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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Advanced composites structural concepts and materials technologies for primary aircraft structures: Design/manufacturing concept assessment

Composite Wing and Fuselage Structural Design/Manufacturing Concepts have been developed and evaluated. Trade studies were performed to determine how well the concepts satisfy the program goals of 25 percent cost savings, 40 percent weight savings with aircraft resizing, and 50 percent part count reduction as compared to the aluminum Lockheed L-1011 baseline. The concepts developed using emerging technologies such as large scale resin transfer molding (RTM), automatic tow placed (ATP), braiding, out-of-autoclave and automated manufacturing processes for both thermoset and thermoplastic materials were evaluated for possible application in the design concepts. Trade studies were used to determine which concepts carry into the detailed design development subtask.

Chu, Robert L.↗
NASA NTRS1994

Linear Proof Mass Actuator

This paper describes the mechanical design, analysis, fabrication, testing, and lessons learned by developing a uniquely designed spaceflight-like actuator. The linear proof mass actuator (LPMA) was designed to attach to both a large space structure and a ground test model without modification. Previous designs lacked the power to perform in a terrestrial environment while other designs failed to produce the desired accelerations or frequency range for spaceflight applications. Thus, the design for a unique actuator was conceived and developed at NASA Langley Research Center. The basic design consists of four large mechanical parts (mass, upper housing, lower housing, and center support) and numerous smaller supporting components including an accelerometer, encoder, and four drive motors. Fabrication personnel were included early in the design phase of the LPMA as part of an integrated manufacturing process to alleviate potential difficulties in machining an already challenging design. Operating testing of the LPMA demonstrated that the actuator is capable of various types of load functions.

Holloway, Sidney E., III↗
NASA NTRS1994

LCX: Proposal for a low-cost commercial transport

The LCX has been developed in response to a request for proposal for an aircraft with 153 passenger capacity and a range of 3000 nautical miles. The goals of the LCX are to provide an aircraft which will achieve the stated mission requirements at the lowest cost possible, both for the manufacturer and the operator. Low cost in this request is defined as short and long term profitability. To achieve this objective, modern technologies attributing to low-cost operation without greatly increasing the cost of manufacturing were employed. These technologies include hybrid laminar flow control and the use of developing new manufacturing processes and philosophies. The LCX will provide a competitive alternative to the use of the Airbus A319/320/321 and the Boeing 737 series of aircraft. The LCX has a maximum weight of 150,000 lb. carried by a wing of 1140 ft(exp 2) and an aspect ratio of 10. The selling price of the LCX is 31 million in 1994 US dollars.

Hartman, Troy↗
NASA NTRS1995

Thermal behavior spiral bevel gears

An experimental and analytical study of the thermal behavior of spiral bevel gears is presented. Experimental data were taken using thermocoupled test hardware and an infrared microscope. Many operational parameters were varied to investigate their effects on the thermal behavior. The data taken were also used to validate the boundary conditions applied to the analytical model. A finite element-based solution sequence was developed. The three-dimensional model was developed based on the manufacturing process for these gears. Contact between the meshing gears was found using tooth contact analysis to describe the location, curvatures, orientations, and surface velocities. This information was then used in a three-dimensional Hertzian contact analysis to predict contact ellipse size and maximum pressure. From these results, an estimate of the heat flux magnitude and the location on the finite element model was made. The finite element model used time-averaged boundary conditions to permit the solution to attain steady state in a computationally efficient manner.Then time- and position-varying boundary conditions were applied to the model to analyze the cyclic heating and cooling due to the gears meshing and transferring heat to the surroundings, respectively. The model was run in this mode until the temperature behavior stabilized. The transient flash temperature on the surface was therefore described. The analysis can be used to predict the overall expected thermal behavior of spiral bevel gears. The experimental and analytical results were compared for this study and also with a limited number of other studies. The experimental and analytical results attained in the current study were basically within 10% of each other for the cases compared. The experimental comparison was for bulk thermocouple locations and data taken with an infrared microscope. The results of a limited number of other studies were compared with those obtained herein and predicted the same basic behavior.

