Substantiation data for hypersonic cruise vehicle wing structure evaluation - Volume 1, sections 1-10
Trajectory, load, aerodynamic heating, materials, structural, and thermal analyses for hypersonic cruise vehicle wings
Davis, G. W.↗
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Analytical Ultrasonics in Materials Research and Testing
Research results in analytical ultrasonics for characterizing structural materials from metals and ceramics to composites are presented. General topics covered by the conference included: status and advances in analytical ultrasonics for characterizing material microstructures and mechanical properties; status and prospects for ultrasonic measurements of microdamage, degradation, and underlying morphological factors; status and problems in precision measurements of frequency-dependent velocity and attenuation for materials analysis; procedures and requirements for automated, digital signal acquisition, processing, analysis, and interpretation; incentives for analytical ultrasonics in materials research and materials processing, testing, and inspection; and examples of progress in ultrasonics for interrelating microstructure, mechanical properites, and dynamic response.
Vary, A.↗
Evaluation of nonmetallic thermal protection materials for the manned space shuttle. Volume 1, task 1: Assessment of technical risks associated with utilization of nonmetallic thermal protection system
Technical problems of design and flight qualification of the proposed classes of surface insulation materials and leading edge materials were reviewed. A screening test plan, a preliminary design data test plan and a design data test plan were outlined. This program defined the apparent critical differences between the surface insulators and the leading edge materials, structuring specialized screening test plans for each of these two classes of materials. Unique testing techniques were shown to be important in evaluating the structural interaction aspects of the surface insulators and a separate task was defined to validate the test plan. In addition, a compilation was made of available information on proposed material (including metallic TPS), previous shuttle programs, pertinent test procedures, and other national programs of merit. This material was collected and summarized in an informally structured workbook.
Wilkinson, W. H.↗
Facesheet Delamination of Composite Sandwich Materials at Cryogenic Temperatures
The next generation of space transportation vehicles will require advances in lightweight structural materials and related design concepts to meet the increased demands on performance. One potential source for significant structural weight reduction is the replacement of traditional metallic cryogenic fuel tanks with new designs for polymeric matrix composite tanks. These new tank designs may take the form of thin-walled sandwich constructed with lightweight core and composite facesheets. Life-time durability requirements imply the materials must safely carry pressure loads, external structural loads, resist leakage and operate over an extremely wide temperature range. Aside from catastrophic events like tank wall penetration, one of the most likely scenarios for failure of a tank wall of sandwich construction is the permeation of cryogenic fluid into the sandwich core and the subsequent delamination of the sandwich facesheet due to the build-up of excessive internal pressure. The research presented in this paper was undertaken to help understand this specific problem of core to facesheet delamination in cryogenic environments and relate this data to basic mechanical properties. The experimental results presented herein provide data on the strain energy release rate (toughness) of the interface between the facesheet and the core of a composite sandwich subjected to simulated internal pressure. A unique test apparatus and associated test methods are described and the results are presented to highlight the effects of cryogenic temperature on the measured material properties.
Gates, Thomas S.↗
Research and test facilities
A description is given of each of the following Langley research and test facilities: 0.3-Meter Transonic Cryogenic Tunnel, 7-by 10-Foot High Speed Tunnel, 8-Foot Transonic Pressure Tunnel, 13-Inch Magnetic Suspension & Balance System, 14-by 22-Foot Subsonic Tunnel, 16-Foot Transonic Tunnel, 16-by 24-Inch Water Tunnel, 20-Foot Vertical Spin Tunnel, 30-by 60-Foot Wind Tunnel, Advanced Civil Transport Simulator (ACTS), Advanced Technology Research Laboratory, Aerospace Controls Research Laboratory (ACRL), Aerothermal Loads Complex, Aircraft Landing Dynamics Facility (ALDF), Avionics Integration Research Laboratory, Basic Aerodynamics Research Tunnel (BART), Compact Range Test Facility, Differential Maneuvering Simulator (DMS), Enhanced/Synthetic Vision & Spatial Displays Laboratory, Experimental Test Range (ETR) Flight Research Facility, General Aviation Simulator (GAS), High Intensity Radiated Fields Facility, Human Engineering Methods Laboratory, Hypersonic Facilities Complex, Impact Dynamics Research Facility, Jet Noise Laboratory & Anechoic Jet Facility, Light Alloy Laboratory, Low Frequency Antenna Test Facility, Low Turbulence Pressure Tunnel, Mechanics of Metals Laboratory, National Transonic Facility (NTF), NDE Research Laboratory, Polymers & Composites Laboratory, Pyrotechnic Test Facility, Quiet Flow Facility, Robotics Facilities, Scientific Visualization System, Scramjet Test Complex, Space Materials Research Laboratory, Space Simulation & Environmental Test Complex, Structural Dynamics Research Laboratory, Structural Dynamics Test Beds, Structures & Materials Research Laboratory, Supersonic Low Disturbance Pilot Tunnel, Thermal Acoustic Fatigue Apparatus (TAFA), Transonic Dynamics Tunnel (TDT), Transport Systems Research Vehicle, Unitary Plan Wind Tunnel, and the Visual Motion Simulator (VMS).
