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NASA NTRS1976

Advanced composites: Fabrication processes for selected resin matrix materials

This design note is based on present state of the art for epoxy and polyimide matrix composite fabrication technology. Boron/epoxy and polyimide and graphite/epoxy and polyimide structural parts can be successfully fabricated. Fabrication cycles for polyimide matrix composites have been shortened to near epoxy cycle times. Nondestructive testing has proven useful in detecting defects and anomalies in composite structure elements. Fabrication methods and tooling materials are discussed along with the advantages and disadvantages of different tooling materials. Types of honeycomb core, material costs and fabrication methods are shown in table form for comparison. Fabrication limits based on tooling size, pressure capabilities and various machining operations are also discussed.

Welhart, E. K.↗

NASA NTRS1976

Fiber composite fan blade impact improvement

The improved foreign object damage resistance of a metal matrix advanced composite fan blade was demonstrated. The fabrication, whirl impact test and subsequent evaluation of nine advanced composite fan blades of the "QCSEE" type design were performed. The blades were designed to operate at a tip speed of 282 m/sec. The blade design was the spar/shell type, consisting of a titanium spar and boron/aluminum composite airfoils. The blade retention was designed to rock on impact with large birds, thereby reducing the blade bending stresses. The program demonstrated the ability of the blades to sustain impacts with up to 681 g slices of birds at 0.38 rad with little damage (only 1.4 percent max weight loss) and 788 g slices of birds at 0.56 rad with only 3.2 percent max weight loss. Unbonding did not exceed 1.1 percent of the post-test blade area during any of the tests. All blades in the post-test condition were judged capable of operation in accordance with the FAA guidelines for medium and large bird impacts.

Graff, J.↗

NASA NTRS1978

Elevated temperature properties of boron/aluminum composites

The high temperature properties of boron/aluminum composites, fabricated by an air diffusion bonding technique utilizing vacuum-bonded monolayer tape are reported. Seventeen different combinations of matrix alloy, reinforcement diameter, reinforcement volume percent, angle-ply and matrix enhancement (i.e. titanium cladding and interleaves) were fabricated, inspected, and tested. It is shown that good to excellent mechanical properties could be obtained for air-bonded boron/aluminum composites and that these properties did not decrease significantly up to a test temperature of at least 260 C. Composites made with 8 mil B/W fiber show a much greater longitudinal strength dependence on volume percent fiber than composites made with 5.6 mil fiber. The addition of titanium caused difficulties in composite bonding and yielded composites with reduced strength.

Sullivan, P. G.↗

NASA NTRS1982

Alkaline regenerative fuel cell energy storage system for manned orbital satellites

It is pointed out that the alkaline regenerative fuel cell system represents a highly efficient, lightweight, reliable approach for providing energy storage in an orbiting satellite. In addition to its energy storage function, the system can supply hydrogen and oxygen for attitude control of the satellite and for life support. A summary is presented of the results to date obtained in connection with the NASA-sponsored fuel cell technology advancement program, giving particular attention to the requirements of the alkaline regenerative fuel cell and the low-earth mission. Attention is given to system design guidelines, weight considerations, gold-platinum cathode cell performance, matrix development, the electrolyte reservoir plate, and the cyclical load profile tests.

Martin, R. E.↗

NASA NTRS1986

Investigations of toughening mechanisms of epoxy resins

Composite material technology was applied to the solid rocket booster by the development of a carbon filament-epoxy resin case which yields a net increase of 4000 lbs. in payload in the shuttle. The question of reusability of the new composite tanks has not yet been answered and will depend on the toughness of the matrix resin. The present study was aimed at providing conditions whereby test specimens of the epoxy resin (EPON/85) and curing agents of systematically varied structures could be produced in a controlled manner. Three sets of conditions were found that might allow the isolation of the structural effects on toughness from the cure effects. The kinetic methods leading to the determination of these conditions are described.

Koenig, T.↗

NASA NTRS1987

Improving the interlaminar shear strength of carbon fiber-epoxy composites through carbon fiber bromination

The use of bromine to improve the interlaminar shear strength of PAN-based carbon fibers was investigated. Composite test specimens fabicated from brominated T-300 fibers and a MY720 matrix exhibited on average a 30% improvement in ILSS over their pristine counterparts. Mass, electrical resistivity, density, contact angle, and scanning Auger microscopy results suggested a mechanism in which the bromine was covalently bonded to the surface of the fiber, and this resulted in an increased van der Waal's adhesion between fiber and matrix.

