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At least 631 records · Page 35

Hydrogen gas embrittlement and the disc pressure test

A disc pressure test has been used to study the influenced of a hydrogen gas environment on the mechanical properties of three high strength superalloys, Inconel 718, L-605 and A-286, in static and dynamic conditions. The influence of the hydrogen pressure, loading rate, temperature, mechanical and thermal fatigue has investigated. The permeation characteristics of Inconel 718 have been determined in collaboration with the French AEC. The results complemented by a fractographic study are consistent either with a stress-sorption or with an internal embrittlement type of mechanism.

Bachelet, E. J.↗

Definition of Tire Properties Required for Landing System Analysis

The data bank constructed provided two basic advantages for the user of aircraft tire information. First, computerization of the data bank allowed mechanical property data to be stored, corrected, updated, and revised quickly and easily as more reliable tests and measurements were carried out. Secondly, the format of the book which can be printed from the computerized data bank can be easily adjusted to suit the needs of the users without the great expense normally associated with reprinting and editing books set by ordinary typography.

Clark, S. K.↗

Characterization of path effects on the properties of balloon films

The effect of stress and temperature path on the mechanical properties of a balloon film material (Astrofilm E2) have been studied using two techniques. The first technique is based on uniaxial tensile measurements of prestrained strips of the film as a function of temperature. Data are analyzed in terms of two temperature coefficients, defined here as a stiffness coefficient and a strength coefficient; and by comparing the areas under the stress-strain curves. The second technique investigated the effect of stress and temperature path on inflated cylinders of the same material. The changes in the mechanical properties due to preconditioning in the biaxial stress state were evaluated using the ball burst test. Preliminary findings indicate that the material is stress and temperature path dependent. Changes in stiffness coefficient, draw strength and toughness were measured and discussed. The above techniques may be suitable to document path dependent changes, and to discriminate among films of different manufacture.

Said, Magdi A.↗

Material Properties for Fiber-Reinforced Silica Aerogels

Ceramic fiber-reinforced silica aerogels are novel materials for high performance insulation, including thermal protection materials. Experimental data are presented for the thermal and mechanical properties, showing the trends exhibited over a range of fiber loadings and silica aerogel densities. Test results are compared to that of unreinforced bulk aerogels.

White, Susan↗

Friction Stir Weld Restart+Reweld Repair Allowables

A friction stir weld (FSW) repair method has been developed and successfully implemented on Al 2195 plate material for the Space Shuttle External Fuel Tank (ET). The method includes restarting the friction stir weld in the termination hole of the original weld followed by two reweld passes. Room temperature and cryogenic temperature mechanical properties exceeded minimum FSW design strength and compared well with the development data. Simulated service test results also compared closely to historical data for initial FSW, confirming no change to the critical flaw size or inspection requirements for the repaired weld. Testing of VPPA fusion/FSW intersection weld specimens exhibited acceptable strength and exceeded the minimum design value. Porosity, when present at the intersection was on the root side toe of the fusion weld, the "worst case" being 0.7 inch long. While such porosity may be removed by sanding, this "worst case" porosity condition was tested "as is" and demonstrated that porosity did not negatively affect the strength of the intersection weld. Large, 15-inch "wide panels" FSW repair welds were tested to demonstrate strength and evaluate residual stresses using photo stress analysis. All results exceeded design minimums, and photo stress analysis showed no significant stress gradients due to the presence of the restart and multi-pass FSW repair weld.

Clifton, Andrew↗

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the-art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts. The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners. However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen Michael Middleton↗

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts.1,2 The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners.1 However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen M Middleton↗