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Development of braided rope engine seals
In this study, after reviewing current seal design concepts, the potential of textile structures for seal design is examined from the material, structural, and fabrication points of view. Braided structures are identified as potential candidates for hypersonic seal structures because of their conformability and design flexibility. A large family of braided structures using 2-D and 3-D architecture can be designed using well established methods to produce a wide range of braiding yarn orientation for wear resistance as well as seal porosity control. As a first demonstration of the approach, 2-D braided fiberglass seals were fabricated according to a factorial design experiment by varying braiding angles, fractional longitudinal fibers, and preload pressure levels. Factorial diagrams and response surfaces were constructed to elucidate the inter-relationship of the braiding parameters as well as the effect of preload pressures on leakage resistance of the seal. It was found that seal resistance is a strong function of fractional longitudinal fiber content. As braiding angle increases, seal leakage resistance increases, especially at high preload pressures and in seals having high proportion of longitudinal fibers.
Ko, Frank K.↗
Adaptive Space Structures
The term adaptive structures refers to a structural control approach in which sensors, actuators, electronics, materials, structures, structural concepts, and system-performance-validation strategies are integrated to achieve specific objectives.
adaptive structures response to external stimulati↗
Assessment and Requirements of Nuclear Reaction Databases for GCR Transport in the Atmosphere and Structures
The transport properties of galactic cosmic rays (GCR) in the atmosphere, material structures, and human body (self-shielding) am of interest in risk assessment for supersonic and subsonic aircraft and for space travel in low-Earth orbit and on interplanetary missions. Nuclear reactions, such as knockout and fragmentation, present large modifications of particle type and energies of the galactic cosmic rays in penetrating materials. We make an assessment of the current nuclear reaction models and improvements in these model for developing required transport code data bases. A new fragmentation data base (QMSFRG) based on microscopic models is compared to the NUCFRG2 model and implications for shield assessment made using the HZETRN radiation transport code. For deep penetration problems, the build-up of light particles, such as nucleons, light clusters and mesons from nuclear reactions in conjunction with the absorption of the heavy ions, leads to the dominance of the charge Z = 0, 1, and 2 hadrons in the exposures at large penetration depths. Light particles are produced through nuclear or cluster knockout and in evaporation events with characteristically distinct spectra which play unique roles in the build-up of secondary radiation's in shielding. We describe models of light particle production in nucleon and heavy ion induced reactions and make an assessment of the importance of light particle multiplicity and spectral parameters in these exposures.
Cucinotta, F. A.↗
Use of lightweight composites for GAS payload structures
A key element in the design of a small self-contained payload is the supporting structure. This structure must support the experiments and other components while using as little space and weight as possible. Hence, the structure material must have characteristics of being both strong and light. Aluminum was used for the structure on the first Purdue University payload, but consumed a relatively large percentage of the total payload weight. The current payload has a larger power supply requirement than did the previous payload. To allow additional weight for the batteries, a composite material has been chosen for the structure which has the required strength while being considerably lighter than aluminum. A radial fin design has been chosen for ease of composite material lay-up and its overall strength of design. A composite plate will connect the free ends of the fins and add strength and reduce vibration. The physical characteristics of the composite material and the method of open lay-up construction is described. Also discussed are the testing, modifications, and problems encountered during assembly of the experiments to the structure.
