Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Lightweight materials”

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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Overview of SBIR Phase II Work on Hollow Graphite Fibers

Ultra-Lightweight materials are enabling for producing space based optical components and support structures. Heretofore, innovative designs using existing materials has been the approach to produce lighter-weight optical systems. Graphite fiber reinforced composites, because of their light weight, have been a material of frequent choice to produce space based optical components. Hollow graphite fibers would be lighter than standard solid graphite fibers and, thus, would save weight in optical components. The Phase I SBIR program demonstrated it is possible to produce hollow carbon fibers that have strengths up to 4.2 GPa which are equivalent to commercial fibers, and composites made from the hollow fibers had substantially equivalent composite strengths as commercial fiber composites at a 46% weight savings. The Phase II SBIR program will optimize processing and properties of the hollow carbon fiber and scale-up processing to produce sufficient fiber for fabricating a large ultra-lightweight mirror for delivery to NASA. Information presented here includes an overview of the strength of some preliminary hollow fibers, photographs of those fibers, and a short discussion of future plans.

Stallcup, Michael↗
NASA NTRS2026

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗
NASA NTRS1975

The long term energy problem and aeronautics

The projected increase in energy consumption by transportation in general and civil aviation in particular is directly opposed to the dwindling supplies of natural petroleum crude oil currently used to produce aircraft fuels. This fact dictates the need to develop even more energy conservative aircraft and propulsion systems than are currently available and to explore the potential of alternative fuels to replace the current petroleum derived hydrocarbons. Advances in technology are described in the areas of improved component efficiency, aircraft and engine integration, control systems, and advanced lightweight materials that are needed to maximize performance and minimize fuel usage. Also, improved turbofan and unconventional engine cycles which can provide significant fuel usage reductions are described. These advancements must be accomplished within expected environmental constraints such as noise and pollution limits. Alternative fuels derived from oil shale and coal are described, and the possible technological advancements needed to use these fuels in aircraft engines are discussed and evaluated with relation to potential differences in fuel characteristics.

Rudey, R. A.↗
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 NTRS1978

Design and fabrication of a radiative actively cooled honeycomb sandwich panel

The mass of a radiative actively cooled panel was compared to the mass of a bare actively cooled panel designed to the same conditions and constraints. The approach was to design and optimize a 0.61 x 6.1 m full scale panel which combines radiative and active cooling to control structural temperatures to levels compatible with use of lightweight materials and to fabricate a 0.61 x 1.22 m panel for performance testing. Results of the design and optimization of the full scale radiative actively cooled structural panel, including radiative concept selection, final configuration details, test panel description, and conclusions are summarized.

Koch, L. C.↗
NASA NTRS1983

Process Yields Strong, Void-Free Laminates

Need for lightweight materials as structural components for future space transportation systems stimulated development of systematic method for manufacturing a polyimide/graphite composite. Laminates manufactured by process are void-free, exhibit excellent thermo-oxidative stability up to 315 degrees C (600 degrees F) and are 40 percent lighter than aluminum. Process is precise, repeatable, and ideally suited for researchers and small-lot producers of composite materials.

Bryant, L. E.↗
NASA NTRS1984

Energy Efficient Transport - Technology in hand

Technologies developed through NASA's Energy Efficient Transport Program are described. The program was charged with research in advanced aerodynamics and active controls, with the goal of increasing the fuel efficiency of transport aircraft by 15 to 20 percent. Research in aerodynamics was directed toward the development of high-aspect-ratio supercritical wings, winglets, computational design methodology, high-lift devices, propulsion airframe integration, and surface coatings. The active control portion of the program investigated Wing Load Alleviation (WLA) through the use of active controls, drag reduction, and the effect of active pitch controls on fuel consumption. It was found that applying active control functions at the beginning of the aircraft design cycle brings the best benefit, and that if active control and advanced aerodynamic airframe configurations are applied to transport aircraft design concurrently with new lightweight materials, fuel consumption can be reduced by as much as 40 percent.

Middleton, D. B.↗
NASA NTRS1989

A new concept for high-cycle-life LEO: Rechargeable MnO2-hydrogen

The nickel-hydrogen secondary battery system is now the one of choice for use in GEO satellites. It offers superior energy density to that of nickel-cadmium, with a lifetime that is at least comparable in terms of both cycle life and overall operating life. While the number of deep cycles required for GEO use is small, LEO satellites with long lifetimes (5 to 10 years) will require secondary battery systems allowing 30,000 to 60,000 useful cycles which are characterized by an approximately 2C charge rate and C average discharge rate. Recent work has shown that birnessite MnO2 doped with bismuth oxide can be cycled at very high rates (6C) over a very large number of cycles (thousands) at depths-of-discharge in the 85 to 90 percent range, based on two electrons, which discharge at the same potential in a flat plateau. The potential is about 0.7 V vs. hydrogen, with a cut-off at 0.6 V. At first sight, this low voltage would seem to be a disadvantage, since the theoretical energy density will be low. However, it permits the use of lightweight materials that are immune from corrosion at the positive. The high utilization and low equivalent weight of the active material, together with the use of teflon-bonded graphite for current collection, result in very light positives, especially when these are compared with those in a derated nickel-hydrogen system. In addition, the weight of the pressure vessel falls somewhat, since the dead volume is lower. Calculations show that a total system will have 2.5 times the Ah capacity of a derated nickel-hydrogen LEO battery, so that the energy density, based on 1.2 V for nickel-hydrogen and 0.7 V for MnO2-hydrogen, will be 45 percent higher for comparable cycling performance.

