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Technique combines theoretical and empirical aspects of structural components. Experimental and analytical program produces test and analysis procedures for predicting extent of noise generated in aircraft. Purpose of program to develop ways of screening candidate materials considered for noise control and establish test procedures for verifying choice of particular control measure.
Manufacturers are developing composite versions of structural components on existing aircraft. Development involves testing of various material options before selecting one and then extensive testing to develop an adequate data base of material strength and stiffness properties. Design options are narrowed through analysis and a varied spectrum of development tests on small and large subcomponents. In parallel with this, a suitable production process including economical ply preparation and cure at high temperature and pressure is evolved, tools are designed and fabricated, and full scale components are then manufactured for ground qualification tests, flight tests, and airline service. The various tests include many that are required by the FAA for flight certification, which must precede airline service. Inspection and repair methods to insure adequate maintenance in service are also developed.
The in situ polymerization of monomer reactants (PMR) approach was demonstrated to be a powerful approach for solving many of the processing difficulties associated with the use of high temperature resistant polymers as matrix resins in high performance composites. The PMR-15 polyimide provides the best overall balance of processing characteristics and elevated temperature properties. The excellent properties and commercial availability of composite materials based on PMR-15 led to their acceptance as viable engineering materials. The PMR-15 composites are used to produce a variety of high quality structural components.
Progress in the development of processes for production of Celion/LARC-160 graphite-polyimide materials, quality control methods, and the fabrication of Space Shuttle composite structure components is reported. The formulation and processing limits for three batches of resin are presented. Process improvements for simplification of the imidizing and autoclave cure cycles are described. Imidized and autoclave cured test panels were prepared. Celion/LARC-160 cure process verification and the fabrication of honeycomb sandwich panel elements and skin/stringer panels are described. C-scans of laminates imidized at 163 C to 218 C for periods from 30 to 180 minutes, and of process verification laminates made from different batches of prepreg are presented. Failure modes and load/strain characteristics of sandwich elements and C-scans of stringer to skin bond joints are also given.
Progress in the development of processes for production of Celion/LARC-160 graphite-polyimide materials, quality control, and the fabrication of Space Shuttle composite structure components is reported. Liquid chromatographic analyses of three repeatibility batches were performed and are compared to previous Hexcel standard production and to variables study LARC-160 intermediate resins. Development of processes for chopped fiber molding are described and flexural strength, elastic modulus, and other physical and mechanical properties of the molding are presented.
As part of a program to reduce wind turbine costs, an evaluation was conducted of a laminated wood composite blade for the Mod-OA 200 kW wind turbine. The effort included the design and fabrication concept for the blade, together with cost and load analyses. The blade structure is composed of laminated Douglas fir veneers for the primary spar and nose sections, and honeycomb cored plywood panels for the trailing edges sections. The attachment of the wood blade to the rotor hub was through load takeoff studs bonded into the blade root. Tests were conducted on specimens of the key structural components to verify the feasibility of the concept. It is concluded that the proposed wood composite blade design and fabrication concept is suitable for Mod-OA size turbines (125-ft diameter rotor) at a cost that is very competitive with other methods of manufacture.
The invention relates to methods for making alminate patterns for a resin matrix composite structural component. A sheet of paper is temporarily adhered to a model of the structrual component. A pen is positioned on the paper with a spindle touching the model surface opposite the pen. The pen and spindle are moved along the path that maintains the aforementioned contacts. The resulting line traced on paper is a model constant-thickness locus and provides a pattern for a single lamination of resin-impregnated fabric. The steps are repeated to make other patterns and each time the steps are repeated the distance between the tracer and the spindle is changed to correspond to the thickness of a lamination.
A generalization and numerical implementation is presented of the Stein-Hedgepeth (1961) continuum theory for the analysis of partly wrinkled membranes, such as the tensioned membrane surfaces which are found in spacecraft structural components. The approach has its basis in experimental observations showing that when wrinkles develop in a membrane parallel to the x direction, the associated overall contraction in the y direction exceeds that predicted by the Poisson's ratio effect.
A study was conducted to exploit the processing advantages of superplastic forming and weld-brazing for the fabrication of titanium skin-stiffened structural components. Small titanium compression panels were fabricated and tested at room temperature. Stiffeners having configurations of a conventional hat shape, beaded shaped web, ribbed shaped web, or stepped shaped web were investigated. The data from the panel tests included load-shortening curves, local buckling strengths, and failure loads. Experimental buckling loads were compared with buckling loads calculated using a finite-element analysis. The superplastic formed/weld-brazed panels having complex shaped stiffeners developed from 20 to 58 percent higher local buckling strengths than panels with conventionally shaped stiffeners.
