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All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Probabilistic Fatigue Life Analysis of High Density Electronics Packaging

The fatigue of thin film metal interconnections in high density electronics packaging subjected to thermal cycling has been evaluated using a probabilistic fracture mechanics methodology. This probabilistic methodology includes characterization of thin film stress using an experimentally calibrated finite element model and simulation of flaw growth in the thin films using a stochastic crack growth model.

thermal cycling fatigue of thin film metal interco↗
NASA NTRS2006

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Agency's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar(TradeMark) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar(TradeMark) filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However, due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to the experimental investigation reported in [1] and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel's residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Greene, N.↗
NASA NTRS2009

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Administration's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to a previously reported experimental investigation and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel s residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Thesken, John C.↗
NASA NTRS2003

Direct Simulation Monte Carlo Calculations in Support of the Columbia Shuttle Orbiter Accident Investigation

The Direct Simulation Monte Carlo method was used to provide 3-D simulations of the early entry phase of the Shuttle Orbiter. Undamaged and damaged scenarios were modeled to provide calibration points for engineering "bridging function" type of analysis. Currently the simulation technology (software and hardware) are mature enough to allow realistic simulations of three dimensional vehicles.

Gallis, Michael A.↗
NASA NTRS2011

LaPlace Transform1 Adaptive Control Law in Support of Large Flight Envelope Modeling Work

This paper presents results of a flight test of the L1 adaptive control architecture designed to directly compensate for significant uncertain cross-coupling in nonlinear systems. The flight test was conducted on the subscale turbine powered Generic Transport Model that is an integral part of the Airborne Subscale Transport Aircraft Research system at the NASA Langley Research Center. The results presented are in support of nonlinear aerodynamic modeling and instrumentation calibration.

Gregory, Irene M.↗
NASA NTRS2013

The Evaluation of a Test Device for Human Occupant Restraint (THOR) Under Vertical Loading Conditions: Part 1 - Experimental Setup and Results

A series of 16 vertical tests were conducted on a Test Device for Human Occupant Restraint (THOR) - NT 50th percentile Anthropomorphic Test Device (ATD) at NASA Langley Research Center (LaRC). The purpose of the tests conducted at NASA LaRC was threefold. The first was to add vertical response data to the growing test database for THOR-NT development and validation. Second, the THOR-NT analytical computational models currently in development must be validated for the vertical loading environment. The computational models have been calibrated for frontal crash environments with concentration on accurately replicating head/neck, thoracic, and lower extremity responses. Finally, familiarity with the THOR ATD is necessary because NASA is interested in evaluating advanced ATDs for use in future flight and research projects. The THOR was subjected to vertical loading conditions ranging between 5 and 16 g in magnitude and 40 to 120 milliseconds (msec) in duration. It was also tested under conditions identical to previous tests conducted on the Hybrid II and III ATDs to allow comparisons to be made. Variations in the test setup were also introduced, such as the addition of a footrest in an attempt to offload some of the impact load into the legs. A full data set of the THOR-NT ATD will be presented and discussed. Results from the tests show that the THOR was largely insensitive to differences in the loading conditions, perhaps due in part to their small magnitudes. THOR responses, when compared to the Hybrid II and III in the lumbar region, demonstrated that the THOR more closely resembled the straight spine Hybrid setup. In the neck region, the THOR behaved more like the Hybrid III. However in both cases, the responses were not identical, indicating that the THOR would show differences in response than the Hybrid II and III ATDs when subjected to identical impact conditions. The addition of a footrest did not significantly affect the THOR response due to the nature of how the loading conditions were applied.

