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Multi-Scale Analysis of Effective Mechanical Properties of 3D Woven Composite Materials

This work aims to compute and analyze the mechanical properties of 3D woven composite materials that share the same yarn structure but differ in their matrix porosity and fiber volume fraction. Assuming linear elastic behavior, the software PuMA, developed at NASA, was used to characterize the different composites from their constituents' data averaging their elastic properties in three main directions to obtain their effective orthotropic mechanical properties. This was performed in three steps: firstly, the different phases (yarns/matrix) were analyzed as anisotropic materials separately at the micro-scale; then, the results from these analyses were homogenized and used to obtain the anisotropic elasticity tensor at the meso-scale for the different woven materials; and finally, assuming orthotropic mechanical behavior for the unit cell the mechanical properties were obtained at the macro-scale. The 3D woven composite materials selected for this study are made of phenolic resin with porosity values between 0 and 0.6, and resin infiltrated carbon fiber with volume fractions between 0.5 and 0.9 for the yarns. Results from PuMA were validated with external FEA simulations for the non-porous 3D woven material with a fiber volume fraction of 0.9 in the yarns. Results will be included in the final paper after completing the study detailed in Section II.

Sergio Fraile Izquierdo↗

A Fundamental Mathematical Model of a Microbial Predenitrification System

Space flight beyond Low Earth Orbit requires sophisticated systems to support all aspects of the mission (life support, real-time communications, etc.). A common concern that cuts across all these systems is the selection of information technology (IT) methodology, software and hardware architectures to provide robust monitoring, diagnosis, and control support. Another dimension of the problem space is that different systems must be integrated seamlessly so that communication speed and data handling appear as a continuum (un-interrupted). One such team investigating this problem is the Advanced Integration Matrix (AIM) team whose role is to define the critical requirements expected of software and hardware to support an integrated approach to the command and control of Advanced Life Support (ALS) for future long-duration human space missions, including permanent human presence on the Moon and Mars. A goal of the AIM team is to set the foundation for testing criteria that will assist in specifying tasks, control schemes and test scenarios to validate and verify systems capabilities. This project is to contribute to the goals of the AIM team by assisting with controls planning for ALS. Control for ALS is an enormous problem it involves air revitalization, water recovery, food production, solids processing and crew. In more general terms, these systems can be characterized as involving both continuous and discrete processes, dynamic interactions among the sub-systems, nonlinear behavior due to the complex operations, and a large number of multivariable interactions due to the dimension of the state space. It is imperative that a baseline approach from which to measure performance is established especially when the expectation for the control system is complete autonomous control.

Hoo, Karlene A.↗

A New Concurrent Engineering Tool for the New Mission Design Center at NASA Ames Research Center

The NASA Ames Mission Design Center (MDC) has undergone a significant transformation process in recent years, culminating in becoming a true Concurrent Engineering Center. The underlying goal of this transformation is to better serve the Ames PI community in a cost-effective and rapidly-responsive way, providing quality products pivotal to the decision-making proposal strategy of our center. The four pillars of the change focus on four areas: personnel, physical places, tools, and training. Personnel: the MDC switched from using a dedicated pool of engineers—mostly entry-level career—for a matrixed approach with more experienced Subject Matter Experts, usually involved in spaceflight projects. These SMEs get detailed to the MDC for the duration of the study on a part-time or full-time basis. Physical places: The physical aspect pertains mostly to the layout of the new Engineering building and the dedicated concurrent engineering layout to foster collaboration. The current plan includes a dedicated space for concurrent engineering sessions as well as dedicated project rooms for concept studies. Tool: the MDC team is developing a new in-house concurrent engineering tool to facilitate concurrent engineering sessions. The team leveraged the many lessons learned and insight gained from using the current concurrent engineering tool, in use since 2007. SMEs have been involved throughout its design and development, ensuring accuracy and providing validity to the implementation approach. This new tool is database-driven and allows a team to work concurrently on the same model of a mission concept. “Workspaces” are provided for each of the traditional spacecraft mission design disciplines, including cost accounting and systems engineering. There are multiple tiers of fidelity available within each workspace, which can be completed parametrically or independently from the other disciplines as needed or synchronously with the other disciplines. A “commit” step synchronizes a workspace with the mission database and identifies any potential conflicts, along with the user who entered the conflicting data. A Mission Summary workspace enables a Study Lead to run an effective CE session, displaying key graphics, workspace status information, and technical and monetary budget information. This new CE tool will be undergoing Beta Testing with its primary user base and a limited Parts database in the summer of 2020. The team plans to release the first fully operational version in December 2020. Training: working in early concept development and maturation for a space mission requires a unique mindset and being comfortable with uncertainties in an environment where requirements are not yet fully developed, and where changes and trade-offs happen at a high tempo. The MDC started a weekly training program to ensure a common knowledge base on how do develop and mature early concept studies, as well as how to operate in a concurrent engineering environment. In conclusion, the MDC transformation will provide the overall PI community focused on cost-effective small satellite scientific missions with a powerful tool to address and mature early concepts more effectively and efficiently.

