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NASA NTRS2011

Approaches for Tensile Testing of Braided Composites

For angleply composites, lamina tension and compression strengths are commonly determined by applying classical lamination theory to test data obtained from testing of angleply composite specimens. For textile composites such as 2D triaxial braids, analysis is more complex and standard test methods do not always yield reliable strength measurements. This paper describes recent research focused on development of more reliable tensile test methods for braided composites and presents preliminary data for various approaches. The materials investigated in this work have 0deg+/-60 2D triaxial braid architecture with nearly equal fiber volume fraction in each of the three fiber directions. Flat composite panels are fabricated by resin transfer molding (RTM) using six layers of the braided preform aligned along the 0deg fiber direction. Various epoxy resins are used as matrix materials. Single layer panels are also fabricated in order to examine local variations in deformation related to the braid architecture. Specimens are cut from these panels in the shape of standard straight-sided coupons, an alternative bowtie geometry, and an alternative notched geometry. Axial tensile properties are measured using specimens loaded along the 0deg fiber direction. Transverse tensile properties are measured using specimens loaded perpendicular to the 0deg fibers. Composite tubes are also fabricated by RTM. These tubes are tested by internal pressurization using a soft rubbery material sealed between the inside diameter of the tube and the load fixtures. The ends of the tube are unconstrained, so the primary load is in the hoop direction. Tubes are fabricated with the 0deg fibers aligned along the tube axis by overbraiding the preform on a mandrel. Since the loading is in the hoop direction, testing of the overbraided tube provides a measure of transverse tensile strength. Previous work has indicated that straight-sided coupons yield a transverse tensile strength that is much lower than the expected material strength because of premature edge-initiated failure. Full-field strain measured during transverse tensile tests clearly showed accumulation of edge damage prior to failure. In the current work, high speed video and testing of single layer specimens are used to investigate potential failure mechanisms in more detail. High speed video clearly shows the edge initiation in six layer transverse tensile test coupons. Specimens with the bowtie geometry and the notched geometry minimize this edge effect and yield significantly higher transverse tensile strength values compared to the straight-sided coupons. However, bowtie and notched specimens geometries are not ideal because of the non-uniform stress and strain fields in the region of failure. Testing of tubes using internal pressurization eliminates edge-initiated failure and provides a more uniform state of stress and strain. Preliminary results indicate that bowtie, notched, and tube specimens yield comparable values for transverse tensile strength and that these values are much higher than the strength measured using a straight-sided coupon.

Roberts, Gary D.↗

NASA NTRS1994

Full-scale testing and analysis of fuselage structure

This paper presents recent results from a program in the Boeing Commercial Airplane Group to study the behavior of cracks in fuselage structures. The goal of this program is to improve methods for analyzing crack growth and residual strength in pressurized fuselages, thus improving new airplane designs and optimizing the required structural inspections for current models. The program consists of full-scale experimental testing of pressurized fuselage panels in both wide-body and narrow-body fixtures and finite element analyses to predict the results. The finite element analyses are geometrically nonlinear with material and fastener nonlinearity included on a case-by-case basis. The analysis results are compared with the strain gage, crack growth, and residual strength data from the experimental program. Most of the studies reported in this paper concern the behavior of single or multiple cracks in the lap joints of narrow-body airplanes (such as 727 and 737 commercial jets). The phenomenon where the crack trajectory is curved creating a 'flap' and resulting in a controlled decompression is discussed.

Miller, M.↗

NASA NTRS1995

Stress-Simulating Witness Panels

Special panel fixtures developed for verifying integrity of bonds between propellants and insulators in solid-fuel rocket motors by applying, to specimens of propellant and insulator material, stresses similar to those caused by shrinkage during fabrication of motors. Assemblies of fixtures and specimens called "stress-simulating witness panels." Concept also applicable to stress testing of bonds in other manufactured products subject to shrinkage or to swelling.