Littell, Justin D.↗
NASA NTRS2016

NASA's Earth Science Flight Program Meets the Challenges of Today and Tomorrow

NASA's Earth science flight program is a dynamic undertaking that consists of a large fleet of operating satellites, an array of satellite and instrument projects in various stages of development, a robust airborne science program, and a massive data archiving and distribution system. Each element of the flight program is complex and present unique challenges. NASA builds upon its successes and learns from its setbacks to manage this evolving portfolio to meet NASA's Earth science objectives. NASA fleet of 16 operating missions provide a wide range of scientific measurements made from dedicated Earth science satellites and from instruments mounted to the International Space Station. For operational missions, the program must address issues such as an aging satellites operating well beyond their prime mission, constellation flying, and collision avoidance with other spacecraft and orbital debris. Projects in development are divided into two broad categories: systematic missions and pathfinders. The Earth Systematic Missions (ESM) include a broad range of multi-disciplinary Earth-observing research satellite missions aimed at understanding the Earth system and its response to natural and human-induced forces and changes. Understanding these forces will help determine how to predict future changes, and how to mitigate or adapt to these changes. The Earth System Science Pathfinder (ESSP) program provides frequent, regular, competitively selected Earth science research opportunities that accommodate new and emerging scientific priorities and measurement capabilities. This results in a series of relatively low-cost, small-sized investigations and missions. Principal investigators whose scientific objectives support a variety of studies lead these missions, including studies of the atmosphere, oceans, land surface, polar ice regions, or solid Earth. This portfolio of missions and investigations provides opportunity for investment in innovative Earth science that enhances NASA's capability for better understanding the current state of the Earth system. ESM and ESSP projects often involve partnerships with other US agencies and/or international organizations. This adds to the complexity of mission development, but allows for a greater scientific return on NASA's investments. The Earth Science Airborne Science Program provides manned and unmanned aircraft systems that further science and advance the use of satellite data. NASA uses these assets worldwide in campaigns to investigate extreme weather events, observe Earth system processes, obtain data for Earth science modeling activities, and calibrate instruments flying aboard Earth science spacecraft. The Airborne Science Program has six dedicated aircraft and access to many other platforms. The Earth Science Multi-Mission Operations program acquires, preserves, and distributes observational data from operating spacecraft to support Earth Science research focus areas. The Earth Observing System Data and Information System (EOSDIS), which has been in operations since 1994, primarily accomplishes this. EOSDIS acquires, processes, archives, and distributes Earth Science data and information products. The archiving of NASA Earth Science information happens at eight Distributed Active Archive Centers (DAACs) and four disciplinary data centers located across the United States. The DAACs specialize by topic area, and make their data available to researchers around the world. The DAACs currently house over 9 petabytes of data, growing at a rate of 6.4 terabytes per day. NASA's current Earth Science portfolio is responsive to the National Research Council (NRC) 2007 Earth Science Decadal Survey and well as the 2010 NASA Response to President Obama's Climate Plan. As the program evolves into the future it will leverage the lessons learned from the current missions in operations and development, and plan for adjustments to future objectives in response to the anticipated 2017 NRC Decadal Survey.

Flight Program↗
NASA NTRS2016

Measurements of the Ionization Coefficient of Simulated Iron Micrometeoroids

The interpretation of meteor radar observations has remained an open problem for decades. One of the most critical parameters to establish the size of an incoming meteoroid from radar echoes is the ionization coefficient, beta, which still remains poorly known. Here we report on new experiments to simulate micrometeoroid ablation in laboratory conditions to measure beta for iron particles impacting N2, air,CO2, and He gases. This new data set is compared to previous laboratory data where we find agreement except for He and air impacts greater than 30 kms. We calibrate the Jones model of beta(v) and provide fit parameters to these gases and find agreement with all gases except CO2 and high-speed air impacts where we observe beta(sub air) greater than 1 for velocities greater than 70 kms. These data therefore demonstrate potential problems with using the Jones model for CO2 atmospheres as well as for high-speed meteors on Earth.

Thomas, Evan↗
NASA NTRS2018

Increased Operational Availability and Simplified Operations Using Dither Gyro Scale Factor Calibration

The traditional approach to on-orbit gyro scale factor calibration has been to perform large angle rotations about each gyro axis. The maneuvers require the science instruments to be taken offline, reducing operational availability and require a significant amount of interaction from the ground. To increase operational availability and to reduce the burden on mission operators, a novel approach to gyro scale factor calibration was developed, modeled and successfully demonstrated on the Geostationary Operational Environmental Satellite (GOES-16) to estimate gyro scale factor errors to within 1500 parts per million (ppm) without taking the science instruments offline.

