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Portable fiber-optic probe detects tiny flaws in transparent materials. Probe transmits light through surface to illuminate interior of material by backscattering off its edges. Light-sensitive contact paper records scratch pattern. Technique can be used for rapid visual checks. Flexible fiber optics are safely used in explosive or flammable areas; they present no hazard of breakage or contamination in controlled environments.
The performance of composite materials is dependent on the constituent materials selected, material structural geometry, and the fabrication process. Flaws can form in composite materials as a result of the fabrication process, handling in the manufacturing environment, and exposure in the service environment to anomalous activity. Often these flaws show no indication on the surface of the material while having the potential of substantially degrading the integrity of the composite structure. For this reason it is important to have available inspection techniques that can reliably detect sub-surface defects such as inter-ply disbonds, inter-ply cracks, porosity, and density changes caused by variations in fiber volume content. Many non-destructive evaluation techniques (NDE) are capable of detecting sub-surface flaws in composite materials. These include shearography, video image correlation, ultrasonic, acoustic emissions, and X-ray. The difficulty with most of these techniques is that they are time consuming and often difficult to apply to full scale structures. An NDE technique that appears to have the capability to quickly and easily detect flaws in composite structure is thermography. This technique uses heat to detect flaws. Heat is applied to the surface of a structure with the use of a heat lamp or heat gun. A thermographic camera is then pointed at the surface and records the surface temperature as the composite structure cools. Flaws in the material will cause the thermal-mechanical material response to change. Thus, the surface over an area where a flaw is present will cool differently than regions where flaws do not exist. This paper discusses the effort made to thermo-mechanically model the thermography process. First the material properties and physical parameters used in the model will be explained. This will be followed by a detailed discussion of the finite element model used. Finally, the result of the model will be summarized along with recommendations for future work.
Over the past century aircraft wing design has transformed from the morphing wing used on the Wright Flyer to rigid wings with little to no shape-tailoring abilities. Modern day wings are designed to fly at a single trim condition and optimized to have a maximum aerodynamic efficiency at only this condition. Shape morphing wings on the other hand have the potential to undergo geometric changes allowing them to adapt to their mission profiles. Several flight demonstrations have been conducted over the decades using morphing-wing technologies. Active wing-twist control was demonstrated on the X-53 Active Aeroelastic Wing (AAW) research project by utilizing multiple leading- and trailing-edge control surfaces. Passive morphing technology has been demonstrated on the Rockwell RPRV-870 Highly Maneuverable Aircraft Technology (HiMAT) aircraft. In the current study, the wings of a small unmanned aerial system (sUAS) were modified to have segmented control surfaces (SCS). The modifications include segmenting the original wing control surfaces (one flap and one aileron per wing) into 44 individual sections, each section having its own independent servo control motor. The wings were also instrumented with a network of over 1800 fiber-optic strain sensors (on four sensing fibers distributed over the top and bottom surfaces of the wing) monitoring the strain response of the wing to aerodynamic loading. The SCS positions were manipulated in real time to modify the spanwise lift distribution of the wings on the sUAS. The change in the structural response of the wings caused by load redistribution was quantified by measuring the bending strains on the upper and lower wing surfaces using an on-board compact fiber-optic strain sensing (cFOSS) system. A feedback controller was developed to control the SCS positions using strain-based shape estimations from the Displacement Transfer Function (DTF). Post-processing of the strain data allowed for the transverse displacement distributions and load distributions to be compared for the conventional and segmented control surface cases using displacements and loads algorithms developed by Richards and Ko at AFRC (refs. 5-10). While the current study focused on the shifting of the spanwise aerodynamic loads as quantified by displacements, future applications for loads or displacement control might include active gust alleviation and flutter suppression.