Appleby, A. John↗
NASA NTRS1993

High-Energy-Density Electrolytic Capacitors

Reductions in weight and volume make new application possible. Supercapacitors and improved ultracapacitors advanced electrolytic capacitors developed for use as electric-load-leveling devices in such applications as electric vehicle propulsion systems, portable power tools, and low-voltage pulsed power supplies. One primary advantage: offer power densities much higher than storage batteries. Capacitors used in pulse mode, with short charge and discharge times. Derived from commercially available ultracapacitors. Made of lightweight materials; incorporate electrode/electrolyte material systems capable of operation at voltages higher than previous electrode/electrolyte systems. By use of innovative designs and manufacturing processes, made in wide range of rated capacitances and in rated operating potentials ranging from few to several hundred volts.

Yen, Shiao-Ping S.↗
NASA NTRS1992

Lunar Lava Tube Sensing

Large (greater than 300 m diameter) lava tube caverns appear to exist on the Moon and could provide substantial safety and cost benefits for lunar bases. Over 40 m of basalt and regolith constitute the lava tube roof and would protect both construction and operations. Constant temperatures of -20 C reduce thermal stress on structures and machines. Base designs need not incorporate heavy shielding, so lightweight materials can be used and construction can be expedited. Identification and characterization of lava tube caverns can be incorporated into current precursor lunar mission plans. Some searches can even be done from Earth. Specific recommendations for lunar lava tube search and exploration are (1) an Earth-based radar interferometer, (2) an Earth-penetrating radar (EPR) orbiter, (3) kinetic penetrators for lunar lava tube confirmation, (4) a 'Moon Bat' hovering rocket vehicle, and (5) the use of other proposed landers and orbiters to help find lunar lava tubes.

York, Cheryl Lynn↗
NASA NTRS1993

Lightweight solar concentrator structures, phase 2

This report summarizes the results of the program conducted by Ultramet under SBIR Phase 2 Contract NAS3-25418. The objective of this program was to develop lightweight materials and processes for advanced high accuracy Space Solar Concentrators using rigidized foam for the substrate structure with an integral optical surface.

Williams, Brian E.↗
NASA NTRS1990

Using input command pre-shaping to suppress multiple mode vibration

Spacecraft, space-borne robotic systems, and manufacturing equipment often utilize lightweight materials and configurations that give rise to vibration problems. Prior research has led to the development of input command pre-shapers that can significantly reduce residual vibration. These shapers exhibit marked insensitivity to errors in natural frequency estimates and can be combined to minimize vibration at more than one frequency. This paper presents a method for the development of multiple mode input shapers which are simpler to implement than previous designs and produce smaller system response delays. The new technique involves the solution of a group of simultaneous non-linear impulse constraint equations. The resulting shapers were tested on a model of MACE, an MIT/NASA experimental flexible structure.

Hyde, James M.↗
NASA NTRS1994

Design and development of an F/A-18 inlet distortion rake: A cost and time saving solution

An innovative inlet total-pressure distortion measurement rake has been designed and developed for the F/A-18 A/B/C/D aircraft inlet. The design was conceived by NASA and General Electric Aircraft Engines (Evendale, Ohio). This rake has been flight qualified and flown in the F-18 High Alpha Research Vehicle (HARV) at NASA Dryden Flight Research Center. The rake's eight-legged, one-piece wagon wheel design was developed at a reduced cost and offers reduced installation time compared with traditional designs. The rake features 40 dual measurement ports for both low- and high-frequency pressure measurements with the high-frequency transducer mounted at the port. The high-frequency transducer offers direct absolute pressure measurements from low frequency to the highest frequency of interest, thereby allowing the rake to be used during highly dynamic aircraft maneuvers. Outstanding structural characteristics are inherent to the design through its construction and use of lightweight materials.

Yuhas, Andrew J.↗
NASA NTRS1995

Design and development of an F/A-18 inlet distortion rake: A cost and time saving solution

An innovative inlet total pressure distortion measurement rake has been designed and developed for the F/A-18 A/B/C/D aircraft inlet. The design was conceived by NASA and General Electric Aircraft Engines personnel. This rake has been flight qualified and flown in the F/A-18 High Alpha Research Vehicle at NASA Dryden Flight Research Center, Edwards, California. The eight-legged, one-piece, wagon wheel design of the rake was developed at a reduced cost and offered reduced installation time compared to traditional designs. The rake features 40 dual-measurement ports for low- and high-frequency pressure measurements with the high-frequency transducer mounted at the port. This high-frequency transducer offers direct absolute pressure measurements from low to high frequencies of interest, thereby allowing the rake to be used during highly dynamic aircraft maneuvers. Outstanding structural characteristics are inherent to the design through its construction and use of lightweight materials.