Graham, Robert P.↗

NASA NTRS1997

High-Temperature Adhesive Strain Gage Developed

Researchers at the NASA Lewis Research Center have developed a unique strain gage and adhesive system for measuring the mechanical properties of polymers and polymer composites at elevated temperatures. This system overcomes some of the problems encountered in using commercial strain gages and adhesives. For example, typical commercial strain gage adhesives require a postcure at temperatures substantially higher than the maximum test temperature. The exposure of the specimen to this temperature may affect subsequent results, and in some cases may be higher than the glass-transition temperature of the polymer. In addition, although typical commercial strain gages can be used for short times at temperatures up to 370 C, their long-term use is limited to 230 C. This precludes their use for testing some high-temperature polyimides near their maximum temperature capability. Lewis' strain gage and adhesive system consists of a nonencapsulated, unbacked gage grid that is bonded directly to the polymer after the specimen has been cured but prior to the normal postcure cycle. The gage is applied with an adhesive specially formulated to cure under the specimen postcure conditions. Special handling, mounting, and electrical connection procedures were developed, and a fixture was designed to calibrate each strain gage after it was applied to a specimen. A variety of tests was conducted to determine the performance characteristics of the gages at elevated temperatures on PMR-15 neat resin and titanium specimens. For these tests, which included static tension, thermal exposure, and creep tests, the gage and adhesive system performed within normal strain gage specifications at 315 C. An example of the performance characteristics of the gage can be seen in the figure, which compares the strain gage measurement on a polyimide specimen at 315 C with an extensometer measurement.

Pereira, J. Michael↗

NASA NTRS1992

Numerical analysis of the Iosipescu specimen for composite materials

A finite element analysis of the Iosipescu shear tests for unidirectional and cross-ply composites is presented. It is shown that an iterative analysis procedure must be used to model the fixture-specimen kinematics. The correction factors which are needed to compensate for the nonuniformity of stress distribution in calculating shear modulus are shown to be dependent on the material orthotropic ratio and the finite element loading models. Test section strain distributions representative of typical graphite-epoxy specimens are also presented.

Ho, H.↗

NASA NTRS1993

Numerical analysis of the Iosipescu specimen for composite materials

Ho, H.↗

NASA NTRS1996

The Extensional Rheology of Non-Newtonian Materials

The evolution of the transient extensional stresses in dilute and semi-dilute viscoelastic polymer solutions are measured with a filament stretching rheometer of a design similar to that first introduced by Sridhar, et al. The solutions are polystyrene-based (PS) Boger fluids that are stretched at constant strain rates ranging from 0.6 less than or equal to epsilon(0) less than or equal to 4s(exp -1) and to Hencky strains of epsilon greater than 4. The test fluids all strain harden and Trouton ratios exceeding 1000 are obtained at high strains. The experimental data strain hardens at lower strain levels than predicted by bead-spring FENE models. In addition to measuring the transient tensile stress growth, we also monitor the decay of the tensile viscoelastic stress difference in the fluid column following cessation of uniaxial elongation as a function of the total imposed Hencky strain and the strain rate. The extensional stresses initially decay very rapidly upon cessation of uniaxial elongation followed by a slower viscoelastic relaxation, and deviate significantly from FENE relaxation predictions. The relaxation at long times t is greater than or equal to 5 s, is compromised by gravitational draining leading to non-uniform filament profiles. For the most elastic fluids, partial decohension of the fluid filament from the endplates of the rheometer is observed in tests conducted at high strain rates. This elastic instability is initiated near the rigid endplate fixtures of the device and it results in the progressive breakup of the fluid column into individual threads or 'fibrils' with a regular azimuthal spacing. These fibrils elongate and bifurcate as the fluid sample is elongated further. Flow visualization experiments using a modified stretching device show that the instability develops as a consequence of an axisymmetry-breaking meniscus instability in the nonhomogeneous region of highly deformed fluid near the rigid endplate.

