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At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Method for forming a glove attachment

An attachment principally for the palm of an astronaut glove to enhance the gripping area of the palm without detracting from the flexibility and utility of the glove is presented. The attachment is a composite construction formed from a layer of silicone rubber having an outer surface with a friction configuration and another layer of silicone rubber in which a Nomex Aramid mesh fabric is embedded prior to curing. The method of construction involves the use of a mold with a friction configuration surface. A first layer of silicone rubber or sealant is disposed in the mold and allowed to set for an hour. A second layer of silicone rubber or sealant is layered over the first layer and leveled. A Nomex Aramid mesh fabric is embedded into the second layer and the composite is permitted to cure. When cured, a configured area of the composite construction is glued or stitched to the palm area of the glove.

Dawn, Frederic S.↗
NASA NTRS1993

Textile composite fuselage structures development

Phase 2 of the NASA ACT Contract (NAS1-18888), Advanced Composite Structural Concepts and Materials Technology for Transport Aircraft Structures, focuses on textile technology, with resin transfer molding or powder coated tows. The use of textiles has the potential for improving damage tolerance, reducing cost and saving weight. This program investigates resin transfer molding (RTM), as a maturing technology for high fiber volume primary structures and powder coated tows as an emerging technology with a high potential for significant cost savings and superior structural properties. Powder coated tow technology has promise for significantly improving the processibility of high temperature resins such as polyimides.

Jackson, Anthony C.↗
NASA NTRS1993

Advanced resin systems and 3D textile preforms for low cost composite structures

Advanced resin systems and 3D textile preforms are being evaluated at Lockheed Aeronautical Systems Company (LASC) under NASA's Advanced Composites Technology (ACT) Program. This work is aimed towards the development of low-cost, damage-tolerant composite fuselage structures. Resin systems for resin transfer molding and powder epoxy towpreg materials are being evaluated for processability, performance and cost. Three developmental epoxy resin systems for resin transfer molding (RTM) and three resin systems for powder towpregging are being investigated. Various 3D textile preform architectures using advanced weaving and braiding processes are also being evaluated. Trials are being conducted with powdered towpreg, in 2D weaving and 3D braiding processes for their textile processability and their potential for fabrication in 'net shape' fuselage structures. The progress in advanced resin screening and textile preform development is reviewed here.

Shukla, J. G.↗
NASA NTRS1993

Mechanical characterization of 2D, 2D stitched, and 3D braided/RTM materials

Braided composite materials have potential for application in aircraft structures. Fuselage frames, floor beams, wing spars, and stiffeners are examples where braided composites could find application if cost effective processing and damage tolerance requirements are met. Another important consideration for braided composites relates to their mechanical properties and how they compare to the properties of composites produced by other textile composite processes being proposed for these applications. Unfortunately, mechanical property data for braided composites do not appear extensively in the literature. Data are presented in this paper on the mechanical characterization of 2D triaxial braid, 2D triaxial braid plus stitching, and 3D (through-the-thickness) braid composite materials. The braided preforms all had the same graphite tow size and the same nominal braid architectures, (+/- 30 deg/0 deg), and were resin transfer molded (RTM) using the same mold for each of two different resin systems. Static data are presented for notched and unnotched tension, notched and unnotched compression, and compression after impact strengths at room temperature. In addition, some static results, after environmental conditioning, are included. Baseline tension and compression fatigue results are also presented, but only for the 3D braided composite material with one of the resin systems.

Deaton, Jerry W.↗
NASA NTRS1993

Test results from large wing and fuselage panels

This paper presents the first results in an assessment of the strength, stiffness, and damage tolerance of stiffened wing and fuselage subcomponents. Under this NASA funded program, 10 large wing and fuselage panels, variously fabricated by automated tow placement and dry-stitched preform/resin transfer molding, are to be tested. The first test of an automated tow placement six-longeron fuselage panel under shear load was completed successfully. Using NASTRAN finite-element analysis the stiffness of the panel in the linear range prior to buckling was predicted within 3.5 percent. A nonlinear analysis predicted the buckling load within 10 percent and final failure load within 6 percent. The first test of a resin transfer molding six-stringer wing panel under compression was also completed. The panel failed unexpectedly in buckling because of inadequate supporting structure. The average strain was 0.43 percent with a line load of 20.3 kips per inch of width. This strain still exceeds the design allowable strains. Also, the stringers did not debond before failure, which is in contrast to the general behavior of unstitched panels.