Handschuh, Robert F.↗
NASA NTRS1994

A roadmap for regulatory survival in the 1990s

There have been many changes over the last several years in the ways that we're required to label, handle, and dispose of the products of our manufacturing processes...and we all know there will be more, not fewer, environmental regulations to deal with in the years to come. It is important to be aware of how a chemical is listed by federal or state regulations or recommending bodies. For example, if a chemical has been listed by OSHA, IARC (International Agency for Research on Cancer), or NTP (the National Toxicology Program) as a carcinogen, this listing will trigger hazard communication requirements. It may cause restrictions on the levels of a chemical that you may release into the air or water as well as how you manage your plant wastes. Understanding how a chemical is listed is the first critical step in overall compliance. Once a chemical makes one of these lists as a hazardous material or a carcinogen, your emissions, labelling, or MSD sheets may need to be changed in order to comply with federal or state regulations. Being fully aware of how the chemicals you use are listed by all pertinent bodies is the essential compass that you must have to follow the regulatory road map.

Sayad, R. S.↗
NASA NTRS1994

A neural network controller for automated composite manufacturing

At McDonnell Douglas Aerospace (MDA), an artificial neural network based control system has been developed and implemented to control laser heating for the fiber placement composite manufacturing process. This neurocontroller learns an approximate inverse model of the process on-line to provide performance that improves with experience and exceeds that of conventional feedback control techniques. When untrained, the control system behaves as a proportional plus integral (PI) controller. However after learning from experience, the neural network feedforward control module provides control signals that greatly improve temperature tracking performance. Faster convergence to new temperature set points and reduced temperature deviation due to changing feed rate have been demonstrated on the machine. A Cerebellar Model Articulation Controller (CMAC) network is used for inverse modeling because of its rapid learning performance. This control system is implemented in an IBM compatible 386 PC with an A/D board interface to the machine.

Lichtenwalner, Peter F.↗
NASA NTRS1995

Design and evaluation of a foam-filled hat-stiffened panel concept for aircraft primary structural applications

A structurally efficient hat-stiffened panel concept that utilizes a structural foam as stiffener core has been designed for aircraft primary structural applications. This stiffener concept utilizes a manufacturing process that can be adapted readily to grid-stiffened structural configurations which possess inherent damage tolerance characteristics due to their multiplicity of load paths. The foam-filled hat-stiffener concept in a prismatically stiffened panel configuration is more efficient than most other stiffened panel configurations in a load range that is typical for both fuselage and wing structures. The prismatically stiffened panel concept investigated here has been designed using AS4/3502 preimpregnated tape and Rohacell foam core and evaluated for its buckling and postbuckling behavior with and without low-speed impact damage. The results from single-stiffener and multi-stiffener specimens suggest that this structural concept responds to loading as anticipated and has good damage tolerance characteristics.

Ambur, Damodar R.↗
NASA NTRS1995

Linear Proof Mass Actuator

This paper describes the mechanical design, analysis, fabrication, testing, and lessons learned by developing a uniquely designed spaceflight-like actuator. The Linear Proof Mass Actuator (LPMA) was designed to attach to both a large space structure and a ground test model without modification. Previous designs lacked the power to perform in a terrestrial environment while other designs failed to produce the desired accelerations or frequency range for spaceflight applications. Thus, the design for a unique actuator was conceived and developed at NASA Langley Research Center. The basic design consists of four large mechanical parts (Mass, Upper Housing, Lower Housing, and Center Support) and numerous smaller supporting components including an accelerometer, encoder, and four drive motors. Fabrication personnel were included early in the design phase of the LPMA as part of an integrated manufacturing process to alleviate potential difficulties in machining an already challenging design. Operational testing of the LPMA demonstrated that the actuator is capable of various types of load functions.

Holloway, S. E., III↗
NASA NTRS1992

Test and analysis results for composite transport fuselage and wing structures

Automated tow placement (ATP) and stitching of dry textile composite preforms followed by resin transfer molding (RTM) are being investigated by researchers at NASA LaRC and Douglas Aircraft Company as cost-effective manufacturing processes for obtaining damage tolerant fuselage and wing structures for transport aircraft. The Douglas work is being performed under a NASA contract entitled 'Innovative Composites Aircraft Primary Structures (ICAPS)'. Data are presented in this paper to assess the damage tolerance of ATP and RTM fuselage elements with stitched-on stiffeners from compression tests of impacted three-J-stiffened panels and from stiffener pull-off tests. Data are also presented to assess the damage tolerance of RTM wing elements which had stitched skin and stiffeners from impacted single stiffener and three blade-stiffened compression tests and stiffener pull-off tests.

