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NASA NTRS2016

Latent Hardeners for the Assembly of Epoxy Composites

Large-scale composite structures are commonly joined by secondary bonding of molded-and-cured thermoset components. This approach may result in unpredictable joint strengths. In contrast, assemblies made by co-curing, although limited in size by the mold, result in stable structures, and are certifiable for commercial aviation because of structural continuity through the joints. Multifunctional epoxy resins were prepared that should produce fully-cured subcomponents with uncured joining surfaces, enabling them to be assembled by co-curing in a subsequent out-of-autoclave process. Aromatic diamines were protected by condensation with a ketone or aldehyde to form imines. Properties of the amine-cured epoxy were compared with those of commercially available thermosetting epoxy resins and rheology and thermal analysis were used to demonstrate the efficacy of imine protection. Optimum conditions to reverse the protecting chemistry in the solid state using moisture and acid catalysis were determined. Alternative chemistries were also investigated. For example, chain reaction depolymerization and photoinitiated catalysts would be expected to minimize liberation of volatile organic content upon deprotection and avoid residual reactive species that could damage the resin. Results from the analysis of protected and deprotected resins will be presented.

Palmieri, Frank↗

NASA NTRS2017

Partitioning of F and Cl Between Apatite and a Synthetic Shergottite Liquid (QUE 94201) at 4 Gpa from 1300 TO 1500 C

Apatite [Ca5(PO4)3(F,Cl,OH)] is present in a wide range of planetary materials. Due to the presence of volatiles within its crystal structure (Xsite), many recent studies have attempted to use apatite to constrain the volatile contents of planetary magmas and mantle sources. In order to use the volatile contents of apatite to accurately determine the abundances of volatiles in coexisting silicate melt or fluids, thermodynamic models for the apatite solid solution and for the apatite components in multicomponent silicate melts and fluids are required. Although some thermodynamic models for apatite have been developed, they are incomplete. Furthermore, no mixing model is available for all of the apatite components in silicate melts or fluids, especially for F and Cl components. Several experimental studies have investigated the apatite-melt and apatite-fluid partitioning behavior of F, Cl, and OH in terrestrial and planetary systems, which have determined that apatite-melt partitioning of volatiles are best described as exchange equilibria similar to Fe-Mg partitioning between olivine and silicate melt. However, McCubbin et al., recently reported that the exchange coefficients vary in portions of apatite compositional space where F, Cl, and OH do not mix ideally in apatite. In particular, solution calorimetry data of apatite compositions along the F-Cl join exhibit substantial excess enthalpies of mixing, and McCubbin et al. reported substantial deviations in the Cl-F exchange Kd along the F-Cl apatite join that could be explained by the preferential incorporation of F into apatite. In the present study, we assess the effect of apatite crystal chemistry on F-Cl exchange equilibria between apatite and melt at 4 GPa over the temperature range of 1300-1500 C. The goal of these experiments is to assess the variation in the Ap-melt Cl-F exchange Kd over a broad range of F:Cl ratios in apatite. The results of these experiments could be used to understand at what composition apatite shifts from a hexagonal unit cell with space group P63/m to a unit cell with monoclinic symmetry within space group P21/b. We anticipate that this transition occurs at >70% chlorapatite based on solution calorimetry data.

McCubbin, F. M.↗

NASA NTRS2017

Analysis of High-order Social Interaction of Female Mice on the International Space Station

Social interactions are adaptive responses to environmental pressures that have evolved to facilitate the success of individual animals and their progeny. Quantifying social behavior in social animals is therefore one method of evaluating an animal's health, wellbeing and their adjustment to changes in their environment. The interaction between environment and animal can influence numerous other physiological and psychological responses that may enhance, deter or shift an animals social paradigm. For this study, we utilized flight video from the Rodent Research Hardware and Operations Validation mission (Rodent Research-1; RR1) on the International Space Station (ISS). Female mice spent 37 days in microgravity on the ISS and video was captured during the final 33 days. In a previous analysis of individual behavior, we also reported an observed spontaneous ambulatory behavior which we termed circling or 'race tracking,' and we anecdotally observed an increase in group organization around this behavior. In this analysis we further examined this behavior, and other social interactions, to determine if (1) animals joining in on this behavior were induced by other cohort members already participating in this circling behavior, (2) rates of joining varied by number already participating.

