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The following advanced composite materials were evaluated for future space shuttle applications: (1) Carbon and boron fiber composites using epoxy and polyimide as resins for stringer and skin panels: (2) high pressure steel tanks where the cylindrical part is reinforced by carbon fiber; and (3) an orbiter cargo door in boron fiber and polyimide resin.
This viewgraph presentation includes the following main concepts. Goal: To evaluate Raman spectroscopy as a potential NDE tool for the detection of stress rupture in Kevlar. Objective: Test a series of strand samples that have been aged under various conditions and evaluate differences and trends in the Raman response. Hypothesis: Reduction in strength associated with stress rupture may manifest from changes in the polymer at a molecular level. If so, than these changes may effect the vibrational characteristics of the material, and consequently the Raman spectra produced from the material. Problem Statement: Kevlar composite over-wrapped pressure vessels (COPVs) on the space shuttles are greater than 25 years old. Stress rupture phenomena is not well understood for COPVs. Other COPVs are planned for hydrogen-fueled vehicles using Carbon composite material. Raman spectroscopy is being explored as an non-destructive evaluation (NDE) technique to predict the onset of stress rupture in Kevlar composite materials. Test aged Kevlar strands to discover trends in the Raman response. Strength reduction in Kevlar polymer will manifest itself on the Raman spectra. Conclusions: Raman spectroscopy has shown relative changes in the intensity and FWHM of the ~1613 cm(exp -1) peak. Reduction in relative intensity for creep, fleet leader, and SIM specimens compared to the virgin strands. Increase in FWHM has been observed for the creep and fleet leader specimens compared to the virgin strands. Changes in the Raman spectra may result from redistributing loads within the material due to the disruption of hydrogen bonding between crystallites or defects in the crystallites from aging the Kevlar strands. Peak shifting has not been observed to date. Analysis is ongoing. Stress measurements may provide a tool in the short term.
In support of the design of wind turbine generator airfoils/blades utilizing Douglas Fir/West System Epoxy laminated composite material, a program was undertaken to define pertinent material properties utilizing small scale test specimens. Task 1 was the development of suitable monotonic tension, compression, short beam shear and full reversed cyclic specimen designs and the companion grips and testing procedures. Task 2 was the generation of the material properties at two environmental conditions utilizing the specimens and procedures developed in Task 1. The monotonic specimens and procedures generated results which compare favorably with other investigators while the cyclic results appear somewhat conservative. Adding moisture and heat or scarf joints degraded the monotonic performance but had a more nebulus effect with cyclic loading.
Materials structures research within framework of mechanical constitutive equation, reviewing fiber reinforced composites from microscopic to macroscopic viewpoints
Designing fiber-reinforced polymer composites (FRPCs) with a tailored nonlinear stress-strain response is crucial for applications such as energy absorption in crash structures, flexible robotics, and impact-resistant protective gear. However, the inherent complexities of composite materials and the multitude of parameters involved, render traditional design and optimization methods inadequate for achieving effective inverse design of composites. In this paper, we present an AI-based inverse design framework that effectively and efficiently generates FRPCs with targeted nonlinear stress-strain responses. We introduce a physically constrained diffusion model (PC3D_Diffusion) capable of managing the complexities of composite materials and producing detailed, high-quality designs. We propose a loss-guided, learning-free approach to generate physically feasible microstructure designs by explicitly enforcing physical constraints during the generation process. For training purposes, 1.35 million FRPC samples were created, and their corresponding stress-strain curves were computed using established physics-based computational models. The results show that PC3D_Diffusion consistently generates high-quality designs with tailored mechanical behaviors, while guaranteeing compliance with the physical constraints. PC3D_Diffusion advances FRPC inverse design and may facilitate the inverse design of other 3D materials, offering potential applications in industries reliant on materials with custom mechanical properties.