Yuhas, Andrew J.↗
NASA NTRS1996

Test Outline for Flutter Analysis of Rectangular Panels in Rarefied Flow Conditions

Jet plume impingement forces acting on large flexible space structures may precipitate dynamically unstable behavior during space flights. Typical operating conditions in space involve rarefied gas flow regimes which are intrinsically distinct from continuum gas flow and are normally modeled using the kinetic theory of gas flow. Docking and undocking operations of the Space Shuttle with the Russian Mir space laboratory represent a scenario in which the stability boundaries of solar panels may be of interest. Extensive literature review of research work on the dynamic stability of rectangular panels in rarefied gas flow conditions indicated the lack of published reports dealing with this phenomenon. A recently completed preliminary study for NASA JSC dealing with the mathematical analysis of the stability of two-degree-of-freedom elastically supported rigid panels under the effect of rarefied gas flow was reviewed. A test plan outline is prepared for the purpose of conducting a series of experiments on four rectangular rigid test articles in a vacuum chamber under the effect of continuous and pulsating Nitrogen jet plumes. The purpose of the test plan is to gather enough data related to a number of key parameters to allow the validation of the two-degree-of-freedom mathematical model. The hardware required careful design to select a very lightweight material while satisfying rigidity and frequency requirements within the constraints of the test environment. The data to be obtained from the vacuum chamber tests can be compared with the predicted behavior of the theoretical two-degree-of-freedom model. Using the data obtained in this study, further research can identify the limitations of the mathematical model. In addition modifications to the mathematical model can be made, if warranted, to accurately predict the behavior of rigid panels under rarefied gas flow regimes.

Akl, Fred A.↗
NASA NTRS1999

Ultrasonic Nondestructive Characterization of Adhesive Bonds

Adhesives and adhesive joints are widely used in various industrial applications to reduce weight and costs, and to increase reliability. For example, advances in aerospace technology have been made possible, in part, through the use of lightweight materials and weight-saving structural designs. Joints, in particular, have been and continue to be areas in which weight can be trimmed from an airframe through the use of novel attachment techniques. In order to save weight over traditional riveted designs, to avoid the introduction of stress concentrations associated with rivet holes, and to take full advantage of advanced composite materials, engineers and designers have been specifying an ever-increasing number of adhesively bonded joints for use on airframes. Nondestructive characterization for quality control and remaining life prediction has been a key enabling technology for the effective use of adhesive joints. Conventional linear ultrasonic techniques generally can only detect flaws (delamination, cracks, voids, etc) in the joint assembly. However, more important to structural reliability is the bond strength. Although strength, in principle, cannot be measured nondestructively, a slight change in material nonlinearity may indicate the onset of failure. Furthermore, microstructural variations due to aging or under-curing may also cause changes in the third order elastic constants, which are related to the ultrasonic nonlinear parameter of the polymer adhesive. It is therefore reasonable to anticipate a correlation between changes in the ultrasonic nonlinear acoustic parameter and the remaining bond strength. It has been observed that higher harmonics of the fundamental frequency are generated when an ultrasonic wave passes through a nonlinear material. It seems that such nonlinearity can be effectively used to characterize bond strength. Several theories have been developed to model this nonlinear effect. Based on a microscopic description of the nonlinear interface binding force, a quantitative method was presented. Recently, a comparison between the experimental and simulated results based on a similar theoretical model was presented. A through-transmission setup for water immersion mode-converted shear waves was used to analyze the ultrasonic nonlinear parameter of an adhesive bond. In addition, ultrasonic guided waves have been used to analyze adhesive or diffusion bonded joints. In this paper, the ultrasonic nonlinear parameter is used to characterize the curing state of a polymer/aluminum adhesive joint. Ultrasonic through-transmission tests were conducted on samples cured under various conditions. The magnitude of the second order harmonic was measured and the corresponding ultrasonic nonlinear parameter was evaluated. A fairly good correlation between the curing condition and the nonlinear parameter is observed. The results show that the nonlinear parameter might be used as a good indicator of the cure state for adhesive joints.

Qu, Jianmin↗
NASA NTRS2000

Nanotube Production and Applications at Johnson Space Center

Promise of applications of carbon nanotubes has led to an intense effort at NASA/JSC, especially in the area of nanotube composites. Using the extraordinary mechanical strength of nanotubes, NASA hopes to design this revolutionary lightweight material for use in aerospace applications. Current research focuses on structural polymeric materials to attempt to lower the weight of spacecraft necessary for interplanetary missions. Other applications of nanotubes are also of interest for energy storage, gas storage, nanoelectronics, field emission, and biomedical applications. In pursuit of these goals, we have set up both laser and arc production processes for nanotubes. An in-depth diagnostic study of the plasma plume in front of the laser target has been studied to try to determine nanotube growth mechanisms. Complementary studies of characterization of nanotube product have added to knowledge of growth conditions. Results of our preliminary experiments in incorporating nanotubes into composites will be presented. Morphology and mechanical properties of the nanotubes composites will be discussed.

Nikolaev, Pavel↗