spacefligh↗

NASA NTRS2018

Inertial Weldment of Rhenium and Inconel 718

Inertia welding has been found to be a successful method for joining pure rhenium to Inconel 718, and with additional experimentation, this process may have great potential for rocket nozzle applications. Refractory metals are ideally suited to this application, where high temperatures and oxidizing environment survivability is required, but not all of the thruster must be made of these materials, only the areas that require them. A bolted joint between the two metals is not ideal, especially for small thrusters where the mess of a bolted join will come at a steep price. A welded joint would be preferred for flight thrusters.

Cavender, D. P.↗

NASA NTRS2017

Kelt-16b: A Highly Irradiated, Ultra-Short Period Hot Jupiter Nearing Tidal Disruption

We announce the discovery of KELT-16b, a highly irradiated, ultra-short period hot Jupiter transiting the relatively bright (visual magnitude equals 11.7) star TYC 2688-1839-1/KELT-16. A global analysis of the system shows KELT-16 to be an F7V star with effective temperature equal to 6236 plus or minus 54 degrees Kelvin, log g (sub asterisk) equal to 4.253 from plus 0.031 to minus 0.036, [Fe/H] equal to minus 0.002 from plus 0.086 to minus 0.085, mass (sub asterisk) equal to 1.211 from plus 0.043 to minus 0.046 times the solar mass, and radius (sub asterisk) equal to 1.360 from plus 0.064 o minus 0.053 times the solar radius. The planet is a relatively high-mass inflated gas giant with planetary mass equal to 2.75 from plus 0.016 to minus 0.15 times Jupiter's mass, planetary radius equal to 1.415 from plus 0.084 to minus 0.067 times Jupiter's radius, density planetary rho equal to 1.20 plus or minus 0.18 grams per cubic centimeter, surface gravity, log planetary gravity equal to 3.530 from plus 0.042 to minus 0.049, and equatorial temperature equal to 2453 from plus 55 to minus 47 degrees Kelvin. The best-fitting linear ephemeris is T(sub C) equal to 22457247.24791 plus or minus 0.00019 BJD (sub TDB) and P equal to 0.9689951 plus or minus 0.0000024 day. KELT-16b joins WASP-18b, -19b, -43b, -103b, and HATS-18b as the only giant transiting planets with periodicity P less than 1 day. Its ultra-short period and high irradiation make it a benchmark target for atmospheric studies by the Hubble Space Telescope, Spitzer, and eventually the James Webb Space Telescope. For example, as a hotter, higher-mass analog of WASP-43b, KELT-16b may feature an atmospheric temperature-pressure inversion and day-to-night temperature swing extreme enough for TiO to rain out at the terminator. KELT-16b could also join WASP-43b in extending tests of the observed mass-metallicity relation of the solar system gas giants to higher masses. KELT-16b currently orbits at a mere approximately 1.7 Roche radii from its host star, and could be tidally disrupted in as little as a few times 10 (sup 5) years (for a stellar tidal quality factor of Q (sup prime) (sub asterisk) equal to 10 (sup 5). Finally, the likely existence of a widely separated bound stellar companion in the KELT-16 system makes it possible that Kozai-Lidov (KL) oscillations played a role in driving KELT-16b inward to its current precarious orbit.

Oberst, Thomas E.↗

NASA NTRS2019

Assembling and Testing NASA’s Space Launch System for First Flight

NASA is planning its next step toward human expansion into the solar system. The Space Launch System (SLS) (Figure 1) is a critical enabling component of that expansion. SLS payloads for its early missions include the Orion crew vehicle and components for Gateway, a lunar outpost orbiting the Moon that will facilitate research, technology and partnerships for eventual Mars missions. All major core stage hardware for test and flight completed structural manufacturing in 2018. The major components for the first flight vehicle are complete or approaching completion of internal equipment installation. The core stage forward join operation is also complete. The 10 booster segments needed for first flight have been cast and are ready to ship to NASA’s Kennedy Space Center (KSC) for mating and stacking. The four RS-25 core stage engines completed processing at NASA’s Stennis Space Center (SSC) and are ready for core stage integration. The Orion Stage Adapter (OSA) joined the Interim Cryogenic Propulsion Stage (ICPS) at KSC to await the rest of SLS flight hardware. Production and preparation of hardware for the second mission is also underway. Looking ahead to a busy 2019, liquid oxygen (LOX) tank, liquid hydrogen (LH2) tank and intertank structural testing will take place. This paper will discuss the current and planned status of SLS development in context of NASA’s overall exploration plans.