Soft x ray window encapsulant for HgI2 detectors

HgI2 is an excellent semiconductor material for a low energy, room temperature x-ray spectrometer. The high values of the atomic numbers for its constituent elements gives high x-ray and gamma ray stopping power. The band gap of HgI2 is significantly higher than other commonly used semiconductors. Owing to the large value band gap, the leakage current for HgI2 devices is smaller, thus allowing low noise performance. Devices fabricated from HgI2 crystals have demonstrated energy resolution sufficient to distinguish the x-ray emission from the neighboring elements on the periodic table. Also the power requirements of HgI2 are very low. These characteristics make a HgI2 spectrometer an ideal component in a satellite based detection system. Unfortunately, HgI2 crystals tend to deteriorate with time, even if protected by standard semiconductor encapsulants. This degradation ruins the performance of the device in terms of its energy resolution and pulse amplitude. The degrading mechanism is believed to be material loss occurring from below the electrodes, due to high vapor pressure of HgI2 at room temperature. To address this major obstacle to rapid expansion of HgI2 technology, a research program aimed at improving device stability by encapsulation with inert polymeric materials was carried out. The program focused specifically on optimizing the encapsulant materials and their deposition techniques. The principal objectives for this program were device encapsulation, device testing, and accelerated testing to ensure very long term stability of these high resolution sensors. A variety of encapsulants were investigated with the selection criteria based on their chemical diffusion barrier properties, mechanical stability, reactivity, and morphology of encapsulant films. The investigation covered different classes of encapsulants including solvent based encapsulants, vapor deposited encapsulants, and plasma polymerized encapsulants. A variety of characterization techniques were employed to examine their effectiveness in stabilizing HgI2 devices; these included permeability evaluation, vacuum and heat testing, scanning electron microscopy (SEM) as well as studying the detector performance of coated detectors. The plasma polymerized films appear to have entirely solved the HgI2 degradation problem. Another achievement of this program was the development of an accelerated testing technique which correlates extremely well with long term tesing.

Entine, G.↗

Effect of Mechanical and Thermal Loading Histories on Residual Properties of SiCf/SiC Ceramic Matrix Composites

Silicon Carbide based Ceramic Matrix Composites (CMCs) are attractive materials for use in high-temperature structural applications in the aerospace and nuclear industries. Under high stresses and temperatures, creep degradation is the dominant damage mechanism in CMCs. Consequently, chemical vapor infiltration (CVI) SiCf/SiC ceramic matrix composites (CMC) incorporating SylramicTM-iBN SiC fibers coated with boron nitride (BN) interphase and CVI-SiC matrix were tested to examine creep behavior in air at a range of elevated temperatures of (2200 - 2700 F). Samples that survived creep tests were evaluated via RT fast fracture tensile tests to determine residual properties, with the use of acoustic emission (AE) to assess stress dependent damage initiation and progression. Microscopy of regions within the gage section of the tested specimens was performed. Observed material degradation mechanisms are discussed.

creep↗

Hypervelocity Impact Experiments on Epoxy/Ultra-High Molecular Weight Polyethylene Composite Panels Reinforced with Nanotubes

Advanced composites with multi-functional capabilities are of great interest to the designers of aerospace structures. Polymer matrix composites (PMCs) reinforced with high strength fibers provide a lightweight and high strength alternative to metals and metal alloys conventionally used in aerospace architectures. Novel reinforcements such as nanofillers offer potential to improve the mechanical properties and add multi-functionality such as radiation resistance and sensing capabilities to the PMCs. This paper reports the hypervelocity impact (HVI) test results on ultra-high molecular weight polyethylene (UHMWPE) fiber composites reinforced with single-walled carbon nanotubes (SWCNT) and boron nitride nanotubes (BNNT). Woven UHMWPE fabrics, in addition to providing excellent impact properties and high strength, also offer radiation resistance due to inherent high hydrogen content. SWCNT have exceptional mechanical and electrical properties. BNNT (figure 1) have high neutron cross section and good mechanical properties that add multi-functionality to this system. In this project, epoxy based UHMWPE composites containing SWCNT and BNNT are assessed for their use as bumper shields and as intermediate plates in a Whipple Shield for HVI resistance. Three composite systems are prepared to compare against one another: (I) Epoxy/UHMWPE, (II) Epoxy/UHMWPE/SWCNT and (III) Epoxy/UHMWPE/SWCNT/BNNT. Each composite is a 10.0 by 10.0 by 0.11 cm3 panel, consisting of 4 layers of fabrics arranged in cross-ply orientation. Both SWCNT and BNNT are 0.5 weight % of the fabric preform. Hypervelocity impact tests are performed using a two-stage light gas gun at Rice University

Khatiwada, Suman↗

Preparation Torque Limit for Composites Joined with Mechanical Fasteners

Current design guidelines for determining torque ranges for composites are based on tests and analysis from isotropic materials. Properties of composites are not taken into account. No design criteria based upon a systematic analytical and test analyses is available. This paper is to study the maximum torque load a composite component could carry prior to any failure. Specifically, the torque-tension tests are conducted. NDT techniques including acoustic emission, thermography and photomicroscopy are also utilized to characterize the damage modes.