Reth, Alan D.↗
NASA NTRS2018

Physics-Based Approach to Predict the Solar Activity Cycles

Observations of the complex highly non-linear dynamics of global turbulent flows and magnetic fields are currently available only from Earth-side observations. Recent progress in helioseismology has provided us some additional information about the subsurface dynamics, but its relation to the magnetic field evolution is not yet understood. These limitations cause uncertainties that are difficult take into account, and perform proper calibration of dynamo models. The current dynamo models have also uncertainties due to the complicated turbulent physics of magnetic field generation, transport and dissipation. Because of the uncertainties in both observations and theory, the data assimilation approach is natural way for the solar cycle prediction and estimating uncertainties of this prediction. I will discuss the prediction results for the upcoming Solar Cycle 25 and their uncertainties and affect of Ensemble Kalman Filter parameters to resulting predictions.

Physics-Based↗
NASA NTRS2017

Wavenumber-frequency Spectra of Pressure Fluctuations on a Generic Space Vehicle Measured via Unsteady Pressure-Sensitive Paint

Time histories of pressure fluctuations on a generic, hammerhead space vehicle model were measured using unsteady Pressure-Sensitive Paint (uPSP). The test was conducted in the 11-foot transonic wind tunnel of NASA Ames Research Center over a Mach number range of 0.6 M 1.2, and angles of attack of -4 4. The model was coated with a porous binder and PtTFPP-based porous polymer paint. An elaborate system of four high-speed cameras, and forty LED lamps was used for image acquisition. Various steps for image registration, reduction of shot noise, photogrammetry procedure to map images from the four cameras on a grid for the model, and finally a calibration procedure to convert the measured fluctuations in light intensity to fluctuating pressure, are discussed in the paper. The calibration process using a set of unsteady pressure sensors mounted on the model, was found to overcome some of the inherent problems of the fast response paint, such as rapid photo-degradation, non-linearity in pressure response, and significant temperature sensitivity. Comparison of spectra of pressure fluctuations between UPSP and pressure sensors demonstrated the ability of the paint to faithfully follow fluctuations up to 10 kHz, the maximum attempted. It was also found that the camera bit-depth and the illumination level limited the lowest measurable levels of pressure fluctuations to around 140dB. The large data set exposed various critical transonic flow physics not seen before, such as a coupling of the shock motion on the Payload Fairing (PF) with the separated flow region on the upper stage of the launch vehicle, and upstream convection of pressure fluctuation on PF at certain Mach numbers. The data also confirmed the expectation of a general lowering of the coefficient of pressure fluctuation with Mach number. The availability of the data set on a dense, regularly-spaced, surface grid allowed for the calculation of wavenumber-frequency (k-) spectra via straightforward applications of Fourier transform. The k- spectra were compared for the separated flow regions on the Second Stage, and the shock-boundary layer interactions on PF. The former showed self-similarity with Mach number while the latter was distinctly different, and confirmed the upstream propagation of pressure fluctuations. The k- spectra were dominated by the convected fluctuations; the acoustic domain was not discernable. These data, valuable for the vibro-acoustics analysis of aerospace vehicles, are believed to be the first obtained for the transonic flight regime, and pave the path for application on production models of aerospace vehicles.