Askin, Bruce R.↗

NASA NTRS2019

NASA’s Space Launch System: Exploration Mission-1 Hardware Nears Completion

The Space Launch System (SLS) Program completed several significant production milestones in 2018 for the launch vehicle’s first mission (Fig. 1) and is poised for greater accomplishments in 2019. With manufacturing and hardware installation finished, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The upper stage, the Interim Cryogenic Propulsion Stage (ICPS), and the Orion Stage Adapter (OSA), where 13 6U CubeSats will ride to deep space on EM-1, were completed and delivered to Exploration Ground Systems at KSC in 2017 and 2018, respectively. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗

NASA NTRS2019

NASA’s Space Launch System: First Mission Hardware Nears Completion

The Space Launch System (SLS) Program (Fig. 1) completed several significant production milestones in 2018 for its first mission and is poised for greater accomplishments in 2019. With manufacturing and hardware installation complete, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success and scientific discovery. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗

NASA NTRS2020

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗

NASA NTRSDate not supplied

Novel insights enabled by combining mouse muscle datasets from the Rodent Research-1 mission

Biological space experiments are often expensive and difficult to conduct. As such, it is critical to maximize the value of the data that is collected during these experiments. One way to do this is to combine multiple–previously separate–datasets. This can increase the number of replicates for the conditions of interest (and hence statistical power), allow new multi-factor questions to be asked, and potentially highlight new patterns that otherwise would not have been identified from single-dataset studies. However, the process of combining datasets introduces noise due to inherent technical variations between experiments. To better understand the insights that can be gained from multi-dataset analyses and the problems that may arise from joining multiple datasets, several mouse muscle RNA-Seq datasets from the Rodent Research-1 mission were first selected. Then, using the R package DESeq2, principal component analysis (PCA) plots and differentially expressed gene (DEG) lists between ground and flight muscle samples were generated for individual datasets and for different pairwise combinations of datasets. Several new DEGs were identified in the combined datasets, and patterns in the PCA plots were affected depending on which datasets were joined. Understanding the results of this work will be critical for future studies that seek to perform multi-dataset analyses.

spaceflight↗

NASA NTRS2024

Electron Beam Welding of Additively Manufactured Niobium Alloy Heat Pipes

Additively manufactured refractory alloy-liquid metal heat pipes are being developed and tested for thermal management systems within nuclear propulsion and power applications. This study investigated electron beam (EB) welded joints on a laser powder bed fusion printed niobium alloy (C-103) and the impact of multiple joined heat pipe sections on working fluid flow and container leak-tightness. Results showed that EB welded joints connecting multiple heat pipe sections do not impact working fluid wicking behavior and the printed C-103 material and the EB welds joining the tubular sections created a leak-tight container. Interestingly, CT data showed an order of magnitude greater number and volume of porosity indications in the ground mating surface weld compared to the as-printed mating surface weld. The work concluded that AM is a viable manufacturing process for niobium alloy heat pipes and provided valuable insights for future AM heat pipe research and development.