Jaworske, Donald A.↗

NASA NTRS1988

Elevated temperature slow plastic deformation of NiAl/TiB2 particulate composites

The 'XD' process for production of discontinuously-reinforced metal-matrix composites has been used to enhance the high-temperature strength of NiAl-TiB2 composites with particulate densities of up to 30 vol pct. SEM, TEM, and optical characterizations of the resulting microstructures showed the average TiB2 particle size to be about 1 micron, while the average grain of the NiAl matrix was of the order of 10 microns. Elevated temperature compression tests conducted at 1200 and 1300 K indicated flow strengths to increase with TiB2 content, so that the 20 vol pct TiB2-reinforced composite was three times stronger than the unreinforced NiAl; this is ascribed to the very high density of microstructural tangled dislocations, loops, and subgrain boundaries connecting the particles.

Whittenberger, J. Daniel↗

NASA NTRS1993

Aeroelastic airfoil smart spar

Aircraft wings and rotor-blades are subject to undesirable bending and twisting excursions that arise from unsteady aerodynamic forces during high speed flight, abrupt maneuvers, or hard landings. These bending excursions can range in amplitude from wing-tip flutter to failure. A continuous-filament construction 'smart' laminated composite box-beam spar is described which corrects itself when subject to undesirable bending excursions or flutter. The load-bearing spar is constructed so that any tendency for the wing or rotor-blade to bend from its normal position is met by opposite twisting of the spar to restore the wing to its normal position. Experimental and theoretical characterization of these spars was made to evaluate the torsion-flexure coupling associated with symmetric lay-ups. The materials used were uniweave AS-4 graphite and a matrix comprised of Shell 8132 resin and U-40 hardener. Experimental tests were conducted on five spars to determine spar twist and bend as a function of load for 0, 17, 30, 45 and 60 deg fiber angle lay-ups. Symmetric fiber lay-ups do exhibit torsion-flexure couplings. Predictions of the twist and bend versus load were made for different fiber orientations in laminated spars using a spline function structural analysis. The analytical results were compared with experimental results for validation. Excellent correlation between experimental and analytical values was found.

Greenhalgh, Skott↗

NASA NTRS1995

Impact damage resistance and residual property assessment of (0/+/-45/90)s SCS-6/Timetal 21S

The impact damage resistance and residual mechanical properties of (0/ +/- 45/90)s SCS-6/Timetal 21S composites were evaluated. Both quasi-static indentation and drop-weight impact tests were used to investigate the impact behavior at two nominal energy levels (5.5 and 8.4 J) and determine the onset of internal damage. Through x-ray inspection, the extent of internal damage was characterized non-destructively. The composite strength and constant amplitude fatigue response were evaluated to assess the effects of the sustained damage. Scanning electron microscopy was used to characterize internal damage from impact in comparison to damage that occurs during mechanical loading alone. The effect of stacking sequence was examined by using specimens with the long dimension of the specimen both parallel (longitudinal) and perpendicular (transverse) to the 0 deg fiber direction. Damage in the form of longitudinal and transverse cracking occurred in all longitudinal specimens tested at energies greater than 6.3 J. Similar results occurred in the transverse specimens tested above 5.4 J. Initial load drop, characteristic of the onset of damage, occurred on average at 6.3 J in longitudinal specimens and at 5.0 J in transverse specimens. X-ray analysis showed broken fibers in the impacted region in specimens tested at the higher impact energies. At low impact energies, visible matrix cracking may occur, but broken fibers may not. Matrix cracking was noted along fiber swims and it appeared to depend on the surface quality of composite. At low impact energies, little damage has been incurred by the composite and the residual strength and residual life is not greatly reduced as compared to an undamaged composite. At higher impact energies, more damage occurred and a greater effect of the impact damage was observed.

Miller, Jennifer L.↗

NASA NTRS1995

Time-Dependent Behavior of a Graphite/Thermoplastic Composite and the Effects of Stress and Physical Aging

Experimental studies were performed to determine the effects of stress and physical aging on the matrix dominated time dependent properties of IM7/8320 composite. Isothermal tensile creep/aging test techniques developed for polymers were adapted for testing of the composite material. Time dependent transverse and shear compliance's for an orthotropic plate were found from short term creep compliance measurements at constant, sub-T(8) temperatures. These compliance terms were shown to be affected by physical aging. Aging time shift factors and shift rates were found to be a function of temperature and applied stress.

Gates, Thomas S.↗

NASA NTRS1997

The Effect of Solid Constituent Particle Size Distributions on TP-H1148 Propellant Slag

Special aluminum and ammonium perchlorate (AP) particle size distributions were prepared for a matrix of five-inch diameter, center-perforated (CP) motor tests to measure the aluminum oxide slag response in Space Shuttle Reusable Solid Rocket Motor (RSRM) propellant. Previous tests of TP-H1148 propellant in five-inch CP spin motors have shown a correlation between aluminum particle size and generated slag. The motors for this study were cast from thirteen five-gallon propellant mixes which used five particle size levels of aluminum powder, five of unground AP and three of ground AP. Aluminum had the greatest effect on slag formation, the more coarse fractions causing greater slag quantities and larger slag particles. Unground AP had about half the effect of aluminum with the coarser fractions again producing more and larger sized slag particles. The variation in ground AP did not have a significant effect on slag formation. Quench bomb tests showed the same trends as the spin motors, that is, larger aluminum and AP particle size distributions generated larger slag particles leaving the propellant surface. Cured propellant mechanical properties were also impacted by particle size variation.

