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At least 811 records · Page 45

Nonlinear analyses of composite aerospace structures in sonic fatigue

This report summarizes the semiannual research progress, accomplishments, and future plans performed under the NASA Langley Research Center Grant No. NAG-1-1358. The primary research effort of this project is the development of analytical methods for the prediction of nonlinear random response of composite aerospace structures subjected to combined acoustic and thermal loads. The progress, accomplishments, and future plates on four sonic fatigue research topics are described. The sonic fatigue design and passive control of random response of shape memory alloy hybrid composites presented in section 4, which is suited especially for HSCT, is a new initiative.

Mei, Chuh↗

Technology integration box beam failure study

Composite structures have the potential to be cost-effective, structurally efficient primary aircraft structures. The Advanced Composites Technology (ACT) Program has the goal to develop the technology to exploit this potential for heavily loaded aircraft structures. As part of the ACT Program, Lockheed Aeronautical Systems Company completed the design and fabrication of the Technology Integration Box Beam (TIBB). The TIBB is an advanced composite prototype structure for the center wing section of the C-130 aircraft. Lockheed subjected the TIBB to downbending, upbending, torsion and combined upbending and torsion load conditions to verify the design. The TIBB failed at 83 percent of design ultimate load for the combined upbending and torsion load condition. The objective of this paper is to describe the mechanisms that led to the failure of the TIBB. The results of a comprehensive analytical and experimental study are presented. Analytical results include strain and deflection results from both a global analysis of the TIBB and a local analysis of the failure region. These analytical results are validated by experimental results from the TIBB tests. The analytical and experimental results from the TIBB tests are used to determine a sequence of events that resulted in failure of the TIBB. A potential cause of failure is high stresses in a stiffener runout region. Analytical and experimental results are also presented for a stiffener runout specimen that was used to simulate the TIBB failure mechanisms.

Shuart, M. J.↗

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Analysis and Testing of a Metallic Repair Applicable to Pressurized Composite Aircraft Structure

Development of repair technology is vital to the long-term application of new structural concepts on aircraft structure. The design, analysis, and testing of a repair concept applicable to a stiffened composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure was recently completed. The damage scenario considered was a mid-bay to mid-bay saw-cut with a severed stiffener, flange, and skin. A bolted metallic repair was selected so that it could be easily applied in the operational environment. The present work describes results obtained from tension and pressure panel tests conducted to validate both the repair concept and finite element analysis techniques used in the design effort. Simulation and experimental strain and displacement results show good correlation, indicating that the finite element modeling techniques applied in the effort are an appropriate compromise between required fidelity and computational effort. Static tests under tension and pressure loadings proved that the proposed repair concept is capable of sustaining load levels that are higher than those resulting from the current working stress allowables. Furthermore, the pressure repair panel was subjected to 55,000 pressure load cycles to verify that the design can withstand a life cycle representative for a transport category aircraft. These findings enable upward revision of the stress allowables that had been kept at an overly-conservative level due to concerns associated with repairability of the panels. This conclusion enables more weight efficient structural designs utilizing the composite concept under investigation.

Przekop, Adam↗

Nondestructive characterization of the elastic constants of fiber reinforced composites

Composite structural components may be subjected to a variety of defects resulting in a sharp reduction in their load carrying capacity or even catastrophic failure. Thus, it is extremely important to have the means to monitor the degradation suffered by critical components of a structure for safe operation during its service life. A nondestructive method based on ultrasonics has recently been developed for the quantitative evaluation of composite structural components during service. The experimental part of the technique uses a two-transducer, pitch-catch type arrangement to generate a variety of elastic waves within the specimen immersed in water. The recorded reflection data are then analyzed by means of a theoretical model to back out the relevant properties. In this paper the method is applied to determine the stiffness constants of unidirectional graphite/epoxy materials. The measurements are shown to be efficient and sufficiently accurate so that it can be used for early detection of material degradation in composite structural elements during service.

Mal, Ajit K.↗

Application of Laser Based Ultrasound for NDE of Damage in Thick Stitched Composites

As design engineers implement new composite systems such as thick, load bearing composite structures, they must have certifiable confidence in structure s durability and worthiness. This confidence builds from understanding the structural response and failure characteristics of simple components loaded in testing machines to tests on full scale sections. Nondestructive evaluation is an important element which can provide quantitative information on the damage initiation, propagation, and final failure modes for the composite structural components. Although ultrasound is generally accepted as a test method, the use of conventional ultrasound for in-situ monitoring of damage during tests of large structures is not practical. The use of lasers to both generate and detect ultrasound extends the application of ultrasound to in- situ sensing of damage in a deformed structure remotely and in a non-contact manner. The goal of the present research is to utilize this technology to monitor damage progression during testing. The present paper describes the application of laser based ultrasound to quantify damage in thick stitched composite structural elements to demonstrate the method. This method involves using a Q-switched laser to generate a rapid, local linear thermal strain on the surface of the structure. This local strain causes the generation of ultrasonic waves into the material. A second laser used with a Fabry-Perot interferometer detects the surface deflections. The use of fiber optics provides for eye safety and a convenient method of delivering the laser over long distances to the specimens. The material for these structural elements is composed of several stacks of composite material assembled together by stitching through the laminate thickness that ranging from 0.5 to 0.8 inches. The specimens used for these nondestructive evaluation studies had either impact damage or skin/stiffener interlaminar failure. Although little or no visible surface damage existed, internal damage was detected by laser based ultrasound.