Madan, Ram C.↗
NASA NTRS1995

Composite-Material Propfan Blades For A Wind-Tunnel Model

Report discusses design and sequence of operations performed in fabricating set of graphite-fiber/epoxy-matrix composite propfan blades. Describes major phases of fabrication of blades, including machining of metal master blades, fabrication of molds from master blades, cutting of graphite-fiber/epoxy prepreg sheets to form plies, stacking of plies to obtain preforms, assembly of pressure-and suction-side preforms into unitary blade preforms, curing preforms in molds, final light finishing, and inspection.

Fite, E. Brian↗
NASA NTRS1995

Processing and properties of fiber reinforced polymeric matrix composites: I. IM7/LARC(TM)-PETI-7 polyimide composites

A phenylethynyl terminated imide oligomer formed from the reaction of benzophenone tetracarboxylic acid dianhydride, an 75:25 molar ratio of 4,4'-oxydianiline and meta-phenylenediamine and 4-phenylethynylphthalic anhydride as the endcapper at a theoretical number average molecular weight (Mn) of approximately 3,700 g/mol was evaluated as a composite resin matrix. A glass transition temperature (Tg) of 315 deg C was reached after 250 deg C/1 hr annealing of the matrix resin. Unidirectional prepreg was made by coating an N-methylpyrrolidinone solution of the amide acid oligomer onto unsized IM7 graphite fibers. The thermal and rheological properties and the solvent/volatile depletion rates of the amide acid/NMP system were determined. This information was used to successfully design a molding cycle for composite fabrication. Composites molded under 800 Psi at 371 C consistently yielded good consolidation as measured by C-scan and optical photomicrography. The composite's short beam shear strength (SBS), longitudinal and transverse flexural strengths and moduli were measured at various temperatures. These composites exhibited excellent room temperature (RT) longitudinal flexural strength and modulus and RT SBS strength retention at 177 C.

Hou, Tan-Hung↗
NASA NTRS1996

Cost Effective Prototyping

This laboratory exercise seeks to develop a cost effective prototype development. The exercise has the potential of linking part design, CAD, mold development, quality control, metrology, mold flow, materials testing, fixture design, automation, limited parts production and other issues as related to plastics manufacturing.

Wickman, Jerry L.↗
NASA NTRS1996

Experiments Related to the Fabrication of Carbon Fiber/AMB-21 Polyimide Composite Tubes Using the RTM Process

AMB-21 is a new polymer developed by Mr. Ray Vannucci, NASA, LeRC as a noncarcinogenic polyimide matrix which may be suitable for fabricating composite parts by the Resin Transfer Modeling (RTM) process. The polyimide for this project was prepared at the Center of Composite Materials Research at N.C. A&T State University because it is not currently an item of commerce. The RTM process is especially suitable for producing geometrically complex composite parts at a low cost. Because of the high melting point and very high viscosity at the time of processing, polyimides have not been extensively used in the RTM process. The process for preparing AMB-21 as well as the process for fabricating composite plates will be described. The basic fabrication process consists of injecting a solvent solution of AMP-21 into a carbon fiber preform, evaporating the solvent, imidizing the polyimide, and vacuum/compression modeling the impregnated preform. All the above molding steps are preformed in a specially designed RTM mold which will be described. The results of this process have been inconsistent. Where as some experiments have resulted in a reasonably sound panels, others have not. Further refinements of the process are required to establish a reliable process.