Spiegelberg, Stephen H.↗

NASA NTRS2008

Solid-State Lighting Module (SSLM)

The project's goal was to build a light-emitting-diode (LED)-based light fixture that is identical in fit, form, and function to the existing International Space Station (ISS) General Luminaire Assembly (GLA) light fixture and fly it on the ISS in early FY 2008 as a Station Detailed Test Objective (SDTO). Our design offers the following strengths: proven component hardware: Our design uses components flown in other KSC-developed hardware; heat path thermal pad: LED array heat is transferred from the circuit board by silicon pad, negating the need for a cooling fan; variable colorimetry: The output light color can be changed by inserting different LED combinations.

Source record↗

NASA NTRS2013

NASA-USRP Summer 2013 Internship Final Report

Three major projects were undertaken during the Summer 2013 USRP Internship: (A) assisting the cTAPS group with component and pressure vessel system analyses and documentation, (B) designing a hoisting fixture for a solid rocket motor, (C) finding an alternative to removing the DOT rated gaseous nitrogen tank from the roof for hydrostatic testing. Hypergolic Material Assessments (HMAs) and pressure calculations were performed on components of pressure systems. Additionally, component information was logged in the Standard Parts Database to provide a location where system designers can find information regarding components, including their specifications and compatibility with fluids. A hoisting fixture was designed to hoist a solid rocket motor and meets the specifications related to stress and size. However, there are issues with the fixtures bolt head allotment, the bolt spacing, and the complexity of the part. Finally, calculations were performed on an expiring DOT rated gaseous nitrogen tank in an attempt to re-rate it per ASME standards. This was unsuccessful so other options are being explored for the tank. While much progress was made on all three projects, there is still work to be performed on each project to achieve the desired results.

Gurganus, S. Christine↗

NASA NTRS1993

Simulating flight boundary conditions for orbiter payload modal survey

An approach to simulate the characteristics of the payload/orbiter interfaces for the payload modal survey was developed. The flexure designed for this approach is required to provide adequate stiffness separation in the free and constrained interface degrees of freedom to closely resemble the flight boundary condition. Payloads will behave linearly and demonstrate similar modal effective mass distribution and load path as the flight if the flexure fixture is used for the payload modal survey. The potential non-linearities caused by the trunnion slippage during the conventional fixed base modal survey may be eliminated. Consequently, the effort to correlate the test and analysis models can be significantly reduced. An example is given to illustrate the selection and the sensitivity of the flexure stiffness. The advantages of using flexure fixtures for the modal survey and for the analytical model verification are also demonstrated.

Chung, Y. T.↗

NASA NTRS1992

Thermal conductance of two interface materials and their applications in space systems

The temperature control of spacecraft and instrument systems and subsystems requires heat transfer interface materials that possess good thermal and structural characteristics, among other properties, to respond to the vacuum environment of space. These materials must be easy to apply to, and remove from, the surfaces where they are applied, and must be able to withstand power dissipation extremes, and be used for different clamping configurations and pressures. Silicone based greases, used in the past, tend to migrate and to contaminate nearby surfaces. Bare metal to metal contact offers low thermal conductance and difficulties in estimating the actual heat transfer. Several polymeric materials containing different thermal conductive compounds and structural reinforcements were prepared to overcome grease and metal problems. Two polymeric materials were evaluated: Cho-Therm 1671 elastomer; and the CV-2946, a conductive RTV silicone. Tests were done to learn more about these products. Results indicate that the tightly bolted, torqued fixtures did not buckle or distort, and provided optimum thermal conductance. Fixtures simulating actual spacecraft configuration suffered bowing and separating.

Scialdone, J. J.↗

NASA NTRS1992

X-ray scattering measurements from thin foil X-ray mirrors

Thin foil X-ray mirrors are to be used as the reflecting elements in the telescopes of the X-ray satellites Spectrum-X-Gamma (SRG) and ASTRO-D. High resolution X-ray scattering measurements from the Au coated and dip-lacquered Al foils are presented. These were obtained from SRG mirrors positioned in a test quadrant of the telescope structure and from ASTRO-D foils held in a simple fixture. The X-ray data is compared with laser data and other surface structure data such as STM, atomic force microscopy (AFM), TEM, and electron micrography. The data obtained at Cu K-alpha(1), (8.05 keV) from all the mirrors produced on Al foils shows a scatter which limits the obtainable half-power width to above 1.5 arcmin. Mirrors based on electroformed Ni foils, however, show local regions with a factor of 4 better performance, and they are being developed for future applications.

