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At least 937 records · Page 52

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NASA NTRS1994

Flight service evaluation of composite helicopter components

This paper presents the results of a NASA funded contract and Sikorsky research and development programs to evaluate structural composite components in flight service on Sikorsky Model S-76 helicopters. Selected components were removed and tested at prescribed intervals over a nine year time frame. Four horizontal stabilizers and thirteen tail rotor spars were returned from commercial service in West Palm Beach, Florida and in the Gulf Coast region of Louisiana to determine the long term effects of operations in hot and humid climates on component performance. Concurrent with the flight component evaluation, panels of materials used in their fabrication were exposed to the environment in ground racks. Selected panels were tested annually to determine the effects of exposure on physical and mechanical properties. The results of 55,741 component flight hours and 911 months of field exposure are reported and compared with initial Federal Aviation Administration (FAA) certification data. The findings of this program have provided increased confidence in the long term durability of advanced composite materials used in helicopter structural applications.

Mardoian, George H.↗

NASA NTRS2001

Feasibility of Actively Cooled Silicon Nitride Airfoil for Turbine Applications Demonstrated

Nickel-base superalloys currently limit gas turbine engine performance. Active cooling has extended the temperature range of service of nickel-base superalloys in current gas turbine engines, but the margin for further improvement appears modest. Therefore, significant advancements in materials technology are needed to raise turbine inlet temperatures above 2400 F to increase engine specific thrust and operating efficiency. Because of their low density and high-temperature strength and thermal conductivity, in situ toughened silicon nitride ceramics have received a great deal of attention for cooled structures. However, the high processing costs and low impact resistance of silicon nitride ceramics have proven to be major obstacles for widespread applications. Advanced rapid prototyping technology in combination with conventional gel casting and sintering can reduce high processing costs and may offer an affordable manufacturing approach. Researchers at the NASA Glenn Research Center, in cooperation with a local university and an aerospace company, are developing actively cooled and functionally graded ceramic structures. The objective of this program is to develop cost-effective manufacturing technology and experimental and analytical capabilities for environmentally stable, aerodynamically efficient, foreign-object-damage-resistant, in situ toughened silicon nitride turbine nozzle vanes, and to test these vanes under simulated engine conditions. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. With cooling, the surface temperature decreased to approximately 1910 F--a drop of approximately 440 F. This preliminary study demonstrates that a near-net-shape silicon nitride airfoil can be fabricated and that silicon nitride can sustain severe thermal shock and the thermal gradients induced by cooling and, thus, is a viable candidate for cooled components.

Bhatt, Ramakrishna T.↗

NASA NTRS1988

Status and prognosis for alternative engine materials

The current state of research and development of new materials for advanced aircraft engines is reviewed. The advantages and disadvantages of intermetallic compounds and refractory metals as replacements for today's nickel-base alloys are discussed along with some results of research directed at overcoming some of the problems which restrict their application. It is concluded that continuous fiber reinforced intermetallic matrix composites offer one of the best chances for success. However, major technical barriers still exist, especially in the development of suitable fibers. The introduction of these materials into aircraft engines is expected to take in excess of 5 to 10 years.

Stephens, Joseph R.↗

NASA NTRS1988

Status and prognosis for alternative engine materials

Stephens, Joseph R.↗

NASA NTRS1998

Continuum Damage Mechanics Used to Predict the Creep Life of Monolithic Ceramics

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated temperature applications. High-temperature and long-duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. An analytical methodology in the form of the integrated design program-Ceramics Analysis and Reliability Evaluation of Structures/Creep (CARES/Creep) has been developed by the NASA Lewis Research Center to predict the life of ceramic structural components subjected to creep rupture conditions. This program utilizes commercially available finite element packages and takes into account the transient state of stress and creep strain distributions (stress relaxation as well as the asymmetric response to tension and compression). The creep life of a component is discretized into short time steps, during which the stress distribution is assumed constant. Then, the damage is calculated for each time step on the basis of a modified Monkman-Grant (MMG) creep rupture criterion. The cumulative damage is subsequently calculated as time elapses in a manner similar to Miner's rule for cyclic fatigue loading. Failure is assumed to occur when the normalized cumulative damage at any point in the component reaches unity. The corresponding time is the creep rupture life for that component.