buffet↗
NASA NTRS2019

TPSAS-NF1676L-32920-DND

In June 2019, a full-scale crash test of a Fokker F28 Fellowship aircraft will be conducted at NASA Langley Research Center?s Landing and Impact Research (LandIR) Facility. The F28 is a high-performance twin-turbo fan narrow-body aircraft with seating in a 3+2 configuration. The MK4000 variant, used in this test, is capable of carrying up to 85 passengers on medium range routes. The F28 was first type certified by the Federal Aviation Administration (FAA) in 1969 and now the majority of the F28 fleet has retired from service in the United States. In 2016, the FAA and NASA Langley Research Center (LaRC) signed an interagency agreement for conducting a research program to obtain test data that will support the development of airframe level crash requirements for transport category airplanes [1]. The objectives of the full-scale crash test can be divided into six categories: (1) To compare and contrast responses in identical aircraft undergoing vertical only to combined vertical and horizontal loading conditions, (2) To examine the effects of horizontal loading on aircraft structure during a crash event, (3) To generate data for the use in calibration of computer modelling efforts, (4) To generate data from onboard Anthropomorphic Test Devices (ATDs) for the evaluation of injury, (5) To obtain data from experimental seats, and (6) To obtain data from new and novel ATD designs including Warrior Injury Assessment MANikin (WIAMan) [2], Test device for Human Occupant Response (THOR), and other newly developed child ATDs. The focus of this presentation will be to document finite element model development of the full-scale F28 aircraft and to present preliminary test-analysis predictions. NASA obtained the full-scale F28 aircraft, plus three fuselage sections and two sets of wings with funding through the NASA Aviation Safety Program in 1998. In addition to the hardware, NASA purchased a full NASTRAN model of the airframe that had been developed by the Dutch manufacturer, Fokker. Beginning in 2016, the NASTRAN model was converted to LS-DYNA? [4, 5] format and modified by combining parts, adding missing parts of internal structure, and including ballast for loading weights, etc. It contains: 89,223 nodes; 24,065 beam elements; 55,404 shell elements; 29,044 solid elements; 740 parts; 80 material definitions; and, 46 Constrained Nodal Rigid Bodies (CNRBs). The aircraft model will be executed in LSDYNA to simulate the test article impact onto a 2-ft.-high bed of soil under combined velocity conditions of 70-ft/s forward and 30-ft/s vertical velocity. Pre-test simulation predictions will be generated and correlated with test data.

Karen E Jackson↗
NASA NTRSDate not supplied

500+ Million Years of Volcanism in Australe

The roughly circular collection of mare deposits in the "Mare Australe" region (38.9°S, 93°E) is ~900 km in diameter. The maria erupted into post-basin impact craters but are generally disconnected from each other. The distribution of maria could reflect what might have been the early stages of other basin filling mare eruptions, but which are preserved in Australe and some farside locations [1-3]. Topographic data fail to indicate a 900-km basin, but gravity and topographic data suggest a 600-km basin in the northern part of Australe [6]. The relationship between the basin and the wider-spread mare deposits is unclear, particularly outside the basin. We utilized images, gravity, topography, and composition to investigate the timing of volcanism in "Mare Australe" to interpret the evolution of magmatism in Australe and how it might relate to other mare sources. Humboldt crater (~3.6 Ga) makes an excellent stratigraphic marker that can be traced across much of the deposits and serves as a stratigraphic calibration for absolute model ages (AMAs) derived from crater size-frequency distributions (CSFDs). We found a range of AMAs from ~3.3 to 3.8 Ga in north Australe, similar to previous studies [4], and there is also evidence for multiple deposits of older cryptomaria. The age range, however, is narrower than for maria in other basins (e.g., Imbrium and South Pole-Aitken [4-5]), suggesting different magmatism in Australe. Most of the mare deposits are >3.5 Ga; younger deposits are co-located in the north basin. The basin may have provided additional pathways for rising magma to the surface over time. We also found evidence of a several interconnected deposits within the north basin. Other, smaller deposits, however, clearly show distinct age differences between units within a single topographic depression (e.g., Lyot crater) and likely represent discrete eruptions. Additionally, there are no floor fractured craters other than Humboldt [6], suggesting that magma generally did not stall out near the surface, also consistent with gravity and (lack of) magnetic anomalies (in contrast to Marius Hills and South Pole-Aitken basin [7-8]).