Exum, Daniel↗
NASA NTRS1996

Hybrid Flexible and Rigid Ceramic Insulation

A method is provided for closing out the edges of a flexible ceramic insulation member including inner and outer mold line covering layers. A rigid, segmented, ceramic frame is placed round the edges of the insulation member and exposed edges of the inner and outer mold line covering layers are affixed to the ceramic frame. In one embodiment wherein the covering layers comprise fabrics, the outer fabric is bonded to the top surface and to grooved portion of the side surface of the frame. In another embodiment wherein the outer cover layer comprises a metallic foil, clips on the edges of the frame are used to engage foil extensions. The ceramic frame is coated with a high emittance densifier coating.

Rasky, Daniel J.↗
NASA NTRS1995

Recent Developments in Microsystems Fabricated by the Liga-Technique

As an example of microsystems fabricated by the LIGA-technique (x-ray lithography, electroplating and molding), three systems are described and characterized: a triaxial acceleration sensor system, a micro-optical switch, and a microsystem for the analysis of pollutants. The fabrication technologies are reviewed with respect to the key components of the three systems: an acceleration sensor, and electrostatic actuator, and a spectrometer made by the LIGA-technique. Aa micro-pump and micro-valve made by using micromachined tools for molding and optical fiber imaging are made possible by combining LIGA and anisotropic etching of silicon in a batch process. These examples show that the combination of technologies and components is the key to complex microsystems. The design of such microsystems will be facilitated is standardized interfaces are available.

Schulz, J.↗
NASA NTRS1995

High Modulus and High T(sub g) Thermally Stable Polymers from p-Ethynyl-Terminated Rigid-Rod Monomers

Novel p-ethynyl-substituted rigid rod monomers were studied by pressure Differential Scanning Calorimetry (DSC), ThermoGravimetric Analysis (TGA), IsothermoGravimetric Analysis (IGA), and TGA-IR. These monomers, 4,4'-bis(((4-ethynylphenyl)carbonyl)oxy)biphenyl, designated 1, 1,5-bis-(((4-ethynylphenyl)carbonyl)oxy)naphthalene, designated 2, and bis(4-ethynylphenyl)pyromellitimide, designated 3, were polymerized in the solid state. Thermal polymerization in N2 or air produced highly cross-linked resins with polymerization exotherms centered between 212 and 276 C. The (delta)H's of polymerization of these resins in air were found to be double those in N2. When monomers 1 and 2 were heated in air from 23 to 750 C at 10 C/min, the main decomposition product was carbon dioxide, evolving at a maximum rate between 500 and 600 C; water was also detected as a decomposition product. Void-free neat resin moldings, designated lp to 3p, were made by compression molding the monomers and then heating them. The resulting polymers were highly cross-linked, and their glass transition temperatures (T(sub g)) were much higher than their polymerization temperatures. Using ThermoMechanical Analysis (TMA), we found that polymers lp to 3p had T(sub g)'s of 422, 329, and 380 C, respectively. The thermal and thermooxidative stabilities improved when lp to 3p were postcured in N2 (the postcured polymers were designated 1pp to 3pp). The Linear Thermal Expansions (LTE) for lp and 3p were 1% between 23 and 420 C. Using rheological analysis, we could not clearly detect the T(sub g)'s of lp to 3p because their moduli dropped only slightly between 23 and 490 C and the changes in tan beta were very low. Because of high cross-link density, their moduli changed little as the resins went from a glassy to a rubbery state. Their shear storage moduli in air ranged from 0.82 (3p, 3pp) to 1.6 GPa (lpp) at 23 C, from 0.16 (2p) to 0.7GPa(lpp) at 380 C, and from 0.18(lpp)to 0.6GPa(2p) at 490 C. Finally, these novel-p-ethynyl polymers exhibited an excellent combination of high T(sub g), low LTE, and high thermooxidative stability. Most notably, 3pp lost only 3% of its initial weight when it was aged for 500 h at 288 C in air.

