Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Lightweight Structures”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Bioinspired multilayered cellular composites with enhanced energy absorption and shape recovery

Inspired by the multiscale configuration of the microstructure of cork, the paper describes the design, 3D printing, and evaluation of a new type of multilayered cellular composite (MCC) structure composed of hard brittle and soft flexible phases. The mechanical behavior of 3D printed MCC structures have been investigated both experimentally and numerically. The experiments show that the MCC structure absorbs four times the amount of energy of a conventional cellular configuration under compressive strains up to 70%. Finite element simulations and 2D digital image correlation (DIC) also show that the multilayered architecture provides a more uniform strain distribution and higher stress transfer efficiency, with a resulting progressive failure mode rather than a catastrophic one. Cyclic loading tests demonstrate that the MCC structure also possesses exceptional shape recoverability under compressive deformations up to 40%. These remarkable performance characteristics result from synergies between the properties of the two constituent materials and the chosen multilayered cellular microstructure. The soft phase, in particular, plays a pivotal role in absorbing elastic energy during loading and then releasing the stored energy while unloading. The volume fraction of the soft phase is also essential to control energy absorption and the transition of failure modes. The deformation mechanisms demonstrated here are robust and applicable to other architected cellular materials across multiple length scales and suggest new ways to design lightweight and high-resilience structural materials.

bioinspired composites↗
DOE OSTI2021

Computational investigations of Dienes defect- and vacancy-induced changes in the electronic and vibrational properties of carbon fiber structural units

Carbon fiber (CF) is a promising lightweight alternative to steel and is of significant interest for energy applications. As CF continues to find new uses and is exposed to new external conditions, a noninvasive method of monitoring its structural integrity is critical. Raman spectroscopy is a commonly used method for this monitoring; however, it is highly inferential, and the interpretation of the data is not always straightforward. In this work, we perform density functional theory (DFT) calculations to investigate changes in the vibrational properties of CF structural units (i.e., graphene and graphite) caused by monovacancy and Dienes defects as a foundation for modeling more complex defects that move our model toward that of realistic CF. Using large computational supercells, we can understand how these defects change the electronic structure and vibrational properties of graphene and graphite for interdefect distances near those of the lower experimental limit. The monovacancy opens an electronic bandgap at the K point. Although no such electronic gap is opened by the Dienes defect, both defects introduce flat defect bands near the Fermi energy. The Dienes defect creates long-range deviations of the phonons, leading to substantial broadening of the highest frequency optical modes in the band structure compared to that of the pristine material. In contrast, the phonon changes caused by the monovacancy are short range, and only minor changes in the band structure or phonon density of states were observed. These findings can assist in the interpretation of experimental results by providing atomic-scale insight into key electronic and vibrational features.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2013

The Use of Additive Manufacturing for Fabrication of Multi-Function Small Satellite Structures

The use of small satellites in constellations is limited only by the growing functionality of smallsats themselves. Additive manufacturing provides exciting new design opportunities for development of multifunction CubeSat structures that integrate such functions as propulsion and thermal control into the satellite structures themselves. Manufacturing of these complex multifunction structures is now possible in lightweight, high strength, materials such as titanium by using existing electron beam melting additive manufacturing processes. However, the use of today's additive manufacturing capabilities is often cost-prohibitive for small companies due to the large capital investments required. To alleviate this impediment the U.S. Department of Energy has established a Manufacturing Demonstration Facility (MDF) at their Oak Ridge National Laboratory (ORNL) in Tennessee that provides industry access to a broad range of energy-efficient additive manufacturing equipment for collaborative use by both small and large organizations. This paper presents a notional CubeSat multifunction design that integrates the propulsion system into a three-unit (3U) CubeSat structure. The full-scale structure has been designed and fabricated at the ORNL MDF. The use of additive manufacturing for spacecraft fabrication is opening up many new possibilities in design and fabrication capabilities for what had previously been impossible structures to fabricate.