David Mauro↗

Multiphase complete exchange: A theoretical analysis

Complete Exchange requires each of N processors to send a unique message to each of the remaining N-1 processors. For a circuit switched hypercube with N = 2(sub d) processors, the Direct and Standard algorithms for Complete Exchange are optimal for very large and very small message sizes, respectively. For intermediate sizes, a hybrid Multiphase algorithm is better. This carries out Direct exchanges on a set of subcubes whose dimensions are a partition of the integer d. The best such algorithm for a given message size m could hitherto only be found by enumerating all partitions of d. The Multiphase algorithm is analyzed assuming a high performance communication network. It is proved that only algorithms corresponding to equipartitions of d (partitions in which the maximum and minimum elements differ by at most 1) can possibly be optimal. The run times of these algorithms plotted against m form a hull of optimality. It is proved that, although there is an exponential number of partitions, (1) the number of faces on this hull is Theta(square root of d), (2) the hull can be found in theta(square root of d) time, and (3) once it has been found, the optimal algorithm for any given m can be found in Theta(log d) time. These results provide a very fast technique for minimizing communication overhead in many important applications, such as matrix transpose, Fast Fourier transform, and ADI.

Bokhari, Shahid H.↗

A fully associative, nonisothermal, nonlinear kinematic, unified viscoplastic model for titanium alloys

Specific forms for both the Gibb's and complementary dissipation potentials are chosen such that a complete (i.e., fully associative) potential base multiaxial, nonisothermal unified viscoplastic model is obtained. This model possesses one tensorial internal state variable (that is, associated with dislocation substructure) and an evolutionary law that has nonlinear kinematic hardening and both thermal and strain induced recovery mechanisms. A unique aspect of the present model is the inclusion of nonlinear hardening through the use of a compliance operator, derived from the Gibb's potential, in the evolution law for the back stress. This nonlinear tensorial operator is significant in that it allows both the flow and evolutionary laws to be fully associative (and therefore easily integrated), greatly influences the multiaxial response under non-proportional loading paths, and in the case of nonisothermal histories, introduces an instantaneous thermal softening mechanism proportional to the rate of change in temperature. In addition to this nonlinear compliance operator, a new consistent, potential preserving, internal strain unloading criterion has been introduced to prevent abnormalities in the predicted stress-strain curves, which are present with nonlinear hardening formulations, during unloading and reversed loading of the external variables. The specific model proposed is characterized for a representative titanium alloy commonly used as the matrix material in SiC fiber reinforced composites, i.e., TIMETAL 21S. Verification of the proposed model is shown using 'specialized' non-standard isothermal and thermomechanical deformation tests.