The considered program has the objective to develop and validate repair procedures for composite structures which are adaptable to commercial airline maintenance operations. Questions concerning the design and the fabrication of repairs are discussed, taking into account a vertical fin cover panel, a wing cover panel, and a vertical fin spar. The test results indicate that the use of graphite patch repairs, either precured bonded or employing cure-in-place, is satisfactory for the repair of lightly loaded and highly loaded parts. The use of bolted repairs is satisfactory for lightly loaded structural components. The repair of composite substructures can be accomplished using comparable approaches to those evaluated for skin cover repairs in many previous programs.
Double Linear Damage Rule (DLDR) method for use by structural designers to determine fatigue-crack-initiation life when structure subjected to unsteady, variable-amplitude cyclic loadings. Method calculates in advance of service how many loading cycles imposed on structural component before macroscopic crack initiates. Approach eventually used in design of high performance systems and incorporated into design handbooks and codes.
The free-flyer biostack experiment is part of a radiobiological space research program that includes experiments in space as well as in accelerators on Earth. The program has been specially designed to increase knowledge concerning the importance, effectiveness, and hazards of the structured components of cosmic radiation to man and to any biological specimen in space. Up to now, our understanding of the ways in which HZE particles might affect biological matter is based on a few spaceflight experiments from the last Apollo missions and on the limited data available from heavy-ion irradiation from accelerators. In the near future, accelerators capable of accelerating particles up to higher atomic numbers and higher energies will promote increased activity in ground-based studies on biological effects of HZE particles. Comparison of data from such irradiation experiments on Earth with those from an actual spaceflight experiment will show any potential influence of the inevitably attendant spaceflight factors (e.g., weightlessness) on the radiobiological events.
A completely implantable intracranial pressure sensor designed for long-term measurement of intraventricular pressure in hydrocephalic patients is described. The measurement principal of the device is discussed along with the electronic and component structure and sources of instrument error. Clinical tests of this implanted pressure device involving both humans and animals showed it to be comparable to other methods of intracranial pressure measurement.
Structurally efficient fuselage panels are often designed to allow buckling to occur at applied loads below ultimate. Interest in applying graphite-epoxy materials to fuselage primary structure led to several studies of the post-buckling behavior of graphite-epoxy structural components. Studies of the postbuckling behavior of flat and curved, unstiffened and stiffened graphite-epoxy panels loaded in compression and shear were summarized. The response and failure characteristics of specimens studied experimentally were described, and analytical and experimental results were compared. The specimens tested in the studies described were fabricated from commercially available 0.005-inch-thick unidirectional graphite-fiber tapes preimpregnated with 350 F cure thermosetting epoxy resins.
The structural components of the skeleton develop and are maintained in a 1 g environment, shaped by the mechanical load to which they are constantly exposed. Altering such a mechanical load by reducing the gravitational force imposed on the system, as in space flight, has profound effects on the skeleton and permits an exploration of the molecular events which regulate normal skeletal homeostasis. The objective was to determine whether simulated weightlessness reduced intestinal calcium transport, and if so, to determine the molecular mechanisms for such an effect. A nonstressful tail suspension in which the rats gained weight normally while suspended was used to simulate weightlessness. A significant change in intestinal calcium transport was not demonstrated. However, a cyclic change in bone formation with suspension was shown. Based on these observations, the objective changed to determination of the hormonal regulation of bone formation during simulated weightlessness.
Due to the stringent design requirement for aerospace or nuclear structural components, considerable research interests have been generated on the development of constitutive models for representing the inelastic behavior of metals at elevated temperatures. In particular, a class of unified theories (or viscoplastic constitutive models) have been proposed to simulate material responses such as cyclic plasticity, rate sensitivity, creep deformations, strain hardening or softening, etc. This approach differs from the conventional creep and plasticity theory in that both the creep and plastic deformations are treated as unified time-dependent quantities. Although most of viscoplastic models give better material behavior representation, the associated constitutive differential equations have stiff regimes which present numerical difficulties in time-dependent analysis. In this connection, appropriate solution algorithm must be developed for viscoplastic analysis via finite element method.
Single mode optical fiber waveguide has been used to determine the two-dimensional strain distribution on a simply supported rectangular plate. Each of the fifty individual fibers in the rectangular grid array attached to one surface of the plate yields a measurement of the strain integrated along the length of that fiber on the specimen. By using similar sensor information from all of the fibers, both the functional form and the amplitude of the distribution may be determined. Limits on the dynamic range and spatial resolution are indicated. Applications in the measurement of internal strain and the monitoring of physically small critical-structural components are suggested.
A set of thermoviscoplastic nonlinear constitutive relationships (1VP-NCR) is presented. The set was developed for application to high temperature metal matrix composites (HT-MMC) and is applicable to thermal and mechanical properties. Formulation of the TVP-NCR is based at the micromechanics level. The TVP-NCR are of simple form and readily integrated into nonlinear composite structural analysis. It is shown that the set of TVP-NCR is computationally effective. The set directly predicts complex materials behavior at all levels of the composite simulation, from the constituent materials, through the several levels of composite mechanics, and up to the global response of complex HT-MMC structural components.