Thomas, Frank P.↗

Performance degradation mechanisms and modes in terrestrial photovoltaic arrays and technology for their diagnosis

Accelerated life-prediction test methodologies have been developed for the validation of a 20-year service life for low-cost photovoltaic arrays. Array failure modes, relevant materials property changes, and primary degradation mechanisms are discussed as a prerequisite to identifying suitable measurement techniques and instruments. Measurements must provide sufficient confidence to permit selection among alternative designs and materials and to stimulate widespread deployment of such arrays. Furthermore, the diversity of candidate materials and designs, and the variety of potential environmental stress combinations, degradation mechanisms and failure modes require that combinations of measurement techniques be identified which are suitable for the characterization of various encapsulation system-cell structure-environment combinations.

Noel, G. T.↗

Experimental study of the minority-carrier transport at the polysilicon-monosilicon interface

This paper presents the results of an experimental study designed to explore both qualitatively and quantitatively the mechanism of the improved current gain in bipolar transistors with polysilicon emitter contacts. Polysilicon contacts were deposited and heat treated at different conditions. The electrical properties were measured using p-n junction test structures that are much more sensitive to the contact properties than are bipolar transistors. A simple phenomenological model was used to correlate the structural properties with electrical measurements. Possible transport mechanisms are examined and estimates are made about upper bounds on transport parameters in the principal regions of the devices. The main conclusion of this study is that the minority-carrier transport in the polycrystalline silicon is dominated by a highly disordered layer at the polysilicon-monosilicon interface characterized by very low minority-carrier mobility. The effective recombination velocity at the n(+) polysilicon-n(+) monosilicon interface was found to be a strong function of fabrication conditions. The results indicate that the recombination velocity can be much smaller than 10,000 cm/s.

Neugroschel, A.↗

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

This report documents the progress achieved over the past 6 to 12 months on four graduate student projects conducted within the NASA-UVA Light Aerospace Alloy and Structures Technology Program. These studies were aimed specifically at light metallic alloy issues relevant to the High Speed Civil Transport. Research on Hydrogen-Enhanced Fracture of High-Strength Titanium Alloy Sheet refined successfully the high resolution R-curve method necessary to characterize initiation and growth fracture toughnesses. For solution treated and aged Low Cost Beta without hydrogen precharging, fracture is by ductile transgranular processes at 25 C, but standardized initiation toughnesses are somewhat low and crack extension is resolved at still lower K-levels. This fracture resistance is degraded substantially, by between 700 and 1000 wppm of dissolved hydrogen, and a fracture mode change is affected. The surface oxide on P-titanium alloys hinders hydrogen uptake and complicates the electrochemical introduction of low hydrogen concentrations that are critical to applications of these alloys. Ti-15-3 sheet was obtained for study during the next reporting period. Research on Mechanisms of deformation and Fracture in High-Strength Titanium Alloys is examining the microstructure and fatigue resistance of very thin sheet. Aging experiments on 0. 14 mm thick (0.0055 inch) foil show microstructural agility that may be used to enhance fatigue performance. Fatigue testing of Ti-15-3 sheet has begun. The effects of various thermo-mechanical processing regimens on mechanical properties will be examined and deformation modes identified. Research on the Effect of Texture and Precipitates on Mechanical Property Anisotropy of Al-Cu-Mg-X and Al-Cu alloys demonstrated that models predict a minor influence of stress-induced alignment of Phi, caused by the application of a tensile stress during aging, on the yield stress anisotropy of both modified AA2519 and a model Al-Cu binary alloy. This project is no longer included in the NASA-UVA LAST program. Research on the Creep Behavior and Microstructural stability of Al-Cu-Mg-Ag and Al-Cu-Li-Mg-Ag showed that the creep resistance of three candidate aluminum alloys (C415, C416 and ML377) was much superior compared to that of the current Concorde alloy, AA2618. Creep induced change in precipitates at grain boundaries was observed in the alloy which exhibits the highest creep strain of the three examined. The other two alloys developed no detectable microstructural changes at grain boundaries under the creep conditions tested.