Melissaris, Anastasios P.↗
NASA NTRS1998

Composite Bus Structure for the SMEX/WIRE Satellite

In an effort to reduce the weight and optimize the structural design of the Small Explorer (SMEX) Wide-Field Infrared Explorer (WIRE) spacecraft, it has become desirable to change the material and construction from mechanically fastened aluminum structure to a fully bonded fiber-reinforced composite (FRC) structure. GSFC has developed the WIRE spacecraft structural bus design concept, including the instrument and launch vehicle requirements. The WIRE Satellite is the fifth of a series of SMEX satellites to be launched once per year. GSFC has chosen Composite Optics Inc. (COI) as the prime contractor for the development and procurement of the WIRE composite structure. The detailed design of the fully bonded FRC structure is based on COI's Short Notice Accelerated Production SATellite ("SNAPSAT") approach. SNAPSAT is a state of the art design and manufacturing technology for advanced composite materials which utilizes flat-stock detail parts bonded together to produce a final structural assembly. The structural design approach adopted for the WIRE structure provides a very viable alternative to both traditional aluminum construction as well as high tech. molded type composite structures. This approach to composite structure design is much less costly than molded or honeycomb sandwich type composite construction, but may cost slightly more than conventional aluminum construction on the subsystem level. However on the overall program level the weight saving achieved is very cost effective, since the primary objective is to allocate more mass for science payloads.

Rosanova, Giulio G.↗
NASA NTRS1998

Development of Textile Reinforced Composites for Aircraft Structures

NASA has been a leader in development of composite materials for aircraft applications during the past 25 years. In the early 1980's NASA and others conducted research to improve damage tolerance of composite structures through the use of toughened resins but these resins were not cost-effective. The aircraft industry wanted affordable, robust structures that could withstand the rigors of flight service with minimal damage. The cost and damage tolerance barriers of conventional laminated composites led NASA to focus on new concepts in composites which would incorporate the automated manufacturing methods of the textiles industry and which would incorporate through-the-thickness reinforcements. The NASA Advanced Composites Technology (ACT) Program provided the resources to extensively investigate the application of textile processes to next generation aircraft wing and fuselage structures. This paper discusses advanced textile material forms that have been developed, innovative machine concepts and key technology advancements required for future application of textile reinforced composites in commercial transport aircraft. Multiaxial warp knitting, triaxial braiding and through-the-thickness stitching are the three textile processes that have surfaced as the most promising for further development. Textile reinforced composite structural elements that have been developed in the NASA ACT Program are discussed. Included are braided fuselage frames and window-belt reinforcements, woven/stitched lower fuselage side panels, stitched multiaxial warp knit wing skins, and braided wing stiffeners. In addition, low-cost processing concepts such as resin transfer molding (RTM), resin film infusion (RFI), and vacuum-assisted resin transfer molding (VARTM) are discussed. Process modeling concepts to predict resin flow and cure in textile preforms are also discussed.

Dexter, H. Benson↗
NASA NTRS2000

Low Cost Al-Si Casting Alloy As In-Situ Composite for High Temperature Applications

A new aluminum-silicon (Al-Si) alloy has been successfully developed at NASA- Marshall Space Flight Center (MSFC) that has significant improvement in tensile and fatigue strength at elevated temperatures (500 F-700 F). The alloy offers a number of benefits such as light weight, high hardness, low thermal expansion and high surface wear resistance. In hypereutectic form, this alloy is considered as an in-situ Al-Si composite with tensile strength of about 90% higher than the auto industry 390 alloy at 600 F. This composite is very economically produced by using either conventional permanent steel molds or die casting. The projected material cost is less than $0.90 per pound, and automotive components such as pistons can be cast for high production rate using conventional casting techniques with a low and fully accounted cost. Key Words: Metal matrix composites, In-situ composite, aluminum-silicon alloy, hypereutectic alloy, permanent mold casting, die casting.

Lee, Jonathan A.↗
NASA NTRS1998

Phenylethynyl Containing Polyarylene Ethers/Polyimides Resin Infiltration of Composites