Powers, Lynn M.↗

NASA NTRS2001

Development of Core Cladding Fabrication Techniques for Phase I Fission Propulsion Systems

Phase I fission propulsion systems focus on safety, timely development, and affordability. Prototype and flight units can be tested at full thrust, using resistance heaters to closely simulate heat from a fission reaction. In Phase I ground testing, one goal is to establish a reliable and affordable manufacturing technique for fabricating a flight-like core. A refractory metal (Mo) has been suggested for the core substrate, primarily due to the existence of a significant database for Mo/LJ02 fuel. The core can be fabricated by bundling Mo tubes with a bonding system that meets preliminary test goals. These criteria include materials compatibility, ability to maintain thermal and structural integrity during 10,000 hours of operation, and fabrication with existing facilities. This paper describes an effort to investigate several fabrication techniques in a cost-effective manner. First, inexpensive materials were tested at low temperatures to determine the relative effectiveness of such techniques as welding, brazing, plating, and vacuum plasma spraying (VPSing). Promising techniques were chosen for further evaluation, including thermal and structural studies, using ceramic tubing at intermediate temperatures. The most desirable technique will be tested on actual Mo tubing at anticipated operating temperatures. This work is being performed by the National Aeronautics & Space Administration (NASA) at George C. Marshall Space Flight Center (MSFC), Los Alamos National Laboratory (LANL), and Advanced Methods & Materials (AMM), Inc.

Salvail, Patrick G.↗

NASA NTRS2022

Liquid crystals of neat boron nitride nanotubes and their assembly into ordered macroscopic materials

Boron nitride nanotubes (BNNTs) have attracted attention for their predicted extraordinary properties; yet, challenges in synthesis and processing have stifled progress on macroscopic materials. Recent advances have led to the production of highly pure BNNTs. Here we report that neat BNNTs dissolve in chlorosulfonic acid (CSA) and form birefringent liquid crystal domains at concentrations above 170 ppmw. These tactoidal domains merge into millimeter- sized regions upon light sonication in capillaries. Cryogenic electron microscopy directly shows nematic alignment of BNNTs in solution. BNNT liquid crystals can be processed into aligned films and extruded into neat BNNT fibers. This study of nematic liquid crystals of BNNTs demonstrates their ability to form macroscopic materials to be used in high- performance applications.

Cedric J. Simonsen Ginestra↗

NASA NTRS1984

Study of utilization of advanced composites in fuselage structures of large transports

The effort required by the transport aircraft manufacturers to support the introduction of advanced composite materials into the fuselage structure of future commercial and military transport aircraft is investigated. Technology issues, potential benefits to military life cycle costs and commercial operating costs, and development plans are examined. The most urgent technology issues defined are impact dynamics, acoustic transmission, pressure containment and damage tolerance, post-buckling, cutouts, and joints and splices. A technology demonstration program is defined and a rough cost and schedule identified. The fabrication and test of a full-scale fuselage barrel section is presented. Commercial and military benefits are identified. Fuselage structure weight savings from use of advanced composites are 16.4 percent for the commercial and 21.8 percent for the military. For the all-composite airplanes the savings are 26 percent and 29 percent, respectively. Commercial/operating costs are reduced by 5 percent for the all-composite airplane and military life cycle costs by 10 percent.

Jackson, A. C.↗

NASA NTRS1988

Advanced composite airframe program: Today's technology

The Advanced Composite Airframe Program (ACAP) was undertaken to demonstrate the advantages of the application of advanced composite materials and structural design concepts to the airframe structure on helicopters designed to stringent military requirements. The primary goals of the program were the reduction of airframe production costs and airframe weight by 17 and 22 percent respectively. The ACAP effort consisted of a preliminary design phase, detail design, and design support testing, full-scale fabrication, laboratory testing, and a ground/flight test demonstration. Since the completion of the flight test demonstration programs follow-on efforts were initiated to more fully evaluate a variety of military characteristics of the composite airframe structures developed under the original ACAP advanced development contracts. An overview of the ACAP program is provided and some of the design features, design support testing, manufacturing approaches, and the results of the flight test evaluation, as well as, an overview of Militarization Test and Evaluation efforts are described.

Good, Danny E.↗

NASA NTRSDate not supplied

REACTER 2.0: Quantum-Informed Reaction Constraints and Automated Interaction Typing