Julie Dawn Stopar↗
NASA NTRSDate not supplied

Multi-Anvil Experimentation Applied to Planetary Differentiation

Planets undergo differentiation that includes segregation of metal from silicate at high temperatures and pressures ranging from deep planetary core pressures (>300 GPa for Earth)to very shallow conditions of asteroids (<100 MPa).The multi-anvil solid media apparatus accesses the middle part of this range from 3 to 30 GPa –pressure relevant to the interior of Mercury, Venus, Earth, Earth’s Moon, and Mars. Early planets are thought to have experienced high temperatures from a combination of heat sources including radioactive decay, gravitational and accretional heating, and impact processes. These heating events led to melting of mantles and cores, thus requiring an understanding of solid-liquid equilibria in metal-silicate systems. In 2006 we established a multi-anvil facility at NASA-JSC combining an 880 ton press and a Kawai/Walker type module from Rockland Research. Our high PT work has been greatly facilitated by use of the COMPRES multi-anvil assemblies (1). Our recent work has included studies of element partitioning between liquid metal and liquid silicate(e.g., 2), as well as between minerals and melts(e.g., 3), both of which have led to better constraints on the timing and conditions of planetary differentiation(e.g. 4). Several examples involving sustained efforts will be summarized below and for the presentation. The distribution of siderophile (iron-loving) elements between core and mantle is controlled by metal-silicate equilibrium across a wide range of pressures. Therefore, experimentation across this pressure range helps to calibrate elemental partitioning models that can be applied to planets, and used to predict mantle chemistry and composition during planetary differentiation. Our studies have focused on a wide range of siderophile elements (refractory Ni, Co, W, Mo; volatile P, Ga, Cu, Sn, Sb; highly siderophile Au, Pd) that have constrained partitioning, valence, and isotopic fractionation, and applied to Earth, Moon, and Mars. When molten mantles (magma oceans) cool enough to initiate crystallization, the solids precipitate at depth and in large planets this involves high pressure phases like garnet, majorite, akimotoite, and ringwoodite. As these solids precipitate they can segregate from liquid by density contrasts, thus causing elemental fractionation which can be used to decipher timing of differentiation. Mineral/melt and metal/silicate equilibria in our lab have helped to better understand high pressure fractionation of isotopic parent/daughter pairs Hf/W, Mn/Cr, Pd/Ag, Pt/Os, Re/Os, and U/Pb, and their application to Earth, Moon and Mars. There remains great potential for multi-anvil experimentation to shed light on many pressure–dependent aspects of planetary evolution such as core formation, high pressure phase equilibria, redox equilibria, and volatile evolution and storage. References1. Leinenweber, K., et al.(2012) American Mineralogist,97, 353–368. 2.Righter, K., et al.(2020) Geochem. Persp. Lett.15, 1-6.3. Righter, K., et al.(2020) Met. Planet. Sci 55, 2741-2757.4. Righter, K., et al.(2020)Earth and Planetary Science Letters,552, 116590.

pressure↗
NASA NTRS2021

Improvements to the Search for Cosmic Dawn Using the Long Wavelength Array

We present recent improvements to the search for the global Cosmic Dawn signature using the Long Wavelength Array station located on the Sevilleta National Wildlife Refuge in New Mexico, USA (LWA{SV). These improvements are both in the methodology of the experiment and the hardware of the station. An improved observing strategy along with more sophisticated temperature calibration and foreground modelling schemes have led to improved residual RMS limits. A large improvement over previous work using LWA{SV is the use of a novel achromatic beamforming technique which has been developed for LWA{SV. We present results from an observing campaign which contains 29 days of observations between March 10th, 2021 and April 10th 2021. The reported residual RMS limits are 6 times above the amplitude of the potential signal reported by the Experiment to Detect the Global EoR Signature (EDGES) collaboration.

Christopher Dilullo↗
NASA NTRSDate not supplied

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

thermoplastic composites↗
NASA NTRSDate not supplied

Using Digital Image Correlation for Material Testing at Cryogenic Temperatures

Recent efforts were made to parametrize an aluminum alloy at cryogenic temperatures to calibrate finite element models simulating material deformation. Digital image correlation (DIC) was used to measure material properties using front/back strains of specimens during tensile tests. Data acquired from DIC was compared to physical extensometer measurements. Two camera pairs (front and back) were mounted via aluminum extrusion to the exterior of an environmental chamber of a hydraulic test stand. Images were taken through single-pane optical glass windows of the environment chamber. Positive pressure bags encased the cameras, attaching to the perimeter of the glass to keep out moisture and prevent windows from frosting. Figure 1 shows the environmental setup and the camera setup during cryogenic testing. Some of the challenges during testing at cryogenic temperatures include the gaseous flow of liquid nitrogen in the optical path of the mounted cameras, frost buildup on the windows as seen in Figure 1b, and frost on the test coupon. The temperature gradient present during the introduction of liquid nitrogen into the chamber can increase the projection error of images captured of the specimen. Figure 2 shows the estimated projection error from DIC as a function of temperature during the cool down process. This presentation addresses some of the concerns and observations when using DIC for testing at cryogenic temperatures using methods of isolated camera system and techniques for maintaining the glass panel clear from frost.

Joseph Cochran↗
NASA NTRS2022

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

laser heating↗