Spencer, Mark B.↗
Stochastic-Strength-Based Damage Simulation Tool for Ceramic Matrix and Polymer Matrix Composite Structures
Stochastic-based, discrete-event progressive damage simulations of ceramic-matrix composite and polymer matrix composite material structures have been enabled through the development of a unique multiscale modeling tool. This effort involves coupling three independently developed software programs: (1) the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC), (2) the Ceramics Analysis and Reliability Evaluation of Structures Life Prediction Program (CARES/ Life), and (3) the Abaqus finite element analysis (FEA) program. MAC/GMC contributes multiscale modeling capabilities and micromechanics relations to determine stresses and deformations at the microscale of the composite material repeating unit cell (RUC). CARES/Life contributes statistical multiaxial failure criteria that can be applied to the individual brittle-material constituents of the RUC. Abaqus is used at the global scale to model the overall composite structure. An Abaqus user-defined material (UMAT) interface, referred to here as "FEAMAC/CARES," was developed that enables MAC/GMC and CARES/Life to operate seamlessly with the Abaqus FEA code. For each FEAMAC/CARES simulation trial, the stochastic nature of brittle material strength results in random, discrete damage events, which incrementally progress and lead to ultimate structural failure. This report describes the FEAMAC/CARES methodology and discusses examples that illustrate the performance of the tool. A comprehensive example problem, simulating the progressive damage of laminated ceramic matrix composites under various off-axis loading conditions and including a double notched tensile specimen geometry, is described in a separate report.
composite structures↗
Morphology and microstructure of composite materials
Lightweight continuous carbon fiber based polymeric composites are currently enjoying increasing acceptance as structural materials capable of replacing metals and alloys in load bearing applications. As with most new materials, these composites are undergoing trials with several competing processing techniques aimed at cost effectively producing void free consolidations with good mechanical properties. As metallic materials have been in use for several centuries, a considerable database exists on their morphology - microstructure; and the interrelationships between structure and properties have been well documented. Numerous studies on composites have established the crucial relationship between microstructure - morphology and properties. The various microstructural and morphological features of composite materials, particularly those accompanying different processing routes, are documented.
Tiwari, S. N.↗
The application of thermally stable graphite composites to a space telescope structure
An optical bench and associated mirror support structural components were designed and fabricated for the HEAO-B satellite. Stringent dimensional stability criteria dictated the use of a graphite/epoxy composite as the basic structural material. Design, analysis, and fabrication aspects are discussed for the resulting structures, which pioneer the use of advanced composite materials for significant applications to orbital flight hardware.
Prunty, J.↗
Design, fabrication, and test of lightweight shell structure
A cylindrical shell skirt structure was subjected to a design and analysis study using a wide variety of structural materials and concepts. The design loading, axial compression, and torsion is representative of that expected on a typical space tug skirt section. Structural concepts evaluated included honeycomb sandwich, truss, isogrid, and skin/stringer/frame. The materials considered included a wide variety of structural metals as well as glass, graphite, and boron-reinforced composites. Honeycomb sandwich with aluminum faceskins, honeycomb sandwich with graphite/epoxy faceskins, and aluminum truss with fiberglass meteoroid protection layers were the designs selected for further evaluation. Procurement of materials required for fabrication is reported and the structural test plan and fabrication drawings are included. Construction of the graphite/epoxy faceskins, chem mill of the aluminum faceskins, chem mill of aluminum truss components, and fabrication of the graphite/epoxy honeycomb sandwich development panel is also reported.