Arnold, S. M.↗

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗

Theoretical investigation of gas-surface interactions

The investigation into the appearance of intruder states from the negative continuum when some of the two-electron integrals were omitted was completed. The work shows that, provided all integrals involving core contracted functions in an atomic general contraction are included, or that the core functions are radially localized, meaningful results are obtained and intruder states do not appear. In the area of program development, the Dirac-Hartree-Fock (DHF) program for closed-shell polyatomic molecules was extended to permit Kramers-restricted open-shell DHF calculations with one electron in an open shell or one hole in a closed shell, or state-averaged DHF calculations over several particle or hole doublet states. One application of the open-shell code was to the KO molecule. Another major area of program development is the transformation of integrals from the scalar basis in which they are generated to the 2-spinor basis employed in parts of the DHF program, and hence to supermatrix form. Particularly concerning the omission of small component integrals, and with increase in availability of disk space, it is now possible to consider transforming the integrals. The use of ordered integrals, either in the scalar basis or in the 2-spinor basis, would considerably speed up the construction of the Fock matrix, and even more so if supermatrices were constructed. A considerable amount of effort was spent on analyzing the integral ordering and tranformation for the DHF program. The work of assessing the reliability of the relativistic effective core potentials (RECPs) was continued with calculation of the group IV monoxides. The perturbation of the metal atom provided by oxygen is expected to be larger than that provided by hydrogen and thus provide a better test of the qualification of the RECPs. Calculations on some platinum hydrides were carried out at nonrelativistic (NR), perturbation theory (PT) and DHF levels. Reprints of four papers describing this work are included.

Dyall, Kenneth G.↗

The Importance of Chaos and Lenticulae on Europa for the JIMO Mission

The Galileo Solid State Imaging (SSI) experiment provided high-resolution images of Europa's surface allowing identification of surface features barely distinguishable at Voyager's resolution. SSI revealed the visible pitting on Europa's surface to be due to large disrupted features, chaos, and smaller sub-circular patches, lenticulae. Chaos features contain a hummocky matrix material and commonly contain dislocated blocks of ridged plains. Lenticulae are morphologically interrelated and can be divided into three classes: domes, spots, and micro-chaos. Domes are broad, upwarped features that generally do not disrupt the texture of the ridged plains. Spots are areas of low albedo that are generally smooth in texture compared to other units. Micro-chaos are disrupted features with a hummocky matrix material, resembling that observed within chaos regions. Chaos and lenticulae are ubiquitous in the SSI regional map observations, which average approximately 200 meters per pixel (m/pxl) in resolution, and appear in several of the ultra-high resolution, i.e., better than 50 m/pxl, images of Europa as well. SSI also provided a number of multi-spectral observations of chaos and lenticulae. Using this dataset we have undertaken a thorough study of the morphology, size, spacing, stratigraphy, and color of chaos and lenticulae to determine their properties and evaluate models of their formation. Geological mapping indicates that chaos and micro-chaos have a similar internal morphology of in-situ degradation suggesting that a similar process was operating during their formation. The size distribution denotes a dominant size of 4-8 km in diameter for features containing hummocky material (i.e., chaos and micro-chaos). Results indicate a dominant spacing of 15 - 36 km apart. Chaos and lenticulae are generally among the youngest features stratigraphically observed on the surface, suggesting a recent change in resurfacing style. Also, the reddish non-icy materials on Europa's surface have high concentrations in many chaos and lenticulae features. Nonetheless, a complete global map of the distribution of chaos and lenticulae is not possible with the SSI dataset. Only <20% of the surface has been imaged at 200 m/pxl or better resolution, mostly of the near-equatorial regions. Color and ultra-high-res images have much less surface coverage. Thus we suggest that full global imaging of Europa at 200 m/pxl or better resolution, preferably in multi-spectral wavelengths, should be a high priority for the JIMO mission.