May, Douglas H.↗

NASA NTRS2000

Concept for Determining the Life of Ceramic Matrix Composites Using Nondestructive Characterization Techniques

Damping measurements have been taken on ceramic matrix composite (CMC) turbopump blisks in the as fabricated, post proof testing, and post turbopump testing conditions. These results indicate that damping is able to quantify fatigue of the CMC blisk. This gives hope for the potential of determining the actual and residual life of CMC materials using a combination of nondestructive techniques. If successful, then this new paradigm for life prediction of CMCs could revolutionize the approach for designing and servicing CMC components, thereby significantly reducing costs for design, development, health monitoring, and maintenance of CMC components and systems. The Nondestructive Characterization (NDC) life prediction approach would complement life prediction using micromechanics and continuum finite element models. This paper reports on the initial concept of NDC life prediction and how changes in damping and ultrasonic elastic modulus data have established the concept as a possibility.

Effinger, Michael↗

NASA NTRS2002

Acousto-ultrasonics to Assess Material and Structural Properties

This report was created to serve as a manual for applying the Acousto-Ultrasonic NDE method, as practiced at NASA Glenn, to the study of materials and structures for a wide range of applications. Three state of the art acousto-ultrasonic (A-U) analysis parameters, ultrasonic decay (UD) rate, mean time (or skewing factor, "s"), and the centroid of the power spectrum, "f(sub c)," have been studied and applied at GRC for NDE interrogation of various materials and structures of aerospace interest. In addition to this, a unique application of Lamb wave analysis is shown. An appendix gives a brief overview of Lamb Wave analysis. This paper presents the analysis employed to calculate these parameters and the development and reasoning behind their use. It also discusses the planning of A-U measurements for materials and structures to be studied. Types of transducer coupling are discussed including contact and non-contact via laser and air. Experimental planning includes matching transducer frequency range to material and geometry of the specimen to be studied. The effect on results of initially zeroing the DC component of the ultrasonic waveform is compared with not doing so. A wide range of interrogation problems are addressed via the application of these analysis parameters to real specimens is shown for five cases: Case 1: Differences in density in [0] SiC/RBSN ceramic matrix composite. Case 2: Effect of tensile fatigue cycling in [+/-45] SiC/SiC ceramic matrix composite. Case 3: Detecting creep life, and failure, in Udimet 520 Nickel-Based Super Alloy. Case 4: Detecting Surface Layer Formation in T-650-35/PMR-15 Polymer Matrix Composites Panels due to Thermal Aging. Case 5: Detecting Spin Test Degradation in PMC Flywheels. Among these cases a wide range of materials and geometries are studied.

Kautz, Harold E.↗

NASA NTRS2004

Lamb Wave Stiffness Characterization of Composites Undergoing Thermal-Mechanical Aging

The introduction of new, advanced composite materials into aviation systems requires a thorough understanding of the long term effects of combined thermal and mechanical loading upon those materials. Analytical methods investigating the effects of intense thermal heating combined with mechanical loading have been investigated. The damage mechanisms and fatigue lives were dependent on test parameters as well as stress levels. Castelli, et al. identified matrix dominated failure modes for out-of-phase cycling and fiber dominated damage modes for in-phase cycling. In recent years, ultrasonic methods have been developed that can measure the mechanical stiffness of composites. To help evaluate the effect of aging, a suitably designed Lamb wave measurement system is being used to obtain bending and out-of-plane stiffness coefficients of composite laminates undergoing thermal-mechanical loading. The system works by exciting an antisymmetric Lamb wave and calculating the velocity at each frequency from the known transducer separation and the measured time-of-flight. The same peak in the waveforms received at various distances is used to measure the time difference between the signals. The velocity measurements are accurate and repeatable to within 1% resulting in reconstructed stiffness values repeatable to within 4%. Given the material density and plate thickness, the bending and out-of-plane shear stiffnesses are calculated from a reconstruction of the dispersion curve. A mechanical scanner is used to move the sensors over the surface to map the time-of-flight, velocity, or stiffnesses of the entire specimen. Access to only one side of the material is required and no immersion or couplants are required because the sensors are dry coupled to the surface of the plate. In this study, the elastic stiffnesses D(sub 11), D(sub 22), A(sub 44), and A(sub 55) as well as time-of-flight measurements for composite samples that have undergone combined thermal and mechanical aging for a duration of 10,000 hours are reported.

