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This viewgraph presentation provides information on quality control standards in mechanical engineering. The presentation addresses safety, structural loads, nonmetallic composite structural elements, bonded structural joints, externally induced shock, random vibration, acoustic tests, and mechanical function.
Under the Integrated Vehicle Health Management (IVHM) program work was begun to investigate the feasibility of sensor systems for detecting and diagnosing damage to aircraft composite structures and materials. Specific interest for this study was in damage initiated by environmental storm hazards and the direct effect of lightning strikes on the material structures of a composite aircraft in flight. A series of open circuit resonant sensors was designed, fabricated, characterized, and determined to be a potentially viable means for damage detection and diagnosis of composite materials. The results of this research and development effort are documented in this report.
Polycyclic aromatic hydrocarbon (PAH) emission in the Spitzer Infrared Spectrograph spectral map of the northwest photon dominated region (PDR) in NGC 7023 was analyzed exclusively using PAH spectra from the NASA Ames PAH IR Spectroscopic Database (www.astrochem.org/pahdb). The 5-15 micron spectrum at each pixel is fitted using a non-negative-least-squares fitting approach. The fits are of good quality, allowing decomposition of the PAH emission into four subclasses: size, charge, composition, and hydrogen adjacency (structure). Maps tracing PAH subclass distributions across the region paint a coherent astrophysical picture. Once past some 20 seconds of arc from HD 200775, the emission is dominated by the more stable, large, symmetric, compact PAH cations with smaller, neutral PAHs taking over along the lines-of-sight toward the more distant molecular cloud. The boundary between the PDR and the denser cloud material shows up as a distinct discontinuity in the breakdown maps. Noteworthy is the requirement for PANH cations to fit the bulk of the 6.2 and 11.0 micron features and the indication of PAH photo-dehydrogenation and fragmentation close to HD 200775. Decomposition of the spectral maps into "principal" subclass template spectra provides additional insight into the behavior of each subclass. However, the general applicability of this computationally more efficient approach is presently undetermined. This is the first time the spectra of individual PAHs are exclusively used to fit the 5-15 micron region and analyze the spatial behavior of the aromatic infrared bands, providing fundamental, new information about astronomical PAH subpopulations including their dependence on, and response to, changes in local conditions.
NiAl is being evaluated as a potential matrix material as part of an overall program to develop and understand high-temperature structural composites. Currently, continuous fiber composites have been fabricated by the powder cloth technique incorporating either W(218) or single crystal Al2O3 fibers as reinforcements in both binary NiAl and a solute strengthened NiAl(.05 at. pct Zr) matrix. Initial evaluation of these composite systems have included: fiber push-out testing to measure matrix/fiber bond strengths, bend testing to determine strength as a function of temperature and composite structure, and thermal cycling to establish the effect of matrix and fiber properties on composite life. The effect of matrix/fiber bond strength and matrix strength on several composite properties will be discussed.
Seismic data from Apollo Passive Seismic Network stations are analyzed to determine the velocity structure in the lunar crust and mantle. Since the publication of earlier results additional data has become available from the S-IVB impacts of the Apollo 16 and 17 missions and the LM ascent stage impact of the Apollo 17 mission. Data from these artificial impacts now cover a distance range of 9 to 1700 km. Travel times, amplitudes, and theoretical seismograms are used to derive a velocity structure for the outer 150 km of the moon. Preliminary results are given from the analysis of the complete set of seismograms.
The effect of low velocity impact on the strength of laminates fabricated from graphite/epoxy and Kevlar 49/epoxy composite materials was studied. The test laminates were loaded statically either in uniaxial tension or compression when impact occurred to evaluate the effect of loading on the initiation of damage and/or failure. Typical aircraft service conditions such as runway debris encountered during landing were simulated by impacting 1.27-cm-diameter projectiles normal to the plane of the test laminates at velocities between 5.2 and 48.8 m/s.
A reliability based design methodology for laminate sizing and configuration for a special case of composite structures is described. The methodology combines probabilistic composite mechanics with probabilistic structural analysis. The uncertainties of constituent materials (fiber and matrix) to predict macroscopic behavior are simulated using probabilistic theory. Uncertainties in the degradation of composite material properties are included in this design methodology. A multi-factor interaction equation is used to evaluate load and environment dependent degradation of the composite material properties at the micromechanics level. The methodology is integrated into a computer code IPACS (Integrated Probabilistic Assessment of Composite Structures). Versatility of this design approach is demonstrated by performing a multi-level probabilistic analysis to size the laminates for design structural reliability of random type structures. The results show that laminate configurations can be selected to improve the structural reliability from three failures in 1000, to no failures in one million. Results also show that the laminates with the highest reliability are the least sensitive to the loading conditions.