Gangloff, Richard P.↗

Methods for assessing the structural reliability of brittle materials

Failure from contact-induced surface flaws is considered along with controlled indentation flaws for construction of toughness and fatigue master maps, fatigue properties of ceramics with natural and controlled flaws, and a statistical analysis of size and stress state effects on the strength of an alumina ceramic. Attention is also given to dynamic and static fatigue of a machinable glass ceramic, the effect of multiregion crack growth on proof testing, and a fracture mechanics analysis of defect sizes. Other topics explored are related to the effect of temperature and humidity on delayed failure of optical glass fibers, subthreshold indentation flaws in the study of fatigue properties of ultrahigh-strength glass, the lifetime prediction for hot-pressed silicon nitride at high temperatures, static fatigue in high-performance ceramics, and requirements for flexure testing of brittle materials.

Freiman, S. W.↗

High Temperature VARTM of Phenylethynyl Terminated Imides (PETI) Resins

Fabrication of composite structures using vacuum assisted resin transfer molding (VARTM) is generally more affordable than conventional autoclave techniques. Recent efforts have focused on adapting VARTM for the fabrication of high temperature composites. Due to their low melt viscosity and long melt stability, certain phenylethynyl terminated imides (PETI) can be processed into composites using high temperature VARTM (HT-VARTM). However, one of the disadvantages of the current HT-VARTM resin systems has been the high porosity of the resultant composites. For aerospace applications a void fraction of less than 2% is desired. In the current study, two PETI resins, LARCTM PETI-330 and LARCTM PETI-8 have been used to fabricate test specimens using HT-VARTM. The resins were infused into carbon fiber preforms at 260 C and cured between 316 C and 371 C. Modifications to the thermal cycle used in the laminate fabrication have reduced the void content significantly (typically < 3%) for carbon fiber biaxially woven fabric. Photomicrographs of the panels were taken and void contents were determined by acid digestion. For carbon fiber uniaxial fabric, void contents of less than 2% have been obtained using both PETI-8 and PETI-330. Mechanical properties of the panels were determined at both room and elevated temperatures. These include short beam shear and flexure tests. The results of this work are presented herein.

Ghose, Sayata↗

Investigating Durability of 8YSZ via Wear and Erosion Testing for Lunar Applications

As the number of missions to land on the Moon with and without crew continues to increase, there are a plethora of factors to consider that could affect aerospace structures. Lunar dust, or lunar regolith, composed of small rock fragments, glass beads, and minerals, is transformed by years of meteorite impacts. Lunar dust is quite corrosive, abrasive, reactive and adherent, necessitating effective mitigation strategies. Ceramics have emerged as a promising material selection in the aerospace industry for structural protection due to their high strength, excellent thermal properties, and resistance to degradation. Among these ceramics, zirconia (ZrO2) is a promising material, exhibiting exceptional mechanical and thermal properties. This study evaluates the resilience of an 8-wt.% yttria-stabilized zirconia (8YSZ) ceramic coating, tested against wear and erosion to characterize its degradation over time.

Ashley Tirado Pujols↗

High Thermal Conductivity NARloy-Z-Diamond Composite Liner for Advanced Rocket Engines

NARloy-Z (Cu-3Ag-0.5Zr) alloy is state-of-the-art combustion chamber liner material used in liquid propulsion engines such as the RS-68 and RS-25. The performance of future liquid propulsion systems can be improved significantly by increasing the heat transfer through the combustion chamber liner. Prior work1 done at NASA Marshall Space Flight Center (MSFC) has shown that the thermal conductivity of NARloy-Z alloy can be improved significantly by embedding high thermal conductivity diamond particles in the alloy matrix to form NARloy-Z-diamond composite (fig. 1). NARloy-Z-diamond composite containing 40vol% diamond showed 69% higher thermal conductivity than NARloy-Z. It is 24% lighter than NARloy-Z and hence the density normalized thermal conductivity is 120% better. These attributes will improve the performance and life of the advanced rocket engines significantly. The research work consists of (a) developing design properties (thermal and mechanical) of NARloy-Z-D composite, (b) fabrication of net shape subscale combustion chamber liner, and (c) hot-fire testing of the liner to test performance. Initially, NARloy-Z-D composite slabs were made using the Field Assisted Sintering Technology (FAST) for the purpose of determining design properties. In the next step, a cylindrical shape was fabricated to demonstrate feasibility (fig. 3). The liner consists of six cylinders which are sintered separately and then stacked and diffusion bonded to make the liner (fig. 4). The liner will be heat treated, finish-machined, and assembled into a combustion chamber and hot-fire tested in the MSFC test facility (TF 115) to determine perform.

Bhat, Biliyar↗