Seale, Michael D.↗

NASA NTRS2005

Damage Prediction Models for Advanced Materials and Composites

In the present study, the assessment and evaluation of various acoustic tile designs were conducted using three-dimensional finite element analysis, which included static analysis, thermal analysis and modal analysis of integral and non-integral tile design options. Various benchmark specimens for acoustic tile designs, including CMC integral T-joint and notched CMC plate, were tested in both room and elevated temperature environment. Various candidate ceramic matrix composite materials were used in the numerical modeling and experimental study. The research effort in this program evolved from numerical modeling and concept design to a combined numerical analysis and experimental study. Many subjects associated with the design and performance of the acoustic tile in jet engine exhaust nozzle have been investigated.

Xie, Ming↗

NASA NTRS2011

Aeroacoustic Characterization of the NASA Ames Experimental Aero-Physics Branch 32- by 48-Inch Subsonic Wind Tunnel with a 24-Element Phased Microphone Array

The Aero-Physics Branch at NASA Ames Research Center utilizes a 32- by 48-inch subsonic wind tunnel for aerodynamics research. The feasibility of acquiring acoustic measurements with a phased microphone array was recently explored. Acoustic characterization of the wind tunnel was carried out with a floor-mounted 24-element array and two ceiling-mounted speakers. The minimum speaker level for accurate level measurement was evaluated for various tunnel speeds up to a Mach number of 0.15 and streamwise speaker locations. A variety of post-processing procedures, including conventional beamforming and deconvolutional processing such as TIDY, were used. The speaker measurements, with and without flow, were used to compare actual versus simulated in-flow speaker calibrations. Data for wind-off speaker sound and wind-on tunnel background noise were found valuable for predicting sound levels for which the speakers were detectable when the wind was on. Speaker sources were detectable 2 - 10 dB below the peak background noise level with conventional data processing. The effectiveness of background noise cross-spectral matrix subtraction was assessed and found to improve the detectability of test sound sources by approximately 10 dB over a wide frequency range.

Costanza, Bryan T.↗

NASA NTRS2017

Picosecond Pulsed Laser Ablation for the Surface Preparation of Epoxy Composites

As part of a technical challenge under the Advanced Composites Program, methods for improving pre-bond process control for aerospace composite surface treatments and inspections, in conjunction with Federal Aviation Administration guidelines, are under investigation. The overall goal is to demonstrate high fidelity, rapid and reproducible surface treatment and surface characterization methods to reduce uncertainty associated with the bonding process. The desired outcomes are reliable bonded airframe structure, and reduced timeline to certification. In this work, laser ablation was conducted using a q-switched Nd:YVO4 laser capable of nominal pulse durations of 8 picoseconds (ps). Aerospace structural carbon fiber reinforced composites with an epoxy resin matrix were laser treated, characterized, processed into bonded assemblies and mechanically tested. The characterization of ablated surfaces were conducted using scanning electron microscopy (SEM), water contact angle (WCA) goniometry, micro laser induced breakdown spectroscopy (uLIBS), and electron spin resonance (ESR). The bond performance was assessed using a double cantilever beam (DCB) test with an epoxy adhesive. The surface characteristics and bond performance obtained from picosecond ablated carbon fiber reinforced plastics (CFRPs) are presented herein.

Palmieri, Frank↗

NASA NTRSDate not supplied

3D Printed Ceramic Reinforced Polymer Composites Microstructure and Mechanical Properties

In Fused Filament Fabrication (FFF) 3D printing a part is made by extruding material layer by layer. Benefits of FFF are the ability to print complex shapes quickly and at a lower cost compared to other manufacturing methods. In this work, filaments composed of either silicon carbide (SiC) or zirconium silicate ceramic particulates in a polylactic-acid (PLA) matrix were used to print specimens for microstructural analysis and mechanical testing. Pure PLA samples were also printed and tested as a baseline for comparison. A Design of Experiments approach was used to test the interactions between three different parameters and their effect on ultimate strength, Young’s modulus, and yield strength. For compression test specimens, these parameters were infill percentage, number of shells, and print orientation angle. For tensile test specimens, the parameters were layer height, number of shells, and infill orientation angle. Pre- and post-compression test samples were evaluated by scanning electron microscopy for microstructural analysis. Infill percentage had the greatest effect on mechanical properties while number of shells and print orientation angle had minor effects. When changing the layer lines from perpendicular to parallel, relative to the loading direction, SiC-PLA had higher mechanical properties while pure PLA properties had decreased, and zirconium silicate-PLA had mix results.

Fused filament fabrication↗