Spaun, Nicole A.↗

Fabrication and Testing of Ceramic Matrix Composite Rocket Propulsion Components

The National Aeronautics and Space Administration (NASA) is pursuing using ceramic matrix composites (CMC) as primary structural components for advanced rocket engines. This endeavor is due to the requirement of increasing safety by two orders of magnitude and reducing costs from $10,000/lb to $1,000/lb both within ten years. Out year goals are even more aggressive. Safety gains, through using CMCS, will be realized by increasing temperature margins, tolerance for extreme thermal transients, and damping capability of components and systems, by using components with lower weight and thermal conductivity, etc. Gains in cost reduction, through using CMCS, are anticipated by enabling higher performance systems, using lighter weight components and systems, enabling 100 mission reusability without system refurbishment, greatly reducing cooling requirements and erosion rates, selecting safe fabrication processes that are ideally cost competitive with metal processes at low volume production, etc. This philosophy contrasts the previous philosophy of rocket engine development focused largely on achieving the highest performance with metals and ablatives -- cost and safety were not the focal point of the initial design. Rocket engine components currently being pursued, largely C/SiC and SiC/SiC, include blisks or rotors, 10 foot by 8 foot nozzle ramps, gas generators, thrust chambers, and upperstage nozzles. The Simplex Turbopump CMC blisk effort has just successfully completed a 4.5 year development and test program. The other components mentioned are in the design or fabrication stage. Although the temperature limits of the CMC materials are not quantified in a realistic environment yet, CMC materials are projected to be the only way to achieve significant safety risks mitigation and cost reductions simultaneously. We, the end-users, material fabricators, technology facilitators, and government organizations are charged with developing and demonstrating a much safer and a lot less costly Earth-to-Orbit full-scale propulsion system by 2005.

Effinger, Michael↗

Status of Mars Retropropulsion Testing in the Langley Unitary Plan Wind Tunnel

Future Mars human landings will be enabled by a powered descent phase starting at supersonic conditions, something which has never been done before on a Mars mission. Significant aerosciences challenges exist due to jet interactions between the retrorocket engine plumes, freestream flow, and vehicle that will affect the aerodynamic behavior during powered descent. Historically, wind tunnel tests have been used to study the interactions with inert gas exhaust simulants in place of rocket engines. On the computational side, flowfield simulations have been completed at full-scale conditions, but the available ground and flight data are not appropriate for calibrating computational uncertainties for aerodynamic interference on proposed Mars descent vehicles, due to insufficient data, dissimilar vehicle geometries, and disparate operating conditions. A wind tunnel test has been designed to begin addressing powered descent aerodynamics risks for large-scale human Mars entry concepts and to identify gaps in computational predictive capabilities. The test will be conducted in the NASA Langley Unitary Plan Wind Tunnel and is designed with improvements in model design and data products over past tests. The test campaign will be run using sub-scale model geometries derived from NASA powered descent reference vehicles: a blunt low lift-to-drag vehicle and a more slender geometry that generates higher unpowered lift. Both models have been fabricated and are ready for testing. The blunt model is equipped with the flexibility to examine the effects of nozzle pointing direction, number, location, size, and area ratio. The main measurements are heatshield aerodynamic interference forces and moments with a custom flow-through balance, discrete and distributed heatshield pressure, and high-speed flowfield visualization. This paper covers the test objectives, facility, models and instrumentation, and planned test matrix.

Mars↗

Status of Mars Retropropulsion Testing in the Langley Unitary Plan Wind Tunnel

Future Mars human landings will be enabled by a powered descent phase starting at supersonic conditions, something which has never been done before on a Mars mission. Significant aerosciences challenges exist due to jet interactions between the retrorocket engine plumes, freestream flow, and vehicle that will affect the aerodynamic behavior during powered descent. Historically, wind tunnel tests have been used to study the interactions with inert gas exhaust simulants in place of rocket engines. On the computational side, flowfield simulations have been completed at full-scale conditions, but the available ground and flight data are not appropriate for calibrating computational uncertainties for aerodynamic interference on proposed Mars descent vehicles, due to insufficient data, dissimilar vehicle geometries, and disparate operating conditions. A wind tunnel test has been designed to begin addressing powered descent aerodynamics risks for large-scale human Mars entry concepts and to identify gaps in computational predictive capabilities. The test will be conducted in the NASA Langley Unitary Plan Wind Tunnel and is designed with improvements in model design and data products over past tests. The test campaign will be run using sub-scale model geometries derived from NASA powered descent reference vehicles: a blunt low lift-to-drag vehicle and a more slender geometry that generates higher unpowered lift. Both models have been fabricated and are ready for testing. The blunt model is equipped with the flexibility to examine the effects of nozzle pointing direction, number, location, size, and area ratio. The main measurements are heatshield aerodynamic interference forces and moments with a custom flow-through balance, discrete and distributed heatshield pressure, and high-speed flowfield visualization. This paper covers the test objectives, facility, models and instrumentation, and planned test matrix.