The increased use of high-temperature composite materials in modern and next generation aircraft and spacecraft have led to the need for improved nondestructive evaluation and health monitoring techniques. Such technologies are desirable to improve quality control, damage detection, stress evaluation and temperature measurement capabilities. Novel eddy current sensors and sensor arrays, such as Meandering Winding Magnetometers (MWMs) have provided alternate or complimentary techniques to ultrasound and thermography for both nondestructive evaluation (NDE) and structural health monitoring (SHM). This includes imaging of composite material quality, damage detection and .the monitoring of fiber temperatures and multidirectional stresses. Historically, implementation of MWM technology for the inspection of the Space Shuttle Orbiter Reinforced Carbon-Carbon Composite (RCC) leading edge panels was developed by JENTEK Sensors and was subsequently transitioned by NASA as an operational pre and post flight in-situ inspection at the Kennedy Space Center. A manual scanner, which conformed'automatically to the curvature of the RCC panels was developed and used as a secondary technique if a defect was found during an infrared thermography screening, During a recent proof of concept study on composite overwrapped pressure vessels (COPV's), three different MWM sensors were tested at three orientations to demonstrate the ability of the technology to measure stresses at various fiber orientations and depths. These results showed excellent correlation with actual surface strain gage measurements. Recent advancements of this technology have been made applying MWM sensor technology for scanning COPVs for mechanical damage. This presentation will outline the recent advance~ in the MWM.technology and the development of MWM techniques for NDE and SHM of carbon wra~ped composite overwrapped pressure vessels (COPVs) including the measurement of internal stresses via a surface mounted sensor array. In addition, this paper will outline recent efforts to produce sensors capable of making real-time measurements at temperatures up to 850 C, and discuss previous results demonstrating capability to monitor carbon fiber temperature changes within a composite material.
The NASA Aircraft Energy Efficiency (ACEE) Composite Primary Aircraft Structures Program was designed to develop technology for advanced composites in commercial aircraft. Research on composite materials, aircraft structures, and aircraft design is presented herein. The following parameters of composite materials were addressed: residual strength, damage tolerance, toughness, tensile strength, impact resistance, buckling, and noise transmission within composite materials structures.
The use of composite materials for a variety of practical structural applications is presented and the need for an accelerated characterization procedure is assessed. A new experimental and analytical method is presented which allows the prediction of long term properties from short term tests. Some preliminary experimental results are presented.
Celion 6000/V378A graphite/bismaleimide composite materials were aged in air at temperatures of 177, 204, 232 and 260 deg C for various times up to 15,000 hours. Three unidirectional specimen types were aged: short beam shear (SBS), flexure, and 153 mm square panels. Aged specimens of V378A laminates exhibited excellent thermal stability. Extensive cracking was observed during aging on the 0 deg edges of the unidirectional laminates. These cracks penetrated as deep as 12 mm from the edge. The cracking appeared to have little or no effect on the observed properties of the laminates. The study indicates that the useful life of unrestrained unidirectional graphite/V378A laminates is 10,000 hours or greater at 177 C to 232 C and 2,000 to 2,000 hour at 260 C.
The Aerospace Industries Association, Suppliers of Advanced Composite Materials Association, and the National Aeronautics and Space Administration co-sponsored a conference on 'Environmental, Safety, and Health Considerations--Composite Materials in the Aerospace Industry.' The conference was held in Mesa, Arizona, on October 20-21, 1994. Seventeen papers were presented in four sessions including general information, safety, waste, and emissions from composites. Topics range from product stewardship, best work practice, biotransformation of uncured composite materials, to hazardous waste determination and offgassing of composite materials.
New textile composite materials development, production, and application are discussed. Topics covered include: super-high-strength, super-high-modulus fibers, filaments, and materials manufactured on their basis; heat-resistant and nonflammable fibers, filaments, and textile fabrics; fibers and textile fabrics based on fluorocarbon poylmers; antifriction textile fabrics based on polyfen filaments; development of new types of textile combines and composite materials; and carbon filament-based fabrics.