REACTER is a heuristic method for modeling chemical reactions in classical molecular dynamics simulations, implemented in LAMMPS as fix bond/react. The authors recently extended LAMMPS to support alphanumeric labels for atom types, bond types etc., which enables the pre- and post-reaction templates required by the REACTER protocol to be portable between different simulations and greatly simplifies the task of creating simulation-ready reaction templates. To further increase the generality of reaction templates, support for wildcard characters within atom types has been added, along with the automatic assignment of interaction types for new bonds, angles, etc. based on the involved atom types. In some cases, this feature can express a class of reactions with one pair of reaction templates, where previously dozens may have been required. Advanced reaction constraints have also been added, including an Arrhenius constraint to enforce an effective activation energy, a root-mean-square-deviation option for complex geometrical constraints, as well as a custom constraint that leverages LAMMPS’ powerful built-in variable framework. Other new features include variable support for various inputs (e.g., to allow reaction rates or cutoffs to be dependent on overall conversion), on-the-fly update of molecule IDs, and the ability to create new atoms positioned with respect to the reaction site. The new features are applied to modeling polymeric, thermosetting and composite materials, and advanced applications of the new reaction constraints are demonstrated. For example, REACTER is shown to accurately reproduce mechanically-induced bond breaking, as characterized by third-order DFT-based tight-binding (DFTB3) simulations, via a constraint on the total potential energy of the involved atoms.

polymer simulations↗

NASA NTRS1987

Design study of advanced model support systems for the National Transonic Facility (NTF)

It has long been recognized that the sting (or support system) is a very critical part of the model system. The designer is frequently faced with the tradeoff of minimizing sting size, thereby compromising facility and model safety, against a larger sting and the subsequent problems of sting interference effects. In the NASA Langley Research Center National Transonic Facility (NTF), this problem is accentuated by the severe environment of high pressure/low temperature, designed into the facility to provide the desired high Reynolds number. Compromises in the configuration geometry and/or limiting the test envelope are therefore contrary to the purposes and goals of the NTF and are unacceptable. The results of an investigation aimed at improvements of 25% in both strength and Young's modulus of elasticity as compared to high strength cryogenically acceptable steels currently being used are presented. Various materials or combinations of materials were studied along with different design approaches. Design concepts were developed which included conventional material stings, advanced composites, and hybrid configurations. Candidate configurations are recommended.

Source record↗

NASA NTRS2009

Self-Assembling, Flexible, Pre-Ceramic Composite Preforms

In this innovation, light weight, high temperature, compact aerospace structures with increased design options are made possible by using self-assembling, flexible, pre-ceramic composite materials. These materials are comprised of either ceramic or carbon fiber performs, which are infiltrated with polymer precursors that convert to ceramics upon thermal exposure. The preform architecture can vary from chopped fibers formed into blankets or felt, to continuous fibers formed into a variety of 2D or 3D weaves or braids. The matrix material can also vary considerably. For demonstration purposes, a 2D carbon weave was infiltrated with a SiC polymer precursor. The green or unfired material is fabricated into its final shape while it is still pliable. It is then folded or rolled into a much more compact shape, which will occupy a smaller space. With this approach, the part remains as one continuous piece, rather than being fabricated as multiple sections, which would require numerous seals for eventual component use. The infiltrated preform can then be deployed in-situ. The component can be assembled into its final shape by taking advantage of the elasticity of the material, which permits the structure to unfold and spring into its final form under its own stored energy. The pre-ceramic composites are converted to ceramics and rigidized immediately after deployment. The final ceramic composite yields a high-temperature, high-strength material suitable for a variety of aerospace structures. The flexibility of the material, combined with its high-temperature structural capacity after rigidization, leads to a less complex component design with an increased temperature range. The collapsibility of these structures allows for larger components to be designed and used, and also offers the potential for increased vehicle performance. For the case of collapsible nozzle extensions, a larger nozzle, and thus a larger nozzle exit plane, is possible because interference with surrounding structures can be avoided in the collapsed state. The larger exit plane leads to an increase in expansion area ratio, which has the potential to increase thrust and overall rocket performance. In general, the use of advanced ceramic materials can lead to improved engine and vehicle performance. The ceramics can run hotter, so less cooling is required. Fuel to coolant ratios can be balanced more readily to reduce weight. Engine efficiency can also be increased with hotter combustion and exhaust temperatures. In addition, the ceramic composites themselves can reduce the component weight by as much as 50 percent, which can translate into greater payload for the vehicle

Jaskowiak, Martha H.↗

NASA NTRS2000

NASA's Advanced Propulsion Technology Activities for Third Generation Fully Reusable Launch Vehicle Applications