Christensen, F. E.↗

NASA NTRS1995

Orbital atomic oxygen effects on materials: An overview of MSFC experiments on the STS-46 EOIM-3

The third Evaluation of Oxygen Interaction with Materials experiment was flown on Space Shuttle Mission STS-46 (July 31 - August 8, 1992), representing a joint effort of several NASA centers, universities, and contractors. This array of active instrumentation and material exposure sub-assemblies was integrated as a Shuttle cargo bay pallet experiment for investigating the effects of orbital atomic oxygen on candidate space materials. Marshall Space Flight Center contributed several passive exposure trays of material specimens, uniform stress and static stress material exposure fixtures, the Atomic Oxygen Resistance Monitor (AORM), and specimens of thermal coatings for the EOIM-3 variable exposure mechanisms. As a result of 42 hours of spacecraft velocity vector-oriented exposure during the later phases of the STS-46 mission in LEO, EOIM-3 materials were exposed to an atomic oxygen fluence of 2.2 x 10(exp 20) atoms/sq cm. In this paper, an overview is presented of the technical approaches and results from analyses of the MSFC flight specimens, fixtures, and the AORM. More detailed results from earlier EOIM missions, the LDEF, and from laboratory testing are included in associated papers of this conference session.

Linton, Roger C.↗

NASA NTRS2012

Demagnetization Tests Performed on a Linear Alternator for a Stirling Power Convertor

The NASA Glenn Research Center (GRC) is conducting in-house research on rare-earth permanent magnets and linear alternators to assist in developing free-piston Stirling convertors for radioisotope space power systems and for developing advanced linear alternator technology. This research continues at GRC, but, with the exception of Advanced Stirling Radioisotope Generator references, the work presented in this paper was conducted in 2005. A special arc-magnet characterization fixture was designed and built to measure the M-H characteristics of the magnets used in Technology Demonstration Convertors developed under the 110-W Stirling Radioisotope Generator (SRG110) project. This fixture was used to measure these characteristics of the arc magnets and to predict alternator demagnetization temperatures in the SRG110 application. Demagnetization tests using the TDC alternator on the Alternator Test Rig were conducted for two different magnet grades: Sumitomo Neomax 44AH and 42AH. The purpose of these tests was to determine the demagnetization temperatures of the magnets for the alternator under nominal loads. Measurements made during the tests included the linear alternator terminal voltage, current, average power, magnet temperatures, and stator temperatures. The results of these tests were found to be in good agreement with predictions. Alternator demagnetization temperatures in the Advanced Stirling Convertor (ASC-developed under the Advanced Stirling Radioisotope Generator project) were predicted as well because the prediction method had been validated through the SRG110 alternator tests. These predictions led to a specification for maximum temperatures of the ASC pressure vessel.

Geng, Steven M.↗

NASA NTRS2001

Effects of Manufacturing and Deployment on Thin Films for the NGTS Sunshade

The Next Generation Space Telescope (NGST) is being developed as an advanced astronomical observatory. The NGST proposes to utilize several thin film membrane layers to create a shield for protection of the telescope from solar thermal energy and stray light, The shield will take the form of a polygon, approximately 15 x 30 m, with individual membrane layers positioned so that they do not come in contact with one another. The membrane shield will be deployed and supported by a series of booms, which will be packed into a small volume for launch. Finally, the shield will be deployed on orbit. Several film materials are being considered for the membrane shield, including CPI, Kapton E, Kapton RN, and Upilex. Each of these polyimide materials was tested to determine their durability over the 10-year mission. New facets of materials testing have been introduced in this study to develop performance data with greater realism to actual use, particularly that of degradation from packing, launch and deployment processing. Materials were exposed to handling that simulated the life of the materials from manufacture through deployment with standardized fixtures and then exposed to a simulated, L2, 10-year radiation environment. Mechanical and thermal radiative properties were measured before and after each phase of testing. This paper summarizes the program and test results.