The following tasks were performed at NCA&TSU during the second year in performance of the grant. LaRC-LV-1 13 resin was synthesized at NCA&TSU. In order to perform the synthesis, glassware and needed apparatus were purchased with grant funds along with the appropriate monomers. It was found that the LaRC-LV-1 13 resin was easily synthesized by the NMP solvent/toluene imminization/distilled water precipitation process. However, in use this resin exhibited a bubbling/foaming behavior during cure that was detrimental leading to the production of composite panels having a high void content. Composite panels were fabricated using compression molding and resin transfer molding (RTM) techniques. Initial fiber volume determinations were computed at NCA&TSU along with NASA-Langley measured c-scans on the panels produced. The initial results indicated a unsatisfactory level of approximately 20% by volume of voids. Testing of uniaxial coupons in compression to failure also agreed with these results. The uniaxial coupons delaminated as the major mode of failure indicative of an unacceptably low level of resin and to much void content in the final composites produced. In discussions with Dr. Brian Jensen, it was suggested the void fraction needs to be reduced to at least 2% by volume for a useful composite. The panels produced used both resin synthesized at NASA-Langley and NCA&TSU. In reviewing our progress over the past year, it was noted that the resin as formulated by the current synthesis process bubbled at elevated temperature. This was especially observed in neat resin slugs cured at the recommended one, four and eight hour cure temperatures. Pressurized cures where then performed with pressures up to 200 psi and simultaneously the lowest eight hour cure temperatures. Although this procedure reduced the amount of bubbles to some extent in the neat resin slugs it did not completely eliminate them. The cure reaction appears to be very energetic even at the lowest recommended cure temperature. Currently, the pressurized cure apparatus developed at NCA&TSU is limited to 200 psi.

Dunn, DeRome O.↗
NASA NTRS2000

Ice Accretions and Icing Effects for Modern Airfoils

Icing tests were conducted to document ice shapes formed on three different two-dimensional airfoils and to study the effects of the accreted ice on aerodynamic performance. The models tested were representative of airfoil designs in current use for each of the commercial transport, business jet, and general aviation categories of aircraft. The models were subjected to a range of icing conditions in an icing wind tunnel. The conditions were selected primarily from the Federal Aviation Administration's Federal Aviation Regulations 25 Appendix C atmospheric icing conditions. A few large droplet icing conditions were included. To verify the aerodynamic performance measurements, molds were made of selected ice shapes formed in the icing tunnel. Castings of the ice were made from the molds and placed on a model in a dry, low-turbulence wind tunnel where precision aerodynamic performance measurements were made. Documentation of all the ice shapes and the aerodynamic performance measurements made during the icing tunnel tests is included in this report. Results from the dry, low-turbulence wind tunnel tests are also presented.

Addy, Harold E., Jr.↗
NASA NTRS2000

RFI and SCRIMP Model Development and Verification

Vacuum-Assisted Resin Transfer Molding (VARTM) processes are becoming promising technologies in the manufacturing of primary composite structures in the aircraft industry as well as infrastructure. A great deal of work still needs to be done on efforts to reduce the costly trial-and-error methods of VARTM processing that are currently in practice today. A computer simulation model of the VARTM process would provide a cost-effective tool in the manufacturing of composites utilizing this technique. Therefore, the objective of this research was to modify an existing three-dimensional, Resin Film Infusion (RFI)/Resin Transfer Molding (RTM) model to include VARTM simulation capabilities and to verify this model with the fabrication of aircraft structural composites. An additional objective was to use the VARTM model as a process analysis tool, where this tool would enable the user to configure the best process for manufacturing quality composites. Experimental verification of the model was performed by processing several flat composite panels. The parameters verified included flow front patterns and infiltration times. The flow front patterns were determined to be qualitatively accurate, while the simulated infiltration times over predicted experimental times by 8 to 10%. Capillary and gravitational forces were incorporated into the existing RFI/RTM model in order to simulate VARTM processing physics more accurately. The theoretical capillary pressure showed the capability to reduce the simulated infiltration times by as great as 6%. The gravity, on the other hand, was found to be negligible for all cases. Finally, the VARTM model was used as a process analysis tool. This enabled the user to determine such important process constraints as the location and type of injection ports and the permeability and location of the high-permeable media. A process for a three-stiffener composite panel was proposed. This configuration evolved from the variation of the process constraints in the modeling of several different composite panels. The configuration was proposed by considering such factors as: infiltration time, the number of vacuum ports, and possible areas of void entrapment.

Loos, Alfred C.↗