Deaton, Jerry W.↗
NASA NTRS1993

Tension fracture of laminates for transport fuselage. Part 2: Large notches

Tests were conducted on over 200 center-crack specimens to evaluate: (a) the tension-fracture performance of candidate materials and laminates for commercial fuselage applications; and (b) the accuracy of several failure criteria in predicting response. Crack lengths of up to 12 inches were considered. Other variables included fiber/matrix combination, layup, lamination manufacturing process, and intraply hybridization. Laminates fabricated using the automated tow-placement process provided significantly higher tension-fracture strengths than nominally identical tape laminates. This confirmed earlier findings for other layups, and possibly relates to a reduced stress concentration resulting from a larger scale of repeatable material inhomogeneity in the tow-placed laminates. Changes in material and layup result in a trade-off between small-notch and large-notch strengths. Toughened resins and 0 deg-dominate layups result in higher small-notch strengths but lower large-notch strengths than brittle resins, 90 deg and 45 deg dominated layups, and intraply S2-glass hybrid material forms. Test results indicate that strength-prediction methods that allow for a reduced order singularity of the crack-tip stress field are more successful at predicting failure over a range of notch sizes than those relying on the classical square-root singularity. The order of singularity required to accurately predict large-notch strength from small-notch data was affected by both material and layup. Measured crack-tip strain distributions were generally higher than those predicted using classical methods. Traditional methods of correcting for finite specimen width were found to be lacking, confirming earlier findings with other specimen geometries. Fracture tests of two stiffened panels, identical except for differing materials, with severed central stiffeners resulted in nearly identical damage progression and failure sequences. Strain-softening laws implemented within finite element models appear attractive to account for load redistribution in configured structure due to damage-induced crack tip softening

Walker, Tom H.↗
NASA NTRS1993

Engineering design of sub-micron topographies for simultaneously adherent and reflective metal-polymer interfaces

The approach of the project is to base the design of multi-function, reflective topographies on the theory that topographically dependent phenomena react with surfaces and interfaces at certain scales. The first phase of the project emphasizes the development of methods for understanding the sizes of topographic features which influence reflectivity. Subsequent phases, if necessary, will address the scales of interaction for adhesion and manufacturing processes. A simulation of the interaction of electromagnetic radiation, or light, with a reflective surface is performed using specialized software. Reflectivity of the surface as a function of scale is evaluated and the results from the simulation are compared with reflectivity measurements made on multi-function, reflective surfaces.

Brown, Christopher A.↗
NASA NTRS1995

A Probabilistic Design Method Applied to Smart Composite Structures

A probabilistic design method is described and demonstrated using a smart composite wing. Probabilistic structural design incorporates naturally occurring uncertainties including those in constituent (fiber/matrix) material properties, fabrication variables, structure geometry and control-related parameters. Probabilistic sensitivity factors are computed to identify those parameters that have a great influence on a specific structural reliability. Two performance criteria are used to demonstrate this design methodology. The first criterion requires that the actuated angle at the wing tip be bounded by upper and lower limits at a specified reliability. The second criterion requires that the probability of ply damage due to random impact load be smaller than an assigned value. When the relationship between reliability improvement and the sensitivity factors is assessed, the results show that a reduction in the scatter of the random variable with the largest sensitivity factor (absolute value) provides the lowest failure probability. An increase in the mean of the random variable with a negative sensitivity factor will reduce the failure probability. Therefore, the design can be improved by controlling or selecting distribution parameters associated with random variables. This can be implemented during the manufacturing process to obtain maximum benefit with minimum alterations.

Shiao, Michael C.↗
NASA NTRS1993

Minimizing distortion in truss structures -- a Hopfield network solution

Distortions in truss structures can result from random errors in elemental lengths that are typical of a manufacturing process. These distortions may be minimized by an optimal selection of elements from those available for placement between the prescribed nodes -- a combinatorial optimization problem requiring significant investment of computational resource for all but the smallest problems. The present paper describes a formulation in which near-optimal element assignments are obtained as minimum energy, stable states, of an analogous Hopfield neural network. This requires mapping of the optimization problem into an energy function of the appropriate Lyapunov form. The computational architecture is ideally suited to a parallel processor implementation and offers significant savings in computational effort. A numerical implementation of the approach is discussed with reference to planar truss problems.

Fu, B.↗
NASA NTRS1995

Gas Chromatic Mass Spectrometer

Gas chromatograph/mass spectrometer (GC/MS) used to measure and identify combustion species present in trace concentration. Advanced extractive diagnostic method measures to parts per billion (PPB), as well as differentiates between different types of hydrocarbons. Applicable for petrochemical, waste incinerator, diesel transporation, and electric utility companies in accurately monitoring types of hydrocarbon emissions generated by fuel combustion, in order to meet stricter environmental requirements. Other potential applications include manufacturing processes requiring precise detection of toxic gaseous chemicals, biomedical applications requiring precise identification of accumulative gaseous species, and gas utility operations requiring high-sensitivity leak detection.