Wooldridge, Eve M.↗

NASA NTRS1988

Measurement of the properties of lossy materials inside a finite conducting cylinder

Broadband, swept frequency measurement techniques were investigated for the evaluation of the electrical performance of thin, high temperature material coatings. Reflections and transmission measurements using an HP8510B Network Analyzer were developed for an existing high temperature test rig at NASA Lewis Research Center. Reflection measurements will be the initial approach used due to fixture simplicity even though surface wave transmission measurements would be more sensitive. The minimum goal is to monitor the electrical change of the material's performance as a function of temperature. If possible, the materials constitutive parameters, epsilon and muon will be found.

Dominek, A.↗

NASA NTRS1991

Post flight system analysis of FRECOPA (AO 138)

The unexpected duration for the flight of the Long Duration Exposure Facility (LDEF) conducted CNES to create a special investigation group in order to analyze all the materials and systems which compose the French Cooperative Payload (FRECOPA) except the experiments especially prepared for the flight. The FRECOPA tray was on the trailing face (V-) of the LDEF and protected from the atomic oxygen flux during all the flight. However, the solar irradiation was very important with solar flux quite perpendicular to the experiment once an orbit. There was also a good vacuum environment. The objectives are to test the effects of the combined space environment on materials and components like: structure, thermal control coatings and blankets, electronic unit, motors, and mechanical fixtures. When the LDEF returned to Kennedy Space Center, a visual inspection showed the very good behavior of the materials used and it was noted that the three mechanisms to open and close the experiment canisters worked completely. Many impacts of micrometeoroids or space debris on the structure and on the thermal protections were observed. After FRECOPA was brought back to Toulouse, many tests were performed and include: working order tests, mechanical tests (tension), optical and electronic microscopy (SEM), surface analysis (ESCA, SIMS, RBS, AUGER, etc.), thermal analysis, pressure measurements, and gas analysis (outgassing tests). The results of these experiments are discussed.

Durin, Christian↗

NASA NTRS2026

Mechanical Design and Operation of a Novel Lunar Environment Structural Test Rig (LESTR)

The Lunar Environment Structural Test Rig (LESTR) was developed to address a critical gap in mechanical property data for metal alloy wire materials under lunar-relevant conditions down to 40 K. Conventional aerospace material databases provide thermophysical properties for bulk metals over a wide temperature range, but validated mechanical and physical property data below 77 K, particularly for small-diameter wires, remain limited and are generally the exception rather than the rule. These conditions are essential for Artemis mission hardware such as shape memory alloy (SMA) rover tires. LESTR’s design requirements were to combine a high-stiffness electrodynamic load frame with closed- cycle cryogenic cooling, high-vacuum capability (10–6 torr), and noncontact optical strain measurement to enable tensile, four-point bend, and fatigue testing of wires or other materials and geometries at temperatures from 40 to 125 K. These considerable requirements were merged with the need to lower the barrier of testing for the end user as measured in terms of cost-per-test cycle, safety improvement, and reduction in upkeep costs associated with state-of-the-art solutions associated with cryomechanical material characterization. The system incorporates modular gripping and alignment fixtures; precision thermal management using cryocoolers and embedded heaters; and integrated instrumentation for displacement, load, temperature, and vacuum control. Calibration procedures establish correlations between tooling and specimen temperature, ensuring accurate thermal conditions across the design envelope unbound by cryofluid conditions in heritage immersion-based test systems. Initial validation tests using Inconel (Special Metals Corp.) wire demonstrated accurate ultimate strength and post-yield behavior. The load frame operation was also verified under representative service conditions, including thermal cycling and prolonged fatigue loading. By generating mechanical property data at ultralow temperatures, LESTR fills a critical gap in existing materials databases and provides a scalable platform for iterative alloy development and durability assessment for planetary hardware. This capability supports NASA’s long-term objectives for surface exploration by enabling design confidence for components operating in extreme cryogenic environments.

LESTR↗