Anastasi, Robert F.↗

A Six-Node Curved Triangular Element and a Four-Node Quadrilateral Element for Analysis of Laminated Composite Aerospace Structures

Mathematical development and some computed results are presented for Mindlin plate and shell elements, suitable for analysis of laminated composite and sandwich structures. These elements use the conventional 3 (plate) or 5 (shell) nodal degrees of freedom, have no communicable mechanisms, have no spurious shear energy (no shear locking), have no spurious membrane energy (no membrane locking) and do not require arbitrary reduction of out-of-plane shear moduli or under-integration. Artificial out-of-plane rotational stiffnesses are added at the element level to avoid convergence problems or singularity due to flat spots in shells. This report discusses a 6-node curved triangular element and a 4-node quadrilateral element. Findings show that in regular rectangular meshes, the Martin-Breiner 6-node triangular curved shell (MB6) is approximately equivalent to the conventional 8-node quadrilateral with integration. The 4-node quadrilateral (MB4) has very good accuracy for a 4-node element, and may be preferred in vibration analysis because of narrower bandwidth. The mathematical developments used in these elements, those discussed in the seven appendices, have been applied to elements with 3, 4, 6, and 10 nodes and can be applied to other nodal configurations.

Martin, C. Wayne↗

Composite Interstage Structural Concept Down Select Process and Results

NASA's Advanced Composites Technologies (ACT) project evaluated several composite construction options for the Ares V Interstage to support the Constellation Program's goal of reducing the mass of vehicle dry structures. In Phase 1 of the project, eight candidate construction concepts were evaluated for the Ares V Interstage design. Trade studies were performed using finite element analyses to determine weight estimates for the construction concepts. An evaluation process was then used to down select the construction concepts down to two concepts for further consideration in Phase 2 of the project. In Phase 2 of the project, additional trade studies were performed using detailed finite element analyses of the Interstage and a final down select process was used to choose the recommended Interstage construction concept. The results of the study showed that a honeycomb sandwich design was the most favorable Interstage construction concept based on advantages in manufacturing cost. Details of the Phase 1 and Phase 2 trade studies and down select process with final results are presented in the paper.

Sleight, David W.↗

Advanced tow placement of composite fuselage structure

The Hercules NASA ACT program was established to demonstrate and validate the low cost potential of the automated tow placement process for fabrication of aircraft primary structures. The program is currently being conducted as a cooperative program in collaboration with the Boeing ATCAS Program. The Hercules advanced tow placement process has been in development since 1982 and was developed specifically for composite aircraft structures. The second generation machine, now in operation at Hercules, is a production-ready machine that uses a low cost prepreg tow material form to produce structures with laminate properties equivalent to prepreg tape layup. Current program activities are focused on demonstration of the automated tow placement process for fabrication of subsonic transport aircraft fuselage crown quadrants. We are working with Boeing Commercial Aircraft and Douglas Aircraft during this phase of the program. The Douglas demonstration panels has co-cured skin/stringers, and the Boeing demonstration panel is an intricately bonded part with co-cured skin/stringers and co-bonded frames. Other aircraft structures that were evaluated for the automated tow placement process include engine nacelle components, fuselage pressure bulkheads, and fuselage tail cones. Because of the cylindrical shape of these structures, multiple parts can be fabricated on one two placement tool, thus reducing the cost per pound of the finished part.

Anderson, Robert L.↗

Wholly Aromatic Ether-Imides as n-Type Semiconductors

Some wholly aromatic ether-imides consisting of rod-shaped, relatively-low-mass molecules that can form liquid crystals have been investigated for potential utility as electron-donor-type (ntype) organic semiconductors. It is envisioned that after further research to improve understanding of their physical and chemical properties, compounds of this type would be used to make thin film semiconductor devices (e.g., photovoltaic cells and field-effect transistors) on flexible electronic-circuit substrates. This investigation was inspired by several prior developments: Poly(ether-imides) [PEIs] are a class of engineering plastics that have been used extensively in the form of films in a variety of electronic applications, including insulating layers, circuit boards, and low-permittivity coatings. Wholly aromatic PEIs containing naphthalene and perylene moieties have been shown to be useful as electrochromic polymers. More recently, low-molecular-weight imides comprising naphthalene-based molecules with terminal fluorinated tails were shown to be useful as n-type organic semiconductors in such devices as field-effect transistors and Schottky diodes. Poly(etherimide)s as structural resins have been extensively investigated at NASA Langley Research Center for over 30 years. More recently, the need for multi-functional materials has become increasingly important. This n-type semiconductor illustrates the scope of current work towards new families of PEIs that not only can be used as structural resins for carbon-fiber reinforced composites, but also can function as sensors. Such a multi-functional material would permit so-called in-situ health monitoring of composite structures during service. The work presented here demonstrates that parts of the PEI backbone can be used as an n-type semiconductor with such materials being sensitive to damage, temperature, stress, and pressure. In the near future, multi-functional or "smart" composite structures are envisioned to be able to communicate such important parameters to the flight crew and provide vital information with respect to the operational status of their aircraft.