Supersonic Retropropulsion↗

NTP comparison process

The systems engineering process for the concept definition phase of the program involves requirements definition, system definition, and consistent concept definition. The requirements definition process involves obtaining a complete understanding of the system requirements based on customer needs, mission scenarios, and nuclear thermal propulsion (NTP) operating characteristics. A system functional analysis is performed to provide a comprehensive traceability and verification of top-level requirements down to detailed system specifications and provides significant insight into the measures of system effectiveness to be utilized in system evaluation. The second key element in the process is the definition of system concepts to meet the requirements. This part of the process involves engine system and reactor contractor teams to develop alternative NTP system concepts that can be evaluated against specific attributes, as well as a reference configuration against which to compare system benefits and merits. Quality function deployment (QFD), as an excellent tool within Total Quality Management (TQM) techniques, can provide the required structure and provide a link to the voice of the customer in establishing critical system qualities and their relationships. The third element of the process is the consistent performance comparison. The comparison process involves validating developed concept data and quantifying system merits through analysis, computer modeling, simulation, and rapid prototyping of the proposed high risk NTP subsystems. The maximum amount possible of quantitative data will be developed and/or validated to be utilized in the QFD evaluation matrix. If upon evaluation of a new concept or its associated subsystems determine to have substantial merit, those features will be incorporated into the reference configuration for subsequent system definition and comparison efforts.

Corban, Robert↗

The Ozonide Anion: A Theoretical Study

Complete active space self-consistent field (CASSCF) and CASSCF second order perturbation theory (CASPT2) methods have been used for the geometry optimization and calculation of harmonic and fundamental frequencies of the ozonide ion O3(-) and the ozonide lithium complex Li(+)O3(-). For O3(-) harmonic frequencies have also been obtained using the coupled-cluster method, CCSD(T). Infrared intensities are computed from dipole moment derivatives at the CASSCF level. The predicted equilibrium geometry for O3(-) is: Roo = 1.361 Angstroms and angle ooo = 115.4 degrees, and the fundamental frequencies are: nu(sub 1) = 989 per centimeter, nu(sub 2) 556 per centimeter, nu(sub 3) = 870 per centimeter (experimental values are: Roo =1.36 plus or minus 0.02 Angstroms, angle (ooo) = 111.8 plus or minus 2.0 degrees, nu(sub 1) = 975(50) per centimeter, nu(sub 2) = 550(50) per centimeter, nu(sub 3) = 880(50) per centimeter). Corresponding data for the lithium ozonide complex have also been obtained. The presented data contradict the previous interpretation of the IR and Raman spectrum obtained after deposition of ozone in N2, argon, or neon matrices with atomic beams of alkali metals. The presence of the lithium cation raises the asymmetric stretch frequency to about 940 per centimeter, which is contradictory to assumptions made in the assignments of the matrix spectra. Calculations made in a dielectric medium strongly suggest that the effect of the matrix on the IR spectrum is small for O3(-) itself. The dissociation and atomization energies of O3(-) are found to be in agreement with experiment.

