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This paper discusses the Galileo spacecraft adapter: its interface loads and stiffness capability; configuration design/analysis methodology; verification of buckling margin, local stresses, and mass properties; and the basis for graphite-epoxy material selections and tooling approach, as well as the fabrication, layup, machining, assembly, and drilling processes.
The magnetic susceptibilities at 300 K of the acceptor-type intercalation compounds of graphite with Br2 and ICl are calculated; the results are compared with published experimental measurements in graphs; and the charge-transfer parameter f is inferred using a rigid-band model (Loughin et al., 1978; Weinberger et al., 1978; Mattix et al., 1983). Assuming a screening length of 200 pm, the values determined are f = 0.3 for C(8N)Br2 and f = 0.09 for C(13N)ICl.
Results of an experimental and analytical study of the postbuckling behavior of selected curved stiffened graphite-epoxy panels loaded in axial compression are presented. The postbuckling response and failure characteristics of the panels are described. Each panel had four equally-spaced I-shaped stiffeners and 16-ply quasi-isotropic skins. Panels with three different stiffener spacings were tested. Failure of all panels initiated in a skin-stiffener interface region. Analytical results from a nonlinear general shell finite element analysis computer code correlate well with typical postbuckling test results up to failure. The analytical modeling detail necessary to predict accurately the response of the panel is described. Measured initial geometric imperfections were included in the postbuckling analysis.
The C-13 NMR chemical shifts of graphite intercalation compounds have been calculated. For acceptor types, the shifts come mainly from the paramagnetic (Ramsey) intra-atomic terms. They are related to the gross features of the two-dimensional band structures. The calculated anisotropy is about - 140 ppm and is independent of the finer details such as charge transfer. For donor types, the carbon 2p pi orbitals are spin-polarized because of mixing with metal-conduction electrons, thus there is an additional dipolar contribution which may be correlated with the electronic specific heat. The general agreement with experimental data is satisfactory.
The surfaces of the graphite fiber-reinforced polyimide composites presently pretreated prior to bonding with polyimide adhesive contained variable amounts of a fluoropolymer, as determined by X-ray photoelectron spectroscopy. Lap shear strengths were determined for unaged samples and for those aged over 500- and 1000-hour periods at 177 and 232 C. Unaged sample lap strengths, which were the highest obtained, exhibited no variation with surface pretreatment, but a significant decrease is noted with increasing aging temperature. These thermally aged samples, however, had increased surface fluorine concentration, while a minimal concentration was found in unaged samples. SEM demonstrated a progressive shift from cohesive to adhesive failure for elevated temperature-aged composites.
The acoustoultrasonic NDT method proposed by Vary (1976, 1978) for composite laminate damage growth quantitative assessment can both respond to the development of damage states and furnish quantitative parameters that monitor this damage development. Attention is presently given to data obtained for the case of quasi-static loading and fatigue testing of graphite-epoxy laminates. The shape parameters of the power spectral density for the ultrasonic signals correlate well with such other indications of damage development as stiffness degradation.
An effort to evaluate the high temperature performance of a polyimide (PMR-15)-graphite composite which consists of several plies of woven strands of carbon fibers was undertaken. The longterm effect of high temperature on the dry material was studied by exposing polished test specimens of 473 F in a oven for nearly 400 hours. Periodically the specimens were removed and observed microscopically. Gradually surface cracks began to appear and the number of cracks increased over time. At the conclusion of the exposure the specimens were graudually ground down and observed in order to determine the depth of the cracks into the interior of the material. This procedure was repeated at an exposure temperature of 550 F.
The Iosipescu shear test method is used to measure the in-plane and interlaminar shear properties of four T300 graphite fabric/934 epoxy composite materials. Different weave geometries tested include an Oxford weave, a 5-harness satin weave, an 8-harness satin weave, and a plain weave with auxiliary warp yarns. Both orthogonal and quasi-isotropic layup laminates were tested. In-plane and interlaminar shear properties are obtained for laminates of all four fabric types. Overall, little difference in shear properties attributable to the fabric weave pattern is observed. The auxiliary warp material is significantly weaker and less stiff in interlaminar shear parallel to its fill direction. A conventional strain gage extensometer is modified to measure shear strains for use with the Iosipescu shear test. While preliminary results are encouraging, several design iterations failed to produce a reliable shear transducer prototype. Strain gages are still the most reliable shear strain transducers for use with this test method.
A computational procedure for the design of TWT-refocuser-MDC systems was used to design a short dynamic refocusing system and highly efficient four-stage depressed collector for a 200-W, 8- to 18-GHz, TWT. The computations were carried out with advanced, multidimensional computer programs which model the electron beam as a series of disks of charge and follow their trajectories from the RF input of the TWT, through the slow-wave structure and refocusing section, to their points of impact in the depressed collector. Secondary emission losses in the MDC were treated semi-quantitatively by injecting a representative beam of secondary electrons into the MDC analysis at the point of impact of each primary beam. A comparison of computed and measured TWT and MDC performance showed very good agreement. The electrodes of the MDC were fabricated from a particular form of isotropic graphite that was selected for its low secondary electron yield, ease of machinability, and vacuum properties. This MDC was tested (at CW) for more than 1000 hr with negligible degradation in TWT and MDC performances.