NASA's Office of Aeronautics and Space Transportation Technology (OASTT) established the following three major goals, referred to as "The Three Pillars for Success": Global Civil Aviation, Revolutionary Technology Leaps, and Access to Space. The Advanced Space Transportation Program Office (ASTP) at the NASA's Marshall Space Flight Center in Huntsville, Ala. focuses on future space transportation technologies under the "Access to Space" pillar. The Propulsion Projects within ASTP under the investment area of Spaceliner100, focus on the earth-to-orbit (ETO) third generation reusable launch vehicle technologies. The goals of Spaceliner 100 is to reduce cost by a factor of 100 and improve safety by a factor of 10,000 over current conditions. The ETO Propulsion Projects in ASTP, are actively developing combination/combined-cycle propulsion technologies that utilized airbreathing propulsion during a major portion of the trajectory. System integration, components, materials and advanced rocket technologies are also being pursued. Over the last several years, one of the main thrusts has been to develop rocket-based combined cycle (RBCC) technologies. The focus has been on conducting ground tests of several engine designs to establish the RBCC flowpaths performance. Flowpath testing of three different RBCC engine designs is progressing. Additionally, vehicle system studies are being conducted to assess potential operational space access vehicles utilizing combined-cycle propulsion systems. The design, manufacturing, and ground testing of a scale flight-type engine are planned. The first flight demonstration of an airbreathing combined cycle propulsion system is envisioned around 2005. The paper will describe the advanced propulsion technologies that are being being developed under the ETO activities in the ASTP program. Progress, findings, and future activities for the propulsion technologies will be discussed.

Hueter, Uwe↗

NASA NTRS1998

Composite Bus Structure for the SMEX/WIRE Satellite

In an effort to reduce the weight and optimize the structural design of the Small Explorer (SMEX) Wide-Field Infrared Explorer (WIRE) spacecraft, it has become desirable to change the material and construction from mechanically fastened aluminum structure to a fully bonded fiber-reinforced composite (FRC) structure. GSFC has developed the WIRE spacecraft structural bus design concept, including the instrument and launch vehicle requirements. The WIRE Satellite is the fifth of a series of SMEX satellites to be launched once per year. GSFC has chosen Composite Optics Inc. (COI) as the prime contractor for the development and procurement of the WIRE composite structure. The detailed design of the fully bonded FRC structure is based on COI's Short Notice Accelerated Production SATellite ("SNAPSAT") approach. SNAPSAT is a state of the art design and manufacturing technology for advanced composite materials which utilizes flat-stock detail parts bonded together to produce a final structural assembly. The structural design approach adopted for the WIRE structure provides a very viable alternative to both traditional aluminum construction as well as high tech. molded type composite structures. This approach to composite structure design is much less costly than molded or honeycomb sandwich type composite construction, but may cost slightly more than conventional aluminum construction on the subsystem level. However on the overall program level the weight saving achieved is very cost effective, since the primary objective is to allocate more mass for science payloads.

Rosanova, Giulio G.↗

NASA NTRSDate not supplied

Multifaceted Considerations for Fission Surface Power Radiation Shielding Design

The purpose of the Fission Surface Power (FSP) nuclear system is to provide energy on the Moon and Mars for supporting their exploration and colonization. The FSP design and deployment can leverage the past research and development work in areas, such as reactor design, but such crucial components as radiation shielding and instrumentation still need material and manufacturing studies, modeling, and testing. The shielding components are needed for the protection of humans, electronics, and sensitive components. They are essential system components, but they are often the heaviest components of the system for which each kilogram matters. Different material combinations and layouts are possible. The studies presented were focused on the evaluation of several options. The initial analysis included their performance assessment, initial temperature distribution evaluation and manufacturability considerations. Several feasible shield design options were identified and discussed in this paper, as well.

Fission Surface Power↗

NASA NTRS2003

Investigation of Structural Properties of Carbon-Epoxy Composites Using Embedded Fiber-Optic Bragg Gratings

Real time monitoring of the mechanical integrity and stresses on key aerospace composite structures like aircraft wings, walls of pressure vessels and fuel tanks or any other structurally extended components and panels as in space telescopes is very important to NASA. Future military and commercial aircraft as well as NASA space systems such as Space Based Radar and International Space Station will incorporate a monitoring system to sense any degradation to the structure. In the extreme flight conditions of an aerospace vehicle it might be desirable to measure the strain every ten centimeters and thus fully map out the strain field of a composite component. A series of missions and vehicle health management requirements call for these measurements. At the moment thousands of people support a few vehicle launches per year. This number can be significantly reduced by implementing intelligent vehicles with integral nervous systems (smart structures). This would require maintenance to be performed only as needed. Military and commercial aircrafts have an equally compelling case. Annual maintenance costs are currently reaching astronomical heights. Monitoring techniques are therefore required that allow for maintenance to be performed only when needed. This would allow improved safety by insuring that necessary tasks are performed while reducing costs by eliminating procedures that are costly and not needed. The advantages fiber optical sensors have over conventional electro-mechanical systems like strain gauges have been widely extolled in the research literature. These advantages include their small size, low weight, immunity to electrical resistance, corrosion resistance, compatibility with composite materials and process conditions, and multiplexing capabilities. One fiber optic device which is suitable for distributed sensing is the fiber Bragg grating (FBG). This is a periodic perturbation in the refractive index of the fiber core. When a broadband light is coupled into the optical fiber sensor, a reflection peak will be obtained centered around a wavelength called Bragg-wavelength. The Bragg-wavelength depends on the refractive index and the period of the grating, which both change due to mechanical and thermal strain applied to the sensor. The shift in the Bragg-wavelength is directly proportional to the strain. Researchers at NASA MSFC are currently developing techniques for using FBGs for monitoring the integrity of advanced structural materials expected to become the mainstay of the current and future generation space structures. Since carbon-epoxy composites are the materials of choice for the current space structures, the initial study is concentrated on this type of composite. The goals of this activity are to use embedded FBG sensors for measuring strain and temperature of composite structures, and to investigate the effects of various parameters such as composite fiber orientation with respect to the optical sensor, unidirectional fiber composite, fabrication process etc., on the optical performance of the sensor. This paper describes an experiment to demonstrate the use of an embedded FBG for measuring strain in a composite material. The performance of the fiber optic sensor is determined by direct comparison with results from more conventional instrumentation.