A simplified, lightweight system for dissipating heat of a regenerative fuel- cell system would include a heat pipe with its evaporator end placed at the heat source and its condenser end integrated into the wall of the regenerative fuel cell system gas-storage tanks. The tank walls act as heat-radiating surfaces for cooling the regenerative fuel cell system. The system was conceived for use in outer space, where radiation is the only physical mechanism available for transferring heat to the environment. The system could also be adapted for use on propellant tanks or other large-surface-area structures to convert them to space heat-radiating structures. Typically for a regenerative fuel cell system, the radiator is separate from the gas-storage tanks. By using each tank s surface as a heat-radiating surface, the need for a separate, potentially massive radiator structure is eliminated. In addition to the mass savings, overall volume is reduced because a more compact packaging scheme is possible. The underlying tank wall structure provides ample support for heat pipes that help to distribute the heat over the entire tank surface. The heat pipes are attached to the outer surface of each gas-storage tank by use of a high-thermal conductance, carbon-fiber composite-material wrap. Through proper choice of the composite layup, it is possible to exploit the high longitudinal conductivity of the carbon fibers (greater than the thermal conductivity of copper) to minimize the unevenness of the temperature distribution over the tank surface, thereby helping to maximize the overall heat-transfer efficiency. In a prototype of the system, the heat pipe and the composite wrap contribute an average mass of 340 g/sq m of radiator area. Lightweight space radiator panels have a mass of about 3,000 g/sq m of radiator area, so this technique saves almost 90 percent of the mass of separate radiator panels. In tests, the modified surface of the tank was found to have an emissivity of 0.85. The composite wrap remained tightly bound to the surface of the tank throughout the testing in thermal vacuum conditions.
Beta fiber was selected as the primary material for flexible fibrous structures used in spacecraft and crew systems applications in the Apollo program because it was noncombustible in a 100 percent oxygen atmosphere up to 16.5 psia. It met NASA criteria for outgassing, toxicity, odor, and crew comfort, and possessed sufficient durability to last through the mission. Topics discussed include: study of spacecraft applications; design of Beta fiber textile structures to meet the requirements; selection of surface treatments (finishes, coatings, and printing systems) to impart the required durability and special functional use to the textile structures; development of sewing and fabrication techniques; and testing and evaluation programs, and development of production sources.
An anisotropic buckling and flutter analysis is developed with allowance for both bending-extensional coupling and bending-twisting coupling within the framework of linear small deflection theory for simply supported general laminated plates. The extended Galerkin method is used to obtain approximate solutions to the coupled governing equations. The effects of various anisotropic stiffness parameters on the static and dynamic stability of laminated plates are evaluated, with particular emphasis on assessing the range of applicability of classical orthotropic plate theory. It is shown that bending-extensional coupling and bending-twisting stiffness terms have a destabilizing effect on buckling and flutter, the effect being more pronounced for a small number of layers. For symmetric plates, the number of layers required for orthotropic plate theory to be applicable is generally less for the buckling problem than for flutter. For square plates, aligning the fibers with the direction of airflow over the plate surface results in the highest flutter dynamic pressure.
Processes for brazing Borsic/aluminum composite materials that eliminate diffusion of braze alloy constituents into the aluminum matrix developed. One brazing study led to the development of a hybrid composite which combines high strength Borsic/aluminum and ductile titanium to form a material identified as titanium clad Borsic/aluminum. The titanium foil provides the Borsic/aluminum with a durable outer surface and serves as a diffusion barrier which alleviates fiber and matrix degradation during brazing. Titanium clad Borsic/aluminum skin panels were joined to titanium clad Borsic/aluminum stringers by brazing and were tested in end compression at room and elevated temperatures. The data include failure strength, buckling strength, and the effects of brazing on the material properties. Predicted buckling loads are compared with experimental data.
Structural parts feature low weight, low thermal expansion, and high stiffness. Unique, non-labor-intensive manufacturing process developed for fabricating aluminum-clad graphite/epoxy (Gr/E) struts which meet Space Station requirements. Method of manufacturing struts provides procedure for using Gr/E material system in very efficient manner. Technique places all fibers in longitudinal direction for stiffness and strength. Aluminum surfaces provide transverse strength and resistance to atomic oxygen in environment.