Borowski, Poitr↗

Post Test Evaluation of HSCT Nozzle Acoustic Liner Subcomponents Subjected to a Hot Acoustic Durability Test

The acoustic liner system designed for use in the High Speed Civil Transport (HSCT) was tested in a thermal-acoustic environment. Five ceramic matrix composite (CMC) acoustic tile configurations, five bulk acoustic absorbers, and one thermal protection system design were tested. The CMC acoustic tiles were subjected to two 2 3/4 hr ambient temperature acoustic exposures to measure their dynamic response. One exposure was conducted on the tiles alone and the second exposure included the tiles and the T-foam bulk absorber. The measured tile RMS strains were small. With or without the T-foam absorber, the dynamic strains were below strain levels that would cause damage during fatigue loading. After the ambient exposure, a 75-hr durability test of the entire acoustic liner system was conducted using a thermal-acoustic cycle that approximated the anticipated service cycle. Acoustic loads up to 139 dB/Hz and temperatures up to 1670 F (910 C) were employed during this 60 cycle test. During the durability test, the CMC tiles were exposed to temperatures up to 1780 F and a transient through thickness gradient up to 490 F. The TPS peak temperatures on the hot side of the panels ranged from 750 to 1000 F during the 60 cycles. The through thickness delta T ranged from 450 to 650 F, varying with TPS location and cycle number. No damage, such as cracks or chipping, was observed in the CMC tiles after completion of the testing. However, on tile warped during the durability test and was replaced after 43 or 60 cycles. No externally observed damage was found in this tile. No failure of the CMC fasteners occurred, but damage was observed. Cracks and missing material occurred, only in the fastener head region. No indication of damage was observed in the T-foam acoustic absorbers. The SiC foam acoustic absorber experienced damage after about 43 cycles. Cracking in the TPS occurred around the attachment holes and under a vent. In spite of the development of damage, the TPS maintained its insulative capability throughout the durability test. The durability test results demonstrate damage-tolerant CMC tile, CMC fastener, TPS, and T-foam absorber designs for the combined thermal and acoustic engine nozzle environment.

Verrilli, Michael J.↗

Creep Properties of NiAl-1Hf Single Crystals Re-Investigated

NiAl-1Hf single crystals have been shown to be quite strong at 1027 C, with strength levels approaching those of advanced Ni-based superalloys. Initial testing, however, indicated that the properties might not be reproducible. Study of the 1027 C creep behavior of four different NiAl-1Hf single-crystal ingots subjected to several different heat treatments indicated that strength lies in a narrow band. Thus, we concluded that the mechanical properties are reproducible. Recent investigations of the intermetallic NiAl have confirmed that minor alloying additions combined with single-crystal growth technology can produce elevated temperature strength levels approaching those of Ni-based superalloys. For example, General Electric alloy AFN 12 {Ni-48.5(at.%) Al-0.5Hf-1Ti-0.05Ga} has a creep rupture strength equivalent to Rene 80 combined with a approximately 30-percent lower density, a fourfold improvement in thermal conductivity, and the ability to form a self-protective alumina scale in aggressive environments. Although the compositions of strong NiAl single crystals are relatively simple, the microstructures are complex and vary with the heat treatment and with small ingot-toingot variations in the alloy chemistry. In addition, initial testing suggested a strong dependence between microstructure and creep strength. If these observations were true, the ability to utilize NiAl single-crystal rotating components in turbine machinery could be severely limited. To investigate the possible limitations in the creep response of high-strength NiAl single crystals, the NASA Glenn Research Center at Lewis Field initiated an in depth investigation of the effect of heat treatment on the microstructure and subsequent 1027 C creep behavior of [001]-oriented NiAl-1Hf with a nominal chemistry of Ni-47.5Al-1Hf-0.5Si. This alloy was selected since four ingots, grown over a number of years and possessing slightly different compositions, were available for study. Specimens taken from the ingots were subjected to several heat treatment schedules, examined by transmission electron microscopy, and tested in both compression and tension. An example of the microstructure found in a [001]-oriented NiAl-1Hf specimen after a solution treatment at 1317 C for 50 hr followed by air cooling is illustrated in the image on the left, where the NiAl matrix contains a uniform distribution of nanometer-scale Gphase (Ni16Hf6Si7) precipitates. Other heat treating schedules produced microstructures with nanometer-sized G-phase cubes and plates or, in an extreme case, produced a microstructure with all the G-phase converted to Heusler (Ni2AlHf) particles. The results of 1027 C creep strength and strain rate testing are illustrated which summarizes data from tensile and compressive testing of samples cut from all four NiAl-1Hf ingots and subjected to a variety of heat treatment schedules. With one exception, all the strength values lie in a narrow band that spans six orders of magnitude in strain rate. The only factor that produced results outside of this band was the heat treatment schedule that dissolved all the G-phase and replaced it with Heusler precipitates. The results portrayed in this figure lead to the important practical conclusion that the elevated-temperature creep properties of NiAl-1Hf single crystals are reproducible and are not affected by small variations in alloy chemistry from ingot to ingot or by different initial distributions of G-phase in the heat-treated alloy. The only variable in this study that produced a significant and delerious effect on mechanical strength was a post-solution heat treatment that lead to the complete disappearance of the G-phase in favor of Heusler precipitates.