NASA has been a leader in development of composite materials for aircraft applications during the past 25 years. In the early 1980's NASA and others conducted research to improve damage tolerance of composite structures through the use of toughened resins but these resins were not cost-effective. The aircraft industry wanted affordable, robust structures that could withstand the rigors of flight service with minimal damage. The cost and damage tolerance barriers of conventional laminated composites led NASA to focus on new concepts in composites which would incorporate the automated manufacturing methods of the textiles industry and which would incorporate through-the-thickness reinforcements. The NASA Advanced Composites Technology (ACT) Program provided the resources to extensively investigate the application of textile processes to next generation aircraft wing and fuselage structures. This paper discusses advanced textile material forms that have been developed, innovative machine concepts and key technology advancements required for future application of textile reinforced composites in commercial transport aircraft. Multiaxial warp knitting, triaxial braiding and through-the-thickness stitching are the three textile processes that have surfaced as the most promising for further development. Textile reinforced composite structural elements that have been developed in the NASA ACT Program are discussed. Included are braided fuselage frames and window-belt reinforcements, woven/stitched lower fuselage side panels, stitched multiaxial warp knit wing skins, and braided wing stiffeners. In addition, low-cost processing concepts such as resin transfer molding (RTM), resin film infusion (RFI), and vacuum-assisted resin transfer molding (VARTM) are discussed. Process modeling concepts to predict resin flow and cure in textile preforms are also discussed.
A surface fragment of 60017, itself an exposed section of Shadow Rock, has been characterized structurally and chemically using gas adsorption, helium pycnometry, scanning electron microscopy, and Auger and ESCA spectroscopy. The fragment is seen as a partially melted devitrified-glass impact breccia possessing a relatively low surface area, macroporosity, and low absolute density. The fragment appears to be plagioclase-enriched with respect to 60017 and to possess significant surface heterogeneity. Confirmation of the surface reduction of iron was obtained; however, the extent of this reduction varied from point to point. Significant amounts of surface volatiles were also found, and it is hypothesized that these were released during the North Ray cratering event. If this is proved correct, similar volatile concentrations should be found on other North Ray ejecta.
Theoretical lunar mantle seismic velocity and density profiles were calculated for a series of specific bulk composition models, thermal models, and evolutionary models. It was found that most of the calculated seismic profiles are in qualitative agreement with the Nakamura (1983) observational mantle seismic velocity model. With respect to the density modeling results, the most interesting finding is that none of the considered models yield mantle density increases that are sufficient to match the adapted upper bound on the lunar moment-of-inertia factor (0.3928). The results suggest that the moon possesses a dense metallic core with a mass in the range of 1 to 4 percent of the lunar mass and that the alumina-rich models of Morgan et al. (1978) and Taylor (1982) are best able to match the middle mantle velocity increase that characterizes the Nakamura model.
By forming composite structures with Carbon Nanotube (CNT) yarns we achieve materials capable of measuring strain and composite structures with increased mechanical strength. The CNT yarns used are of the 2-ply and 4-ply variety with the yarns having diameters of about 15-30 micrometers. The strain sensing characteristics of the yarns are investigated on test beams with the yarns arranged in a bridge configuration. Additionally, the strain sensing properties are also investigated on yarns embedded on the surface of a flexible membrane. Initial mechanical strength tests also show an increase in the modulus of elasticity of the composite materials while incurring a weight penalty of less than one-percent. Also presented are initial temperature characterizations of the yarns.
Composite cure process induced residual strains and warping deformations in composite components present significant challenges in the manufacturing of advanced composite structure. As a part of the Manufacturing Process and Simulation initiative of the NASA Advanced Composite Project (ACP), research is being conducted on the composite cure process by developing an understanding of the fundamental mechanisms by which the process induced factors influence the residual responses. In this regard, analytical studies have been conducted on the cure process modeling of composite structural parts with varied physical, thermal, and resin flow process characteristics. The cure process simulation results were analyzed to interpret the cure response predictions based on the underlying physics incorporated into the modeling tool. In the cure-kinetic analysis, the model predictions on the degree of cure, resin viscosity and modulus were interpreted with reference to the temperature distribution in the composite panel part and tool setup during autoclave or hot-press curing cycles. In the fiber-bed compaction simulation, the pore pressure and resin flow velocity in the porous media models, and the compaction strain responses under applied pressure were studied to interpret the fiber volume fraction distribution predictions. In the structural simulation, the effect of temperature on the resin and ply modulus, and thermal coefficient changes during curing on predicted mechanical strains and chemical cure shrinkage strains were studied to understand the residual strains and stress response predictions. In addition to computational analysis, experimental studies were conducted to measure strains during the curing of laminated panels by means of optical fiber Bragg grating sensors (FBGs) embedded in the resin impregnated panels. The residual strain measurements from laboratory tests were then compared with the analytical model predictions. The paper describes the cure process procedures and residual strain predications, and discusses pertinent experimental results from the validation studies.