Fiberglass-epoxy composites are considered for use as structural members for the mast of the space station solar array panel. The low Earth orbital environment in which space station is to operate is composed mainly of atomic oxygen, which has been shown to cause erosion of many organic materials and some metals. Ground based testing in a plasma asher was performed to determine the extent of degradation of fiberglass-epoxy composites when exposed to a simulated atomic oxygen environment. During exposure, the epoxy at the surface of the composite was oxidized, exposing individual glass fibers which could easily be removed. Several methods of protecting the composite were evaluated in an atomic oxygen environment and with thermal cycling and flexing. The protection techniques evaluated to date include an aluminum braid covering, an indium-tin eutectic and a silicone based paint. The open aluminum braid offered little protection while the CV-1144 coating offered some initial protection against atomic oxygen, but appears to develop cracks which accelerate degradation when flexed. Coatings such as the In-Sn eutectic may provide adequate protection by containing the glass fibers even though mass loss still occurs.
The extent of degradation of fiberglass-epoxy composite masts of the Space Station solar array panel, when these are exposed to atomic oxygen environment of the low-earth orbit, was investigated in ground testing of fiberglass-epoxy composites in an RF plasma asher. In addition, several methods of protecting the composite structures were evaluated, including an aluminum braid covering, an In-Sn eutectic, and a silicone based paint. It was found that, during exposure, the epoxy at the surface of the composite was oxidized, exposing individual glass fibers which could easily be removed. The results of mass measurements and SEM examination carried out after thermal cycling and flexing of exposed composite samples indicated that coatings such as In-Sn eutectic may provide adequate protection by containing the glass fibers, even though mass loss still occurs.
A dual line laser induced Rayleigh scattering system has been developed to be used in high temperature gas flows such as in combustors, and preliminary tests have been performed in a hot air jet. The qualification measurements included the collection and analysis of Rayleigh signal for time-resolved gas temperature over the two lines of a copper-vapor laser. The dual line signal collection technique is a feature to be used in detecting and discriminating the surface scattered laser light in the Rayleigh signal. Optical fibers are used to transmit the laser beam to the optical probe bench and to carry the collected signal from the bench to the housing of the signal sensors. Incident laser intensity at the probe volume is measured for both lines at each pulse of the laser. This information is used to normalize the signal. Good agreement has been obtained between the two line Rayleigh scattering and thermocouple results in the particle free co-flowing air jet.
The impact damage resistance and residual mechanical properties of (0/ +/- 45/90)s SCS-6/Timetal 21S composites were evaluated. Both quasi-static indentation and drop-weight impact tests were used to investigate the impact behavior at two nominal energy levels (5.5 and 8.4 J) and determine the onset of internal damage. Through x-ray inspection, the extent of internal damage was characterized non-destructively. The composite strength and constant amplitude fatigue response were evaluated to assess the effects of the sustained damage. Scanning electron microscopy was used to characterize internal damage from impact in comparison to damage that occurs during mechanical loading alone. The effect of stacking sequence was examined by using specimens with the long dimension of the specimen both parallel (longitudinal) and perpendicular (transverse) to the 0 deg fiber direction. Damage in the form of longitudinal and transverse cracking occurred in all longitudinal specimens tested at energies greater than 6.3 J. Similar results occurred in the transverse specimens tested above 5.4 J. Initial load drop, characteristic of the onset of damage, occurred on average at 6.3 J in longitudinal specimens and at 5.0 J in transverse specimens. X-ray analysis showed broken fibers in the impacted region in specimens tested at the higher impact energies. At low impact energies, visible matrix cracking may occur, but broken fibers may not. Matrix cracking was noted along fiber swims and it appeared to depend on the surface quality of composite. At low impact energies, little damage has been incurred by the composite and the residual strength and residual life is not greatly reduced as compared to an undamaged composite. At higher impact energies, more damage occurred and a greater effect of the impact damage was observed.
The objective of the program is the development and laboratory demonstration of sensors based on silica optical fibers for measurement of high temperature strain for aerospace materials evaluations. A complete fiber strain sensor system based on white-light interferometry was designed and implemented. An experiment set-up was constructed to permit testing of strain measurement up to 850 C. The strain is created by bending an alumina cantilever beam to which is the fiber sensor is attached. The strain calibration is provided by the application of known beam deflections. To ensure the high temperature operation capability of the sensor, gold-coated single-mode fiber is used. Moreover, a new method of sensor surface attachment which permits accurate sensor gage length determination is also developed. Excellent results were obtained at temperatures up to 800-850 C.