Horais, Brian J↗
NASA NTRS2002

Development of HVOF Sprayed Erosion/Oxidation Resistant Coatings for Composite Structural Components in Propulsion Systems

Thermally sprayed coatings are being studied and developed as methods of enabling lightweight composites to be used more extensively as structural components in propulsion applications in order to reduce costs and improve efficiency through weight reductions. The primary goal of this work is the development of functionally graded material [FGM] polymer/metal matrix composite coatings to provide improved erosion/oxidation resistance to polyimide-based polymer matrix composite [PMC] substrates. The goal is to grade the coating composition from pure polyimide, similar to the PMC substrate matrix on one side, to 100 % WC-Co on the other. Both step-wise and continuous gradation of the loading of the WC-Co reinforcing phase are being investigated. Details of the coating parameter development will be presented, specifically the high velocity oxy-fuel [HVOF] combustion spraying of pure PMR-11 matrix material and layers of various composition PMR-II/WC-Co blends onto steel and PMR-15 composite substrates. Results of the HVOF process optimization, microstructural characterization, and analysis will be presented. The sprayed coatings were evaluated using standard metallographic techniques - optical and scanning electron microscopy [SEM]. An SEM + electron dispersive spectroscopy [EDS] technique has also been used to confirm retention of the PMR-II component. Results of peel/butt adhesion testing to determine adhesion will also be presented.

Knight, R.↗
NASA NTRS1990

Development of HVOF Sprayed Erosion/Oxidation Resistant Coatings for Composite Structural Components in Propulsion Systems

Thermally sprayed coatings are being studied and developed as methods of enabling lightweight composites to be used more extensively as structural components in propulsion applications in order to reduce costs and improve efficiency through weight reductions. The primary goal of this work is the development of functionally graded material [FGM] polymer/metal matrix composite coatings to provide improved erosion/oxidation resistance to polyimide-based polymer matrix composite [PMC] substrates. The goal is to grade the coating composition from pure polyimide, similar to the PMC substrate matrix on one side, to 100% WC-Co on the other. Both step-wise and continuous gradation of the loading of the WC-Co reinforcing phase are being investigated, Details of the coating parameter development will be presented, specifically the high velocity oxy-fuel [HVOF] combustion spraying of pure PMR-I1 matrix material and layers of various composition PMR-II/WC-Co blends onto steel and PMR-15 composite substrates. Results of the HVOF process optimization, microstructural characterization, and analysis will be presented. The sprayed coatings were evaluated using standard metallographic techniques - optical and scanning electron microscopy [SEMI. An SEM + electron dispersive spectroscopy [EDS] technique has also been used to confirm retention of the PMR-I1 component. Results of peel/butt adhesion testing to determine adhesion will also be presented.

Ivosevic, M.↗
NASA NTRS1992

Enhanced softgoods structures for spacesuit micrometeoroid/debris protective systems

A lightweight, flexible thermal micrometeoroid garment (TMG) design for enhanced space suit micrometeoroid/debris (M/D) protection is described. It will consist of an outer layer comprised of orthofabric, multilayers of aluminized Mylar, and a layer of silicone rubber loaded with micron sized particles of tungsten. The shield layers would fragment and/or vaporize the M/D projectile while the backup sheet would stop the resultant debris cloud.

Remington, Brian↗
NASA NTRS2023

Tribological and Radiation Shielding Response of Novel Titanium-Boron Nitride Coatings for Lunar Structural Components

Aluminum (Al) and titanium (Ti) lightweight alloys play a crucial role in space systems due to their exceptional strength-to-weight ratio. However, their premature failure in the presence of lunar regolith and their lack of neutron shielding ability are significant challenges. To address these issues, we have developed air and vacuum plasma-sprayed hBN (hexagonal Boron Nitride) -reinforced titanium coatings with 2 and 10 vol% of hBN. Tribological studies conducted with JSC-1 A lunar regolith simulant revealed a 90 % reduction in wear volume for the Ti/2 vol% hBN coatings compared to conventional materials due to the synergistic action of harder secondary phases and solid lubrication effect of hBN. Additionally, a 27 % enhancement in radiation shielding is obtained based on the mass absorption coefficient (radiation absorbed per sample density and thickness) for VPS Ti/2 vol% hBN coatings.