This first interim report presents the technical background for including environmental effects in the design of helicopter composite structures, and test results after approximately two year field exposure of components and panels. Composite structural components were removed from Sikorsky S-76 helicopters commercially operated in the Gulf Coast region of Louisiana. Fatigue tests were conducted for a graphite/epoxy tail rotor spar and static test for a graphite/epoxy and Kevlar/epoxy stabilizer. Graphite/epoxy and Kevlar/epoxy panels are being exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. For this reporting period the two year panels were returned, moisture measurements taken, and strength tests conducted. Results are compared with initial type certificate strengths for components and with initial laboratory coupon tests for the exposed panels. Comparisons are also presented with predicted and measured moisture contents.
This first interim report presents the technical background for including environmental effects in the design of helicopter composite structures, and test results after approximately two year field exposure of components and panels. Composite structural components were removed from Sikorsky S-76 helicopters commercially operated in the Gulf Coast region of Louisiana. Fatigue tests were conducted for a graphite/epoxy tail rotor spar and static test for a graphite/epoxy and Kevlar/epoxy stabilizer. Graphite/epoxy and Kevlar/epoxy panels are being exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. For this reporting period the two year panels were returned, moisture measurements taken, and strength tests conducted. Results are compared with initial type certificate strengths for components and with initial laboratory coupon tests for the exposed panels. Comparisons are also presented with predicted and measured moisture contents.
NASA Langley has a long history of attacking important technical Opportunities from a broad base of supporting disciplines. The research and development at Langley in this subject area range from the test tube to the test flight, The information covered here will range from the development of innovative new materials, sensors and actuators, to the incorporation of smart sensors and actuators in practical devices, to the optimization of the location of these devices, to, finally, a wide variety of applications of these devices utilizing Langley's facilities and expertise. Advanced materials are being developed for sensors and actuators, as well as polymers for integrating smart devices into composite structures. Contributions reside in three key areas: computational materials; advanced piezoelectric materials; and integrated composite structures.
The properties of planetary ring systems are summarized herein; emphasis is given to the available evidence on their compositions and to their dynamical attributes. Somewhat contaminated water ice makes up the vast expanse of Saturn's rings. Modified methane ice may comprise Uranus' rings while silicates are the likely material of the Jovian ring. Saturn's rings form an elaborate system whose characteristics are still being documented and whose nature is being unravelled following the Voyager flybys. Uranus' nine narrow bands display an intriguing dynamical structure thought to be caused by unseen shephard satellites. Jupiter's ring system is a mere wisp, probably derived as ejecta off hidden parent bodies.
A general analysis method is presented to predict matrix cracks in all plies of a composite laminate, and resulting degraded laminate properties, as functions of temperature or thermal cycles. A shear lag solution of the stresses in the vicinity of cracks and a fracture mechanics crack formation criteria are used to predict cracks. Damage is modeled incrementally, which allows the inclusion of the effects of temperature dependent material properties and softening of the laminate due to previous cracking. The analysis is incorporated into an easy-to-use computer program. The analysis is correlated with experimentally measured crack densities in a variety of laminates exposed to monotonically decreasing temperatures. Crack densities are measured at the edges of specimens by microscopic inspection, and throughout the specimen volumes by x-ray and sanding down of the edges. Correlation between the analytical results and the crack densities in the interiors of the specimens was quite good. Crack densities measured at specimen edges did not agree with internal crack densities (or analyses) in some cases. A free-edge stress analysis clarified the reasons for these discrepancies.
Several Bragg-grating sensors fabricated within the same optical fiber are buried within multiple-ply carbon-epoxy planar and cylindrical structures. Effect of different orientation of fiber-sensors with respect to carbon fibers in the composite structure is investigated. This is done for both fabric and uni-tape material samples. Response of planar structures to axial and transverse strain up to 1 millistrain is investigated with distributed Bragg-grating sensors. Material properties like Young's Modulus and Poisson ratio is measured. A comparison is made between response measured by sensors in different ply-layers and those bonded on the surface. The results from buried fiber- sensors do not completely agree with surface bonded conventional strain gauges. A plausible explanation is given for observed differences. The planar structures are subjected to impacts with energies up to 10 ft-lb. Effect of this impact on the material stiffness is also investigated with buried fiber-optic Bragg sensors. The strain response of such optical sensors is also measured for cylindrical carbon-epoxy composite structures. The sensors are buried within the walls of the cylinder as well as surface bonded in both the axial as well as hoop directions. The response of these fiber-optic sensors is investigated by pressurizing the cylinder up to its burst pressure of around 1500 psi. This is done at both room temperature as well as cryogenic temperatures. The recorded response is compared with that from a conventional strain gauge.