Wey, Chowen↗
NASA NTRS1995

Rhenium material properties

Tensile data were obtained from four different types of rhenium at ambient and elevated temperatures. The four types of rhenium included chemical vapor deposition (CVD) and three powder metallurgy (PM) types, i.e., rolled sheet and pressed and sintered bars, with and without hot isostatic pressure (HIP) treatment. Results revealed a wide range of values with ultimate strengths at ambient temperatures varying from 663 MPa for CVD rhenium to 943 MPa for rolled sheet. A similar spread was also obtained for material tested at 1088 K and 1644 K. The wide variance observed with the different materials indicated that the rhenium manufacturing process, material composition and prior handling strongly dictated its properties. In addition to tensile properties, CVD, pressed and sintered material and HIP rhenium successfully completed 100 cycles of low cycle fatigue. Creep data were also obtained showing that CVD and pressed and sintered rhenium could sustain five hours of testing under a tension of 27.5 MPa at 1922 K.

Biaglow, James A.↗
NASA NTRS1994

Reduced hazard chemicals for solid rocket motor production

During the last three years. the NASA/Thiokol/industry team has developed and started implementation of an environmentally sound manufacturing plan for the continued production of solid rocket motors. NASA Marshall Space Flight Center (MSFC) and Thiokol Corporation have worked with other industry representatives and the U.S. Environmental Protection Agency (EPA) to prepare a comprehensive plan to eliminate all ozone depleting chemicals from manufacturing processes and reduce the use of other hazardous materials used to produce the space shuttle reusable solid rocket motors. The team used a classical approach for problem-solving combined with a creative synthesis of new approaches to attack this challenge.

Larry A. Caddy↗
NASA NTRS1994

An Analytical Tool for Fracture Control

The structural integrity of critical NASA space flight hardware is ensured through a damage tolerance program which is dictated in the fracture control requirements. The goal of a fracture control program is to ensure proper material selection and control, control of working stress levels, use of fracture resistant design concepts, manufacturing process control, and the use of qualified inspection procedures. The damage tolerance philosophy assumes that all components contain initial defects and the damage accumulation process is thus entirely crack propagation. The service capability of fracture critical components is determined by analysis and/or test. A large percentage of NASA fracture critical hardware is certified by analysis only and it is therefore imperative that the analysis code utilized contain the latest state of the art technology. Not all space contractors and vendors are able to develop and maintain an analysis code which meets this requirement. A response to this need has been fulfilled by the development of the NASA/FLAGRO (NASGRO) fracture mechanics code here at the Johnson Space Center. The NASGRO code is based primarily in Linear Elastic Fracture Mechanics (LEFM) and is continually updated to meet to needs of the user community. Development assistance comes from other NASA centers as well as the European Space Agency (ESA). The code currently has a vast materials data file (over 350 different entries) which defines the material strength, fracture toughness, crack growth rate, and crack growth threshold. The code also allows for user defined inputs of data from other sources. The code also provides a large library of stress intensity factor solutions for numerous geometries and loading conditions.

Patin, Raymond M.↗
NASA NTRS1993

Role of strategic planning in engineering management

Today, more than ever before, engineers are faced with uncertain and sometimes chaotic environments in which to function. The traditional roles of an engineer to design, develop, and streamline a manufacturing process for a product are still valued and relevant. However, the need for an engineer to participate in the process of identifying the product to be developed, the schedule and resources required, and the goal of satisfying the customer, has become paramount to achieving the success of the enterprise. When we include these endeavors in the functions of an engineer, management of 'engineering' takes on a new dimension. In this paper, the ramifications of the changing and increased functions of an engineer and consequent impacts on engineering management are explored. The basic principles which should be invoked in order to embrace the new environment for engineering management are outlined. The ultimate finding of this study is that the enterprise strategic plan should be developed in such a way as to allow engineering management to encompass the full spectrum of the responsibilities of engineers. A consequence of this is that the fundamental elements of the strategic process can best be implemented through a project team or group approach. The paper thus concentrates on three areas: evolving environment, strategic plan, and ways to achieve enterprise success.

Krishen, Kumar↗