Whittenberger, J. Daniel↗

Flutter and Divergence Analysis using the Generalized Aeroelastic Analysis Method

The Generalized Aeroelastic Analysis Method (GAAM) is applied to the analysis of three well-studied checkcases: restrained and unrestrained airfoil models, and a wing model. An eigenvalue iteration procedure is used for converging upon roots of the complex stability matrix. For the airfoil models, exact root loci are given which clearly illustrate the nature of the flutter and divergence instabilities. The singularities involved are enumerated, including an additional pole at the origin for the unrestrained airfoil case and the emergence of an additional pole on the positive real axis at the divergence speed for the restrained airfoil case. Inconsistencies and differences among published aeroelastic root loci and the new, exact results are discussed and resolved. The generalization of a Doublet Lattice Method computer code is described and the code is applied to the calculation of root loci for the wing model for incompressible and for subsonic flow conditions. The error introduced in the reduction of the singular integral equation underlying the unsteady lifting surface theory to a linear algebraic equation is discussed. Acknowledging this inherent error, the solutions of the algebraic equation by GAAM are termed 'exact.' The singularities of the problem are discussed and exponential series approximations used in the evaluation of the kernel function shown to introduce a dense collection of poles and zeroes on the negative real axis. Again, inconsistencies and differences among published aeroelastic root loci and the new 'exact' results are discussed and resolved. In all cases, aeroelastic flutter and divergence speeds and frequencies are in good agreement with published results. The GAAM solution procedure allows complete control over Mach number, velocity, density, and complex frequency. Thus all points on the computed root loci can be matched-point, consistent solutions without recourse to complex mode tracking logic or dataset interpolation, as in the k and p-k solution methods.

Edwards, John W.↗

Demonstration of Minimally Machined Honeycomb Silicon Carbide Mirrors

Honeycomb silicon carbide composite mirrors are made from a carbon fiber preform that is molded into a honeycomb shape using a rigid mold. The carbon fiber honeycomb is densified by using polymer infiltration pyrolysis, or through a reaction with liquid silicon. A chemical vapor deposit, or chemical vapor composite (CVC), process is used to deposit a polishable silicon or silicon carbide cladding on the honeycomb structure. Alternatively, the cladding may be replaced by a freestanding, replicated CVC SiC facesheet that is bonded to the honeycomb. The resulting carbon fiber-reinforced silicon carbide honeycomb structure is a ceramic matrix composite material with high stiffness and mechanical strength, high thermal conductivity, and low CTE (coefficient of thermal expansion). This innovation enables rapid, inexpensive manufacturing. The web thickness of the new material is less than 1 millimeter, and core geometries tailored. These parameters are based on precursor carbon-carbon honeycomb material made and patented by Ultracor. It is estimated at the time of this reporting that the HoneySiC(Trademark) will have a net production cost on the order of $38,000 per square meter. This includes an Ultracor raw material cost of about $97,000 per square meter, and a Trex silicon carbide deposition cost of $27,000 per square meter. Even at double this price, HoneySiC would beat NASA's goal of $100,000 per square meter. Cost savings are estimated to be 40 to 100 times that of current mirror technologies. The organic, rich prepreg material has a density of 56 kilograms per cubic meter. A charred carbon-carbon panel (volatile organics burnt off) has a density of 270 kilograms per cubic meter. Therefore, it is estimated that a HoneySiC panel would have a density of no more than 900 kilograms per cubic meter, which is about half that of beryllium and about onethird the density of bulk silicon carbide. It is also estimated that larger mirrors could be produced in a matter of weeks. Each cell is completely uniform, maintaining the shape of the inserted mandrel. Furthermore, the layup creates pressure that insures node bond strength. Each node is a composite laminate using only the inherent resin system to form the bond. This contrasts starkly with the other known method of producing composite honeycomb, in which individual corrugations are formed, cured, and then bonded together in a secondary process. By varying the size of the mandrels within the layup, varying degrees of density can be achieved. Typical sizes are 3/8 and 3/16 in. (approximately 10 and 5 millimeters). Cell sizes up to 1 in. (approximately 25 millimeters) have been manufactured. Similarly, the shape of the core can be altered for a flexible honeycomb structure.