When exposed to combustion environments containing moisture both un-reinforced and fiber reinforced silicon based ceramic materials tend to undergo surface recession. To avoid surface recession environmental barrier coating systems are required. However, due to differences in the elastic and thermal properties of the substrate and the environmental barrier coating, thermal residual stresses can be generated in the coated substrate. Depending on their magnitude and nature thermal residual stresses can have significant influence on the strength and fracture behavior of coated substrates. To determine the maximum residual stresses developed during deposition of the coatings, a finite element model (FEM) was developed. Using this model, the thermal residual stresses were predicted in silicon nitride substrates coated with three environmental coating systems namely barium strontium aluminum silicate (BSAS), rare earth mono silicate (REMS) and earth mono di-silicate (REDS). A parametric study was also conducted to determine the influence of coating layer thickness and material parameters on thermal residual stress. Results indicate that z-direction stresses in all three systems are small and negligible, but maximum in-plane stresses can be significant depending on the composition of the constituent layer and the distance from the substrate. The BSAS and REDS systems show much lower thermal residual stresses than REMS system. Parametric analysis indicates that in each system, the thermal residual stresses can be decreased with decreasing the modulus and thickness of the coating.
Special processes require special skills, knowledge and experienced application. For over 15 years, the NASA Johnson Space Center's Receiving, Inspection and Test Facility (RITF) has provided Agency-wide NASA Workmanship Standards compliance training, issuing more than 500 to 800 training completion certificates annually. It is critical that technicians and inspectors are trained and that they maintain their proficiency to implement the applicable standards and specifications. Training services include "hands-on" training to engineers, technicians, and inspectors in the areas of electrostatic discharge (ESD), soldering, surface mount technology (SMT), crimping, conformal coating, and fiber-optic terminations.
Radiation Budget Instrument (RBI) will be one of five instruments flying aboard the JPSS-2 spacecraft, a polar-orbiting sun-synchronous satellite in Low Earth Orbit. RBI is a passive remote sensing instrument that will follow the successful legacy of the Clouds and Earth's Radiant Energy System (CERES) instruments to make measurement of Earth's short and longwave radiation budget. The goal of RBI is to provide an independent measurement of the broadband reflected solar radiance and Earth's emitted thermal radiance by using three spectral bands (Shortwave, Longwave, and Total) that will have the same overlapped point spread function (PSF) footprint on Earth. To ensure precise NIST-traceable calibration in space the RBI sensor is designed to use a visible calibration target (VCT), a solar calibration target (SCT), and an infrared calibration target (ICT) containing phase change cells (PCC) to enable on-board temperature calibration. The VCT is a thermally controlled integrating sphere with space grade Spectralon covering the inner surface. Two sides of the sphere will have fiber-coupled laser diodes in the UV to IR wavelength region. An electrical substitution radiometer on the integrating sphere will monitor the long term stability of the sources and the possible degradation of the Spectralon in space. In addition the radiometric calibration operations will use the Spectralon diffusers of the SCT to provide accurate measurements of Solar degradation. All those stable on-orbit references will ensure that calibration stability is maintained over the RBI sensor lifetime. For the preflight calibration the RBI will view five calibration sources - two integrating spheres and three CrIS (Cross-track Infrared Sounder ) -like blackbodies whose outputs will be validated with NIST calibration approach. Thermopile are the selected detectors for the RBI. The sensor has a requirement to perform lunar calibration in addition to solar calibration in space in a way similar to CERES instruments approach. To monitor climate change and to get stable and traceable results, it is critical to assure stable calibration over instrument lifetime.
A machine for three-dimensional braiding of fibers is provided in which carrier members travel on a curved, segmented and movable braiding surface. The carrier members are capable of independent, self-propelled motion along the braiding surface. Carrier member position on the braiding surface is controlled and monitored by computer. Also disclosed is a yarn take-up device capable of maintaining tension in the braiding fiber.
A machine for three-dimensional braiding of fibers is provided in which carrier members travel on a curved, segmented and movable braiding surface. The carrier members are capable of independent, self-propelled motion along the braiding surface. Carrier member position on the braiding surface is controlled and monitored by computer. Also disclosed is a yarn take-up device capable of maintaining tension in the braiding fiber.