Osei, Albert J.↗

NASA NTRS1987

Preliminary structural design of composite main rotor blades for minimum weight

A methodology is developed to perform minimum weight structural design for composite or metallic main rotor blades subject to aerodynamic performance, material strength, autorotation, and frequency constraints. The constraints and load cases are developed such that the final preliminary rotor design will satisfy U.S. Army military specifications, as well as take advantage of the versatility of composite materials. A minimum weight design is first developed subject to satisfying the aerodynamic performance, strength, and autorotation constraints for all static load cases. The minimum weight design is then dynamically tuned to avoid resonant frequencies occurring at the design rotor speed. With this methodology, three rotor blade designs were developed based on the geometry of the UH-60A Black Hawk titanium-spar rotor blade. The first design is of a single titanium-spar cross section, which is compared with the UH-60A Black Hawk rotor blade. The second and third designs use single and multiple graphite/epoxy-spar cross sections. These are compared with the titanium-spar design to demonstrate weight savings from use of this design methodology in conjunction with advanced composite materials.

Nixon, Mark W.↗

NASA NTRS1998

MoSi2-Base Hybrid Composite Passed Engine Test

The intermetallics compound molybdenum disilicide (MoSi2) is an attractive high-temperature structural material for advanced engine applications. It has excellent oxidation resistance, a high melting point, relatively low density, and high thermal conductivity, and it is easily machined. Past research'at the NASA Lewis Research Center has resulted in the development of a hybrid composite consisting of a MoSi2 matrix reinforced with silicon nitride (Si3N4) Particulate and silicon carbide (SiC) fibers. This composite has demonstrated attractive strength, toughness, thermal fatigue, and oxidation resistance, including resistance to "pest" oxidation. These properties attracted the interest of the Office of Naval Research and Pratt & Whitney, and a joint NASA/Navy/Pratt & Whitney effort was developed to continue to mature the MoSi2 Composite technology. A turbine blade outer air seal, which was part of the Integrated High Performance Turbine Engine Technology (IHPTET) program, was chosen as a first component on which to focus. The first tasks of the materials development effort were to develop improved processing methods to reduce costs and to use fine-diameter fibers that enable the manufacturing of complex shapes. Tape-casting methods were developed to fully infiltrate the fine SiC fibers with matrix powders. The resulting composites were hot pressed to 100-percent density. Composites with cross-plied fiber architectures with 30 vol. % hi-nicalon SiC fibers and 30 vol. % nitride particles are now made routinely and demonstrate a good balance of properties. The next task entailed the measurement of a wide variety of mechanical properties to confirm the suitability of this composite in engines. In particular, participants in this effort demonstrated that composites made with Hi-Nicalon fibers had strength and toughness properties equal to or better than those of the composites made with the large-diameter fibers that had been used previously. Another critically important property measured was impact resistance. Aircraft engine components require sufficient toughness to resist manufacturing defects, assembly damage, stress concentrations at notches, and foreign object damage. Engine company designers indicated that impact resistance would have to be measured before they would seriously consider these types of composites. The Charpy V-notch test was chosen to assess impact resistance, and both monolithic and composite versions Of MOSi2 were tested from -300 to 1400 C. The results (see the following graphs) show that nitride-particulate-reinforced MoSi2 exhibited impact resistance higher than that of many monolithic ceramics and intermetallics, and that the fiber-reinforced composites had even higher values, approaching that of cast superalloys.

Keith, Theo G., Jr.↗