Weiser, Erik↗

Method and Apparatus for Non-Destructive Evaluation of Materials

Methods and apparatus for characterizing composite materials for manufacturing quality assurance (QA), periodic inspection during the useful life, or for forensic analysis/material testing. System are provided that relate eddy-current sensor responses to the fiber layup of a composite structure, the presence of impact damage on a composite structure with or without a metal liner, volumetric stress within the composite, fiber tow density, and other NDE inspection requirements. Also provided are systems that determine electromagnetic material properties and material dimensions of composite materials from capacitive sensor inspection measurements. These properties are related to the presence of buried defects in non-conductive composite materials, moisture ingress, aging of the material due to service or environmental/thermal exposure, or changes in manufacturing quality.

Goldfine, Neil J.↗

Method and Apparatus for Non-Destructive Evaluation of Materials

Methods and apparatus for characterizing composite materials for manufacturing quality assurance (QA), periodic inspection during the useful life, or for forensic analysis/material testing. System are provided that relate eddy-current sensor responses to the fiber layup of a composite structure, the presence of impact damage on a composite structure with or without a metal liner, volumetric stress within the composite, fiber tow density, and other NDE inspection requirements. Also provided are systems that determine electromagnetic material properties and material dimensions of composite materials from capacitive sensor inspection measurements. These properties are related to the presence of buried defects in non-conductive composite materials, moisture ingress, aging of the material due to service or environmental/thermal exposure, or changes in manufacturing quality.

Goldfine, Neil J.↗

Land management explains major trends in forest structure and composition over the last millennium in California’s Klamath Mountains

Significance We provide the first assessment of aboveground live tree biomass in a mixed conifer forest over the late Holocene. The biomass record, coupled with local Native oral history and fire scar records, shows that Native burning practices, along with a natural lightning-based fire regime, promoted long-term stability of the forest structure and composition for at least 1 millennium in a California forest. This record demonstrates that climate alone cannot account for observed forest conditions. Instead, forests were also shaped by a regime of frequent fire, including intentional ignitions by Native people. This work suggests a large-scale intervention could be required to achieve the historical conditions that supported forest resiliency and reflected Indigenous influence.

Knight, Clarke A.↗

Application of a design-build-team approach to low cost and weight composite fuselage structure

Relationships between manufacturing costs and design details must be understood to promote the application of advanced composite technologies to transport fuselage structures. A team approach, integrating the disciplines responsible for aircraft structural design and manufacturing, was developed to perform cost and weight trade studies for a twenty-foot diameter aft fuselage section. Baseline composite design and manufacturing concepts were selected for large quadrant panels in crown, side, and keel areas of the fuselage section. The associated technical issues were also identified. Detailed evaluation of crown panels indicated the potential for large weight savings and costs competitive with aluminum technology in the 1995 timeframe. Different processes and material forms were selected for the various elements that comprise the fuselage structure. Additional cost and weight savings potential was estimated for future advancements.

Ilcewicz, L. B.↗

Hybrid composite laminate structures

An invention which relates to laminate structures and specifically to essentially anisotropic fiber composite laminates is described. Metal foils are selectively disposed within the laminate to produce increased resistance to high velocity impact, fracture, surface erosion, and other stresses within the laminate.

Chamis, C. C.↗

Composition and structure of the Venus atmosphere - Results from Pioneer Venus

The composition of the Venusian atmosphere was studied using a mass spectrometer on the Pioneer Venus sounder probe. The single-focusing magnetic-sector spectrometer scanned the mass range from hydrogen through mercury with a dynamic range of six decades. Data taken by the mass spectrometer were compared with those of a gas chromatograph, resulting in slight discrepancies due to the use of a sputter ion pump acting as a sink for entry of rare gases through the inlet leak. A surprisingly large concentration of primordial Ar-36 and Ar-38 was discovered in a ratio of 5 to 1. It was concluded that the large excess of primordial argon was a valid result and that the mixing of HCl in the lower Venusian atmosphere was less than a few parts per million. Arguments against the sun as the source for excess primordial gases on Venus were presented. Concentrations of other elements such as Ne, Kr, He, S, and O were discussed. Although the mass peaks in the spectrum were real, it was not clear whether all of the chemical reactions (i.e., COS production) actually occurred in the atmosphere. Until further analysis can be made, it will be uncertain how the inlet system, which is at atmospheric temperature, affected the results.

Hoffman, J. H.↗

Uranus

Observations and theoretical investigations of the Uranus (U) system from the period 1983-1986 are reviewed, with an emphasis on the Voyager 2 encounter with U on January 26, 1986. Topics addressed include the bulk U composition, structure, and heat flux; the U atmospheric composition, structure, and circulation; the U rings; the major and minor U satellites; the U magnetosphere; and the Lyman-alpha 'electroglow' observed on the sunlit hemisphere of U.

Bergstralh, Jay T.↗