Source record↗
Multi-Functional BN-BN Composite
Multifunctional Boron Nitride nanotube-Boron Nitride (BN-BN) nanocomposites for energy transducers, thermal conductors, anti-penetrator/wear resistance coatings, and radiation hardened materials for harsh environments. An all boron-nitride structured BN-BN composite is synthesized. A boron nitride containing precursor is synthesized, then mixed with boron nitride nanotubes (BNNTs) to produce a composite solution which is used to make green bodies of different forms including, for example, fibers, mats, films, and plates. The green bodies are pyrolized to facilitate transformation into BN-BN composite ceramics. The pyrolysis temperature, pressure, atmosphere and time are controlled to produce a desired BN crystalline structure. The wholly BN structured materials exhibit excellent thermal stability, high thermal conductivity, piezoelectricity as well as enhanced toughness, hardness, and radiation shielding properties. By substituting with other elements into the original structure of the nanotubes and/or matrix, new nanocomposites (i.e., BCN, BCSiN ceramics) which possess excellent hardness, tailored photonic bandgap and photoluminescence, result.
Kang, Jin Ho↗
Thermal contact conductance between metals in a vacuum environment
Basic heat transfer data for structural materials used in the Saturn 1B/V 1U component case structural design were obtained. The main emphasis is on thermal contact conductance between dissimilar metallic surfaces, since thermal conductivity values within solids have been sufficiently established previously. The test program outline and test results are described. The following materials were tested: aluminum 6061-T6 (12 samples), aluminum 356 (as cast), almag 35 (as cast), magnesium AZ91C-T4 (4 samples), and mag lithium LA-141 (2 samples).
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An assessment of test specimens and test techniques useful to the evaluation of structural reinforced plastic materials at cryogenic temperatures.
Physical and thermal properties of structural reinforced plastic materials at cryogenic temperatures
REINFORCED PLASTIC↗
High Performance Materials Applications to Moon/Mars Missions and Bases
Two classes of material processing scenarios will feature prominently in future interplanetary exploration: in situ production using locally available materials in lunar or planetary landings and high performance structural materials which carve out a set of properties for uniquely hostile space environments. To be competitive, high performance materials must typically offer orders of magnitude improvements in thermal conductivity or insulation, deliver high strength-to-weight ratios, or provide superior durability (low corrosion and/or ablative character, e.g., in heat shields). The space-related environmental parameters of high radiation flux, low weight, and superior reliability limits many typical aerospace materials to a short list comprising high performance alloys, nanocomposites and thin-layer metal laminates (Al-Cu, Al-Ag) with typical dimensions less than the Frank-Reed-type dislocation source. Extremely light weight carbon-carbon composites and carbon aerogels will be presented as novel examples which define broadened material parameters, particularly owing to their extreme thermal insulation (R-32-64) and low densities (<0.01 g/cu cm) approaching that of air itself. Even with these low-weight payload additions, rocket thrust limits and transport costs will always place a premium on assembling as much structural and life support resources upon interplanetary, lunar, or asteroid arrival. As an example, for in situ lunar glass manufacture, solar furnaces reaching 1700 C for pure silica glass manufacture in situ are compared with sol-gel technology and acid-leached ultrapure (<0.1% FeO) silica aerogel precursors.
Noever, David A.↗
High Performance Materials Applications to Moon/Mars Missions and Bases
Two classes of material processing scenarios will feature prominently in future interplanetary exploration- in situ production using locally available materials in lunar or planetary landings and high performance structural materials which carve out a set of properties for uniquely hostile space environments. To be competitive, high performance materials must typically offer orders of magnitude improvements in thermal conductivity or insulation, deliver high strength-to-weight ratios, or provide superior durability (low corrosion and/or ablative character, e.g. in heat shields). The space-related environmental parameters of high radiation flux, low weight and superior reliability limits many typical aerospace materials to a short list comprising high performance alloys, nanocomposites and thin-layer metal laminates (Al-Cu, Al-Ag) with typical dimensions less than the Frank-Reed-type dislocation source. Extremely light weight carbon-carbon composites and car on aerogels will be presented as novel examples which define broadened material parameters, particularly owing to their extreme thermal insulation (R-32-64) and low densities (less than 0.01 g/cc) approaching that of air itself. Even with these low weight payload additions, rocket thrust limits and transport costs will always place a premium on assembling as much structural and life support resources upon interplanetary, lunar or asteroid arrival. As an example for in situ lunar glass manufacture, solar furnaces reaching 1700 C for pure silica glass manufacture in situ are compared with sol-gel technology and acid-leached ultrapure (less than 0.1% FeO) silica aerogel precursors.
Noever, David A.↗