (region of low axial stiffness). The panels were relatively insensitive to impact damage in the regions of low axial stiffness but were very sensitive to impact damage in the regions of high axial stiffness. Test results suggest that impact damage may be more dependent on the matrix properties than on the fiber properties of the composite materials considered.

Rhodes, M. D.↗

NASA NTRS1989

Polyimide matrix composites - Polyimidesulfone/LARC-TPI (1:1) blend

Polyimide matrix composites were fabricated from unidirectional unsized AS-4 carbon fiber and a doped 1:1 blend of two polyimides: PISO2 and LARC-TPI. To enhance melt flow properties, the molecular weight of the PISO2 was controlled by end-capping with phthalic anhydride and addition of 5 percent by weight p-phenylenediamine-phthalic anhydride bisamic acid dopant. Prepreg was drum-wound using a diglyme slurry comprised of the soluble polyamideacid of PISO2, the soluble bisamideacid of the dopant, and the insoluble imidized LARC-TPI powder. Melt flow studies with a rotary rheometer and parallel plate plastometer on neat resin and prepreg helped develop an optimum cure cycle. Composite mechanical properties at room and elevated temperatures, dry and moisture-saturated, were evaluated, including short beam shear strength and flexure, tensile, shear, and compression properties. Two 18 x 24-inch skin-stringer panels were fabricated, one of which was tested in compression to failure.

Johnston, Norman J.↗

NASA NTRS1993

Energetic particle environment in the early solar system - Extremely long pre-compaction meteoritic ages or an enhanced early particle flux

Individual mineral grains from meteorites have been exposed to energetic particles prior to inclusion in the host meteorite matrix, an event which occurred quite early in solar system history. Spallation-produced noble gases in such grains are observed to be orders of magnitude greater in abundance than could be produced after meteorite formation and thus provide a record of precompaction irradiation by energetic particles. If attributed to the contemporary particle environment (current galactic and solar cosmic rays) a minimum exposure time for these grains in the CM parent-body regolith of 150 Myr is obtained, with more realistic models suggesting an active parent body regolith for 300 Myr. Constraints on when meteorite compaction occurred and current models for meteorite evolution suggest that this is unreasonably long, that the time available for exposure to energetic particles on the surface of the parent-body regolith is much less than this. Pre-compaction exposure, compressed into a shorter span of time by constraints on the compaction times of carbonaceous meteorites, would require energetic particle fluxes in excess of those in the contemporary solar system and point toward an active early (T Tauri) sun as its source.

Woolum, Dorothy S.↗

NASA NTRS1993

Schlieren photographs and internal pressure distributions for three-dimensional sidewall-compression scramjet inlets at a Mach number of 6 in CF4

Three-dimensional sidewall-compression scramjet inlets with leading-edge sweeps of 30 deg and 70 deg were tested in the Langley Hypersonic CF4 Tunnel at a Mach number of 6 and a free-stream ratio of specific heats of 1.2. The parametric effects of leading-edge sweep, cowl position, contraction ratio, and Reynolds number were investigated. The models were instrumented with static pressure orifices distributed on the sidewalls, baseplate, and cowl. Schlieren movies were made of selected tunnel runs for flow visualization of the entrance plane and cowl region. Although these movies could not show the internal flow, the effect of the internal flow on the external flow was evident by way of spillage. The purpose is to provide a preliminary data release for the investigation. The models, facility, and testing methods are described, and the test matrix and a tabulation of tunnel runs are provided. Line plots highlighting the stated parametric effects and a representative set of schlieren photographs are presented without analysis.

Holland, Scott D.↗

NASA NTRS1996

Perceptually Lossless Wavelet Compression

The Discrete Wavelet Transform (DWT) decomposes an image into bands that vary in spatial frequency and orientation. It is widely used for image compression. Measures of the visibility of DWT quantization errors are required to achieve optimal compression. Uniform quantization of a single band of coefficients results in an artifact that is the sum of a lattice of random amplitude basis functions of the corresponding DWT synthesis filter, which we call DWT uniform quantization noise. We measured visual detection thresholds for samples of DWT uniform quantization noise in Y, Cb, and Cr color channels. The spatial frequency of a wavelet is r 2(exp -1), where r is display visual resolution in pixels/degree, and L is the wavelet level. Amplitude thresholds increase rapidly with spatial frequency. Thresholds also increase from Y to Cr to Cb, and with orientation from low-pass to horizontal/vertical to diagonal. We propose a mathematical model for DWT noise detection thresholds that is a function of level, orientation, and display visual resolution. This allows calculation of a 'perceptually lossless' quantization matrix for which all errors are in theory below the visual threshold. The model may also be used as the basis for adaptive quantization schemes.

Watson, Andrew B.↗

NASA NTRS1995

Visibility of Wavelet Quantization Noise

The Discrete Wavelet Transform (DWT) decomposes an image into bands that vary in spatial frequency and orientation. It is widely used for image compression. Measures of the visibility of DWT quantization errors are required to achieve optimal compression. Uniform quantization of a single band of coefficients results in an artifact that is the sum of a lattice of random amplitude basis functions of the corresponding DWT synthesis filter, which we call DWT uniform quantization noise. We measured visual detection thresholds for samples of DWT uniform quantization noise in Y, Cb, and Cr color channels. The spatial frequency of a wavelet is r 2(exp)-L , where r is display visual resolution in pixels/degree, and L is the wavelet level. Amplitude thresholds increase rapidly with spatial frequency. Thresholds also increase from Y to Cr to Cb, and with orientation from low-pass to horizontal/vertical to diagonal. We describe a mathematical model to predict DWT noise detection thresholds as a function of level, orientation, and display visual resolution. This allows calculation of a "perceptually lossless" quantization matrix for which all errors are in theory below the visual threshold. The model may also be used as the basis for adaptive quantization schemes.

Watson, Andrew B.↗

NASA NTRS2010

Parametric Geometry, Structured Grid Generation, and Initial Design Study for REST-Class Hypersonic Inlets

Computational design and analysis of three-dimensional hypersonic inlets with shape transition has been a significant challenge due to the complex geometry and grid required for three-dimensional viscous flow calculations. Currently, the design process utilizes an inviscid design tool to produce initial inlet shapes by streamline tracing through an axisymmetric compression field. However, the shape is defined by a large number of points rather than a continuous surface and lacks important features such as blunt leading edges. Therefore, a design system has been developed to parametrically construct true CAD geometry and link the topology of a structured grid to the geometry. The Adaptive Modeling Language (AML) constitutes the underlying framework that is used to build the geometry and grid topology. Parameterization of the CAD geometry allows the inlet shapes produced by the inviscid design tool to be generated, but also allows a great deal of flexibility to modify the shape to account for three-dimensional viscous effects. By linking the grid topology to the parametric geometry, the GridPro grid generation software can be used efficiently to produce a smooth hexahedral multiblock grid. To demonstrate the new capability, a matrix of inlets were designed by varying four geometry parameters in the inviscid design tool. The goals of the initial design study were to explore inviscid design tool geometry variations with a three-dimensional analysis approach, demonstrate a solution rate which would enable the use of high-fidelity viscous three-dimensional CFD in future design efforts, process the results for important performance parameters, and perform a sample optimization.

Ferlemann, Paul G.↗

NASA NTRS1997

Low Cost Manufacturing Approach of High Temperature PMC Components

The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

Kannmacher, Kevin↗