As the use of advanced composite materials continues to increase in the aerospace community, the need for a quantitative, rapid, in situ inspection technology has become a critical concern throughout the industry. In many applications it is necessary to monitor changes in these materials over an extended period of time to determine the effects of various load conditions. Additionally, the detection and characterization of defects such as delaminations, is of great concern. This paper will present the application of infrared thermography to characterize various composite materials and show the advantages of different heat source types. Finally, various analysis methodologies used for quantitative material property characterization will be discussed.
Carbon fiber/polymer matrix composite materials look promising as a material to construct liquid oxygen (LOX) tanks. Based on mechanical impact tests the risk will be greater than aluminum, however, the risk can probably be managed to an acceptable level. Proper tank design and operation can minimize risk. A risk assessment (hazard analysis) will be used to determine the overall acceptability for using polymer matrix composite materials.
The utilization of composite materials in the Space Shuttle and Advanced Space Transportation Programs is reviewed. Topics include goals and challenges, descriptions of multi-generational launch vehicles, and an overview of composite materials research and technologies that support program objectives. A brief discussion of planned composite materials research and technology concludes the presentation.
Composite materials are discussed with emphasis on the identification of the characteristics of those materials that make them attractive for use in surface transportation. Potential uses of graphite composites are given including automotive applications and the effects of materials substitution on vehicle characteristics and performance. Preliminary estimates of the economic effects of the use of graphite composite materials on vehicle manufacturers and consumers are included. The combined impact on the national economy of vehicle design changes to meet mandated fuel efficiency requirements and the extensive use of graphite composite materials in the automotive industry is considered.
Space travel is inherently dangerous and, currently, quite expensive. NASA has always done everything possible to minimize the risk associated with the materials chosen for space travel applications by requiring that all materials associated with NASA programs meet the strict requirements established by NASA testing standard NASA-STD-600 1 Flammability, Odor, Offgassing, and Compatibility Requirements and Test Procedures for Materials in Environments that Support Combustion. NASA also has the need to develop lighter weight structural materials that will allow more payload weight to be carried into space. NASA is utilizing composite materials inside the orbiter to lighten the overall weight, but has not considered composite materials for oxygen tanks because of the inherent incompatibility of composite materials with atomic oxygen. This presentation will focus on how oxygen tanks can be built from composite materials. Details will be provided for the design and compatibility testing techniques that will be utilized to create a new NASA standard, NASA-HDBK-6018, which will serve as the starting point for the design of oxygen tanks made from composite materials.
There are a number of interface-dominated composite materials that contain a liquid crystalline (LC) phase in intimate contact with an isotropic phase. For example, polymer- dispersed liquid crystals, used in the fabrication of windows with switchable transparency, consist of micron size LC droplets dispersed in an isotropic polymer matrix. Many other types of liquid crystal composite materials can be envisioned that might have outstanding optical properties that could be exploited in novel chemical sensors, optical switches, and computer displays. This research project was based on the premise that many of these potentially useful LC composite materials can only be fabricated under microgravity conditions where gravity driven flows are absent. In the ground-based research described below, we have focused on a new class of LC composites that we call thermotropic- lyotropic liquid crystal systems (TLLCs). TLLCs consist of nanosize droplets of water dispersed in an LC matrix, with surfactants at the interface that stabilize the structure. By varying the type of surfactant one can access almost an infinite variety of unusual LC composite microstructures. Due to the importance of the interface in these types of systems, we have also developed molecular simulation models for liquid crystals at interfaces, and made some of the first measurements of the interfacial tension between liquid crystals and water.
Double-cantilever beam fracture toughness tests were performed by the Composite Materials Research Group on several different unidirectional composite materials provided by NASA Langley Research Center. The composite materials consisted of Hercules IM-7 carbon fiber and various matrix resin formulations. Multiple formulations of four different families of matrix resins were tested: LaRC - ITPI, LaRC - IA, RPT46T, and RP67/RP55. Report presents the materials tested and pertinent details supplied by NASA. For each material, three replicate specimens were tested. Multiple crack extensions were performed on each replicate.