Wear↗
NASA NTRS2005

Preliminary Analysis of the 30-m UltraBoom Flight Test

Future NASA missions require long, ultra-lightweight booms to enable solar sails, large sunshields, and other gossamer-type spacecraft structures. The space experiment discussed in this paper will flight validate the non-traditional ultra lightweight rigidizable, inflatable, isogrid structure utilizing graphite shape memory polymer (GR/SMP) called UltraBoom(TradeMark). The focus of this paper is the analysis of the 3-m ground test article. The primary objective of the mission is to show that a combination of ground testing and analysis can predict the on-orbit performance of an ultra lightweight boom that is scalable, predictable, and thermomechanically stable.

UltraBoom↗
DOE OSTI2026

Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency

Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber-reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedstock materials for thermoforming, with flexural and tensile testing performed both along the primary fiber direction and in the off-axis orientation to establish baseline stiffness, strength, and anisotropy. As expected, short carbon fiber PETG exhibited the highest stiffness and strength in the primary fiber direction, while all systems showed reduced performance in the off-axis direction. This off-axis performance reduction provides clear justification for the use of additive reinforcement when such thermoformed sheets are intended for structural applications. The intended manufacturing sequence involves thermoforming the reinforced sheet first, followed by the application of additively manufactured lattice reinforcement; therefore, the reinforcement strategy does not impose limitations on sheet formability during thermoforming. Post-forming lattice reinforcement significantly reduced load-normalized displacement by approximately 95–99% relative to non-reinforced sheets and improved weight-normalized stiffness by ~70%. These findings demonstrate that geometry-driven additive reinforcement can effectively compensate for off-axis property reductions in thermoformed PETG composites, enabling enhanced multidirectional structural performance without compromising manufacturability.

Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗
DOE OSTI2020

Solving Eco-Driving Problems Using Indirect Collocation Method and Smooth Representation

Here, we discuss the eco-driving problem, considering both electric and conventional powertrains, and presents a pathway to solving it numerically using an indirect collocation method. Despite the low-order system dynamics, the piecewise fuel/efficiency map, gear shifting, and real-world traffic/road situations bring system discontinuities/switchings and pure state constraints into the problem formulation, which make the problem highly nonlinear and nontrivial to solve. This letter introduces smooth approximations to convert the original problem to an unconstrained (and penalized) smooth boundary-value problem. This approach eliminates the discussion of the switching structure and leads to a lightweight Newton-method-based solution procedure.

42 ENGINEERING↗
DOE OSTI2019

Advances in Dissimilar Metals Joining through Temperature Control of Friction Stir Welding

Lightweighting of vehicles and portable structures is an important undertaking. Multi-material design is required to achieve conflicting design targets such as cost, stiffness, and weight. Friction stir welding (FSW) variants, such as friction stir dovetailing and friction stir scribe, are enabling technologies for joining of dissimilar metals. This work shows that FSW variants are capable of joining aluminum to steel. Characteristics of metallurgical bonding at the dissimilar material interface are strongly affected by weld temperature. Control of FSW process temperature enables metallurgical bonding with suppressed formation of intermetallics at the dissimilar material interface resulting in improved mechanical properties relative to competing techniques. Temperature control is a powerful tool for process development and to ensure weld quality of dissimilar material welds.

Aluminum to Steel Joining, Friction stir welding, ↗
NASA NTRS1972

Proceedings of the Symposium on Welding, Bonding, and Fastening

Various technological processes to achieve lightweight reliable joining systems for structural elements of aircraft and spacecraft are considered. Joining methods, combinations of them, and nondestructive evaluation and quality assurance are emphasized.