Electron beam welding↗

NASA NTRS2024

Tracking Community Building in Open Science

Open Science is enabled by a vibrant community of researchers who regularly engage with the data, from its production to its organization, curation, archiving, dissemination, analysis, and publication. This presentation will examine community building in open science. The NASA Open Science Data Repository (OSDR) makes data available to the public following the FAIR (Findability, Accessibility, Interoperability, and Reusability) principles. OSDR takes open science further with the OS Analysis Working Groups (AWGs) that facilitate community development and promotion. The primary activity of each AWG is to establish and validate analytical processes to generate higher-order data from data housed in OSDR. There are a number of these groups on various topics, including the Animal AWG, Plant AWG, Microbial AWG, Multi-Omics AWG, AI/ML AWG, and the Ames Life Sciences Data Archive (ALSDA) AWG. The international volunteers participating in these AWGs come from academia, citizen science initiatives, industry, and government. They include researchers, principal investigators, professors, trained hobbyists, and students from various domains and disciplines. Anyone may request to join the AWGs, and membership requests are vetted monthly by the group organizers before granting admission. Core to membership is demonstrated expertise through records of training, integrity, work in the professed domain(s), and good community standing. Regular virtual meetings are held for each AWG, with a varying cadence depending on the group's needs and goals. AWG communities share their expertise in research including cutting edge tools, software, frameworks, data formats, and libraries accelerating research collectively. This collaborative approach helps community members cross technology gaps and identify emerging challenges. These diverse communities encompass a wide range of individuals hailing from various sectors within the Science Mission Directorate and beyond. They serve as a means to promote and enhance transparency, accessibility, and inclusion. An annual AWG Symposium brings contributors together in person. Participation in AWGs can be synchronous or asynchronous, with some groups performing most of their work in off hours. Participants gain valuable skills and connections that allow them to add value to their communities and new organizations that they join, resulting in an expanded return on investment for the space life science community. Open science is increasingly a federal mandate and initiatives like NASA's Transform to Open Science and instruments like the Decadal Survey of Biological and Physical Sciences in Space demonstrate the need to carefully consider best practices in this domain. Here, we present greater detail about the makeup and participation metrics of the various AWGs affiliated with OSDR and details of successful peer-reviewed publication campaigns.

Christina M Johnson↗

NASA NTRSDate not supplied

Validation of Multisystem Countermeasures Protocol for Spaceflight during Antarctica Winter-over at Palmer Station (Palmer Countermeasures)

Exploration-class missions beyond the Van Allen belt to the Moon and then Mars will begin soon. Low-Earth orbital spaceflight results in the persistent perturbation of the human immune system, characterized by reductions in T and NK cell function, altered cytokine profiles, and the reactivation of latent herpesviruses. While these alterations have not caused widespread clinical issues, some crewmembers experience immune-related adverse events, including manifestations of symptomatic herpes viral reactivation, allergy, and respiratory distress. Because future deep-space exploration missions will be of unprecedented duration, it is reasonable to hypothesize that the immune perturbations observed aboard International Space Station (ISS) will intensify during longer missions in deep space, thereby placing crewmembers at elevated clinical risk. Thus, it is imperative to preserve the immune vigilance of astronauts by developing a countermeasure strategy. Of all the Earth analogs studied to date, an Antarctica winter-over (AWO) mission most closely reproduces the spaceflight experience: prolonged deployment, extreme environment, circadian misalignment, isolation, station lifestyle, and personal risk. The US maintains three primary stations in Antarctica: South Pole Station, McMurdo, and Palmer. Previous studies suggest that stations located near the interior of Antarctica (South Pole, McMurdo) have confounding effects on the immune system due to persistent hypobaric hypoxia. Thus, it was hypothesized that winter-over at a coastal station (Palmer) would be more akin to spaceflight due to its normoxic but still extreme environment. Therefore, AWO at Palmer Station was chosen as the platform for testing and validating the effectiveness of a NASA multi-system countermeasures protocol designed for deep space missions. The array of countermeasure protocols and monitoring methods deployed for each AWO will consist of diet modifications, nutritional supplementation, prescribed aerobic and resistive exercise, and a protocol of stress relieving virtual reality exercises. A multitude of biological sample types, including blood, saliva, and hair will be collected in tandem with the countermeasures in order to examine the combined effectiveness of the countermeasures. Samples and logs from subjects will be transported from Palmer Station to Johnson Space Center for further processing and distribution to co-investigators at the end of each winter-over. Extracted samples will be analyzed by appropriate testing platforms (Multiplex, qPCR, ELISA, etc.) to monitor alterations in leukocyte distribution, T cell and NK function, cytokine profiles, reactivation of latent herpesviruses, and nutritional factors. The data collected will be compared to a control year in which no countermeasures were deployed to evaluate the overall effectiveness of the analog and to validate the candidate immune countermeasure strategy. With the completion of the Antarctica Winter-Over (WO) 2022 control year, samples for 13 subjects have been successfully returned from Antarctica to NASA/JSC for further processing and distribution to Co-Investigators. WO 2023, the first countermeasure year, has also commenced with 11 subject consenting and performing their base line data collections (BDC) held in Chile. Another 5 subjects, who were already stationed at Palmer Station, Antarctica, joined as participates in the investigation. These 5 subjects were consented, but no BDC was able to be collected due to their joining in-mission. Therefore, there will be a total of 16 subjects participating in Antarctica's 2023 Winter-Over.