In an effort to elucidate the changes in molecular structural and mechanical properties of epoxy/graphite fiber composites upon exposure to ionizing radiation in a simulated space environment, spectroscopic and surface properties of tetraglycidyl-4,4'-diamino diphenyl methane (TGDDM) red with diamino diphenyl sulfone (DDS) and T-300 graphite fiber were investigated following exposure to ionizing radiation. Cobalt-60 gamma radiation and 1/2 MeV electrons were used as radiation sources. The system was studied using electron spin resonance (ESR) spectroscopy, infrared absorption spectroscopy, contact angle measurements, and electron spectroscopy for chemical analysis.
A study was conducted to relate the impact resistance of graphite fiber reinforced composites with matrix properties through gaining an understanding of the basic mechanics involved in the deformation and fracture process, and the effect of the polymer matrix structure on these mechanisms. It was found that the resin matrix structure influences the composite impact resistance in at least two ways. The integration of flexibilizers into the polymer chain structure tends to reduce the T sub g and the mechanical properties of the polymer. The reduction in the mechanical properties of the matrix does not enhance the composite impact resistance because it allows matrix controlled failure to initiate impact damage. It was found that when the instrumented dropweight impact tester is used as a means for assessing resin toughness, the resin toughness is enhanced by the ability of the clamped specimen to deflect enough to produce sufficient membrane action to support a significant amount of the load. The results of this study indicate that crossplied composite impact resistance is very much dependent on the matrix mechanical properties.
Summarized are basic studies that were conducted to correlate the impact resistance of graphite-fiber-reinforced composites with polymer matrix properties. Three crosslinked epoxy resins and a linear polysulfone were selected as composite matrices. As a group, these resins possess a significantly large range of mechanical properties. The mechanical properties of the resins and their respective composites were measured. Neat resin specimens and unidirectional and crossply composite specimens were impact tested with an instrumented dropweight tester. Impact resistances of the specimens were assessed on the basis of loading capability, energy absorption, and extent of damage.
Elasticity solutions for the residual stress state in cross-ply graphite-epoxy tubes subjected to a spatially uniform temperature below the cure temperature are derived. The solutions are valid away from the ends of the tube. Numerical results are presented for three tubes. It is seen that stacking arrangement can affect the residual stresses and that the radial stresses are smaller than the other stress components. The results show that classical lamination theory is in considerable error when the tube radius to wall thickness ratio is less than 20.
An elastomer-toughened epoxy-graphite composite system (CE339/T300) was evaluated for its potential durability in the space radiation environment. The physical and chemical response of this system was characterized following exposure to radiation doses equivalent to 20 to 30 years in geosynchronous orbit using 1 MeV electrons. The results show that electrons generate extensive crosslinking and embrittlement of the matrix. This embrittlement results in chemical and mechanical property changes that would limit the service life of this epoxy system in some space structure applications.
The construction and telescope assembly of the NASA's Hubble Space Telescope (HST) is described with particular reference to the features of its construction material. Due to the hygroscopic nature of the graphite-fiber reinforced epoxy, used for much of the structure of the HST, the telescope, when in orbit, suffers losses of water, absorbed during on-ground procedures, accompanied by shrinkage of the epoxy matrix, and needs periodic realignment. Using a combination of analytic, laboratory measured, and in-space measured data, an operational plan for adjusting the alignment of the HST is presented. The refocusing plan must take into account the preceding ground environment, as well as the prelaunch, lift-off, and predeployment environments of the HST-bearing Space Shuttle.
The critical load levels and associated cracking beyond which a multidirectional laminate can be considered as structurally failed has been determined by loading graphite fiber-reinforced epoxy laminates to different strain levels up to ultimate failure. Transverse matrix cracking was monitored by acoustic and optical methods. The residual stiffness and strength parallel and perpendicular to the cracks were determined and related to the environmental/loading history. Within the range of experimental conditions studied, it is concluded that the transverse cracking process does not have a crucial effect on the structural performance of multidirectional composite laminates.
Graphite fibers intercalated with bromine, iodine monochloride, ferric chloride, and cupric chloride were subjected to stability tests under four environments which are encountered by engineering materials in the aerospace industry: ambient laboratory conditions, as would be experienced during handling operations and terrestrial applications; high vacuum, as would be experienced in space applications; high humidity, as would be experienced in marine applications; and high temperature, as would be experienced in some processing steps and applications. Monitoring the resistance of the fibers at ambient laboratory conditions revealed that only the ferric chloride intercalated fibers were unstable, due to absorption of water from the air. All four types of intercalated fibers were unstable, due to absorption of water from the air. All four types of intercalated fibers were stable for long periods under high vacuum. Ferric chloride, cupric chloride, and iodine monochloride intercalated fibers were sensitive to high humidity conditions. All intercalated fibers began to degrade above 250 C. The order of their thermal stability, from lowest to highest, was cupric chloride, iodine monochloride, bromine, and ferric chloride. Of the four types of intercalated fibers tested, the bromine intercalated fibers appear to have the most potential for application, based on environmental stability.
An anisotropic elasticity crack tip stress analysis is implemented using three crack extension direction criteria (the normal stress ratio, the tensor polynominal and the strain energy density) to predict the direction of crack extension in unidirectional of axis graphite-epoxy. The theoretical predictions of crack extension direction are then compared with experimental results for 15 deg off axis tensile coupons with center cracks. Specimens of various aspect ratios and crack orientations are analyzed. It is shown that only the normal stress ratio criterion predicts the correct direction of crack growth.