Stein, B. A.↗
NASA NTRS1975

Development of restraint material and tucked fabric joints

A study was conducted to evaluate and select a suitable restraint material for the exterior of space suits pressurized to 4.0 PSID for normal operations, and to develop and improve tucked fabric joints for motions associated with the human shoulder, elbow, knee, waist, hip, ankle, and wrist. The many attributes of the end items are summarized to include structural integrity, simplicity, low maintenance, lightweight, high durability, low elongation, full range mobility, long life, and resistance to degradation in the operational environment.

Mcmullen, J. M.↗
NASA NTRS1976

Aerospike thrust chamber program

An existing, but damaged, 25,000-pound thrust, flightweight, oxygen/hydrogen aerospike rocket thrust chamber was disassembled and partially repaired. A description is presented of the aerospike chamber configuration and of the damage it had suffered. Techniques for aerospike thrust chamber repair were developed, and are described, covering repair procedures for lightweight tubular nozzles, titanium thrust structures, and copper channel combustors. Effort was terminated prior to completion of the repairs and conduct of a planned hot fire test program when it was found that the copper alloy walls of many of the thrust chamber's 24 combustors had been degraded in strength and ductility during the initial fabrication of the thrust chamber. The degradation is discussed and traced to a reaction between oxygen and/or oxides diffused into the copper alloy during fabrication processes and the hydrogen utilized as a brazing furnace atmosphere during the initial assembly operation on many of the combustors. The effects of the H2/O2 reaction within the copper alloy are described.

Campbell, J., Jr.↗
NASA NTRS1980

Faired instrumentation for aerodynamic tests

Streamlined package is installed and removed without altering aerodynamic properties of structure being tested. Method uses lightweight materials so that blade balance is maintained.

Long, W. C.↗
NASA NTRS1984

Design and performance analysis of a conical-aerobrake, orbital-transfer vehicle concept

A Shuttle-compatible systems design based on the core concept of attachable modules for the major vehicle components is proposed. The principal features include a disposable cargo/extra-propellant tank module; a porous, radiative, backscattering drag-brake surface material of thin silica cloth; and a lightweight carbon-composite support structure. The mission payload capability for delivery, retrieval, and combined operations is determined for a broad range of missions including NASA/DOD requirements and extending through cis-lunar space. The effects of finite-rate surface catalysis, negative lift, and multiple atmospheric passes in reducing the aerothermal heating rates are also investigated. In addition, the structural and thermal-protection problems of the drag-brake support apparatus are analyzed and recommendations are proposed for future design refinements.

Menees, G. P.↗
NASA NTRS1985

Measurement of orbital dynamics of the OAST-1 Solar Array using recorded video images

The OAST-1 Solar Array Experiment was flown on Shuttle mission STS-41D on August 31, 1984 for NASA's Office of Aeronautics and Space Technology. It is pointed out that this was the first flight demonstration of the operation of a large solar array which was designed for multiple deployments and retractions. The array represents also a new class of very lightweight, flexible, low-frequency structures. A program was, therefore, implemented with the aim to study the structural dynamics of the array on the basis of a photogrammetric analysis of data obtained with the existing Shuttle closed circuit television (CCTV) system. The present paper has the objective to describe the experiment and its implementation, taking into account the unique process of analyzing the video data.

Miller, J. B.↗
NASA NTRS1988

Utilization of spray on foam insulation for manned and unmanned spacecraft and structures

The idea of using spray-on foam insulation as a passive thermal and micrometeorite protection system is explored. The benefits of applying an exterior coating of foam insulation can be: (1) the foam can provide a thermally stable shield that can assist in reducing the strain on traditional space radiator systems and can also act as a passive thermal guard, allowing a greater fault tolerance if the standard system should fail; (2) the foam can act as an ablative shell diminishing the effects of natural and manmade debris striking the structure; (3) the foam is lightweight - about 1/2 ounce per sq ft; (4) the foam is low cost and easy to maintain; and (5) the foam is a stable material that does not react when exposed to earth or lunar environments.

Hancock, Thomas M., III↗