Cody L Gutierrez↗

NASA NTRSDate not supplied

Tracking Community Building in Open Science

Christina M Johnson↗

NASA NTRSDate not supplied

Innovations in Continuous Ultrasonic Welding of Thermoplastic Composites and Evaluation for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite materials were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding of candidate materials to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

NASA NTRSDate not supplied

Finite Element Thermal Model for Ultrasonic Welding of Thermoplastic Composites

Ultrasonic welding, UW, is a fast and energy-efficient technique for joining thermoplastic composites. It involves the use of high-frequency mechanical vibrations and a static welding force to melt and join adherends. Ultrasonic welding is an enabling technology to reduce the cost and complexity of in-space construction because lightweight thermoplastic composite components can be packaged compactly for launch and then efficiently assembled using supervised autonomous robotic technologies on site. However, the temperatures in space present challenges to UW, and it is critical that the efficacy of process parameters selected for manufacturing in space is understood prior to launch. To this end, a three-dimensional finite element model is presented in this technical presentation. The model incorporates equations for effects of viscoelastic heating and heat transfer on the welding process. The proposed model is applied to predict the temperature distribution in single lap shear, SLS, samples composed of AS4/PEEK (TC1200) composite that were welded using a terrestrial machine as part of a comprehensive weldability study. Thermocouple and infrared spot sensor data from the SLS samples provide empirical temperature measurements for calibration and validation of the UW thermal model. Calibration and validation of the model is an important step given the significant uncertainties in material properties such as the loss modulus and necessary assumptions in the physics implementations which allow the model to converge in an acceptable amount of time. The validated thermal model can be used to simulate the process for the space environment. Future validation sample testing is planned in a vacuum chamber. The result will be a model capable of guiding process parameter selection to ensure acceptable weld bonds when manufacturing in space.

Josh Fody↗

NASA NTRS2024

Offset-Stoichiometric Reflowable Composite Bonding Method with Adhesive for Mitigating Strict Faying Surface Tolerances

Inherent susceptibility of adhesive bonds to miniscule quantities of contamination can cause undetectable weakened bonds. For this reason, the Federal Aviation Administration (FAA) places strict regulations on adhesively bonded joints in primary aircraft structures. To meet certification requirements aircraft manufactures resort to redundant load paths in the form of fasteners which inherently add weight to the structure and increase manufacturing time. In prior work, a secondary bonding technique called AERoBOND was developed, which utilized off-stoichiometric epoxymatrix resins to facilitate reflow and diffusion of the resin within the joint interface during a secondary bonding/cure process, thus achieving a bond similar to a co-cured joint. However, the AERoBOND process required tight spatial tolerances between the two parts being joined. This study examined the utilization of conventional adhesive with the AERoBOND method to act as a filler in the joint line, effectively reducing the need for tight tolerances on the joining parts and serving as a flexible alternative for existing manufacturing processes. Ultrasonic inspection, optical microscopy, and ASTM International standard tests were performed to analyze the joints for defects and to quantify the mode-I and mode-II interlaminar fracture toughness and short beam strength of the proposed methodology with varying manufacturing parameters. The comprehensive results indicate that the AERoBOND+ method with and without surface preparation performs comparably to co-cured and conventional, adhesively bonded joints when secondary cured in an autoclave with 791 kPa of pressure. As an example, the AERoBOND+ panel without surface preparation bonded with 791 kPa of pressure (referred to as AB+3 throughout paper) had a mode-I fracture toughness (G Ic ) of 0.643 kJ/m 2 and a mode-II fracture toughness (G IIc ) of 4.000 kJ/m 2 in the non-precracked condition and 4.218 kJ/m 2 in the precracked condition at the adhesive-to-prepreg interface. These results were 96%, 142%, and 217%, respectively, of a co-cured baseline panel (referred to as C1 throughout paper).

Composites↗