Goodman, William↗

Should Pruning be a Pre-Processor of any Linear System?

There are many real-world problems whose mathematical models turn out to be linear systems Ax = b , where A is an m by x n matrix. Each equation of the linear system is an information. An information, in a physical problem, such as 4 mangoes, 6 bananas, and 5 oranges cost $10, is mathematically modeled as 4x(sub 1) + 6x(sub 2) + 5x (sub 3) = 10, where x(sub 1), x(sub 2), x(sub 3) are each cost of one mango, that of one banana, and that of one orange, respectively. All the information put together in a specified context, constitutes the physical problem and need not be all distinct. Some of these could be redundant, which cannot be readily identified by inspection. The resulting mathematical model will thus have equations corresponding to this redundant information and hence are linearly dependent and thus superfluous. Consequently, these equations once identified should be better pruned in the process of solving the system. The benefits are (i) less computation and hence less error and consequently a better quality of solution and (ii) reduced storage requirements. In literature, the pruning concept is not in vogue so far although it is most desirable. In a numerical linear system, the system could be slightly inconsistent or inconsistent of varying degree. If the system is too inconsistent, then we should fall back on to the physical problem (PP), check the correctness of the PP derived from the material universe, modify it, if necessary, and then check the corresponding mathematical model (MM) and correct it. In nature/material universe, inconsistency is completely nonexistent. If the MM becomes inconsistent, it could be due to error introduced by the concerned measuring device and/or due to assumptions made on the PP to obtain an MM which is relatively easily solvable or simply due to human error. No measuring device can usually measure a quantity with an accuracy greater that 0.005% or, equivalently with a relative error less than 0.005%. Hence measurement error is unavoidable in a numerical linear system when the quantities are continuous (or even discrete with extremely large number). Assumptions, though not desirable, are usually made when we find the problem sufficiently difficult to be solved within the available means/tools/resources and hence distort the PP and the corresponding MM. The error thus introduced in the system could (not always necessarily though) make the system somewhat inconsistent. If the inconsistency (contradiction) is too much then one should definitely not proceed to solve the system in terms of getting a least-squares solution or a minimum norm solution or the minimum-norm least-squares solution. All these solutions will be invariably of no real-world use. If, on the other hand, inconsistency is reasonably low, i.e. the system is near-consistent or, equivalently, has near-linearly-dependent rows, then the foregoing solutions are useful. Pruning in such a near-consistent system should be performed based on the desired accuracy and on the definition of near-linear dependence. In this article, we discuss pruning over various kinds of linear systems and strongly suggest its use as a pre-processor or as a part of an algorithm. Ideally pruning should (i) be a part of the solution process (algorithm) of the system, (ii) reduce both computational error and complexity of the process, and (iii) take into account the numerical zero defined in the context. These are precisely what we achieve through our proposed O(mn2) algorithm presented in Matlab, that uses a subprogram of solving a single linear equation and that has embedded in it the pruning.

Sen, Syamal K.↗