Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Composite Material”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 991 records · Page 55

Advanced electromagnetic methods for aerospace vehicles

During this period the research program addressed the following three topics: (1) composite materials; (2) precipitation static (P-Static); and (3) antenna technology. On the topic of Composite Materials our main efforts were directed toward making measurements on several new samples of composite materials made available to ASU by Stanford Research Institute (SRI) through the efforts of Mr. Frank Casler of AVRADA. These samples can be classified into three distinct materials with each material having its own distinct electrical properties. In addition, attempts were made to make predictions of the effects on antenna patterns by composite materials. This will take a greater emphasis in the next reporting period. In Precipitation Static (P-Static), the main effort was devoted toward developing a Voltage Finite-Difference Time-Domain computer code to account for the voltage variation on a conducting body as the primary source of corona discharge, instead of the electric field. Due to complexities stemming from the interactions between the potentials, the fields, and current sources, the decision was made to begin with a simple two-dimensional problem without the corona discharge and check our programs in a series of simple models, culminating in the full corona discharge problem. This report deals with the first stage of such development. During this reporting period, the main effort in Antenna Technology was toward the design, fabrication, and testing of a cavity-backed slot antenna using ferrite material. Using the ferrite material available to us during this period, the resonances of this antenna were around 5 and 8 GHz. Attempts will be made to model such an antenna and to lower its resonance down into the VHF and UHF bands.

Balanis, Constantine A.↗

Aging mechanisms of filled cross-linked polyethylene (XLPE) cable insulation material exposed to simultaneous thermal and gamma radiation

Thermal and simultaneous thermal and gamma radiation aging experiments were conducted on an industry grade cross-linked polyethylene (XLPE) cable insulation material, which is a composite material with XLPE as polymer matrix and various additives and fillers. Reverse engineering was conducted to identify and quantify the material composition given that this information was not revealed by the cable manufacture. Samples were then aged at temperatures of 60, 90, and 115 °C, exposed to gamma radiation for total doses of 0 to 324 kGy, and at dose rates of 0 to 540 Gy/h. Aging mechanisms were studied using various materials characterization techniques including pyrolysis gas chromatography mass spectrometry (Py-GCMS), differential scanning calorimetry (DSC), nuclear magnetic resonance spectroscopy (NMR), and gel-fraction tests. Results show that the flame-retardant components were decomposed into smaller molecules when the material was exposed to gamma radiation, while no changes were observed when the samples were aged thermally without gamma radiation. With exposure to gamma radiation, the crystalline phase of the XLPE were damaged by gamma radiation introducing defects in the crystals, resulting in smaller and less perfect crystals. The dominance of chain scission or chain reformation process largely depends on the chain mobility, which is decided by the aging temperature. Chain scission was seen to dominate when the material was exposed to gamma radiation at 60 °C. Chain cross-linking slightly dominated when the material was exposed to gamma radiation at 90 °C and became more dominant with exposure to gamma radiation at 115 °C. No significant change to the XLPE polymer matrix was observed when the samples were exposed to thermal aging without gamma radiation. Finally, antioxidant is more effective in protecting the XLPE polymer matrix under thermal aging, but less effective with sample exposure to gamma radiation.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Tool for Generation of MAC/GMC Representative Unit Cell for CMC/PMC Analysis

This document describes a recently developed analysis tool that enhances the resident capabilities of the Micromechanics Analysis Code with the Generalized Method of Cells (MAC/GMC) 4.0. This tool is especially useful in analyzing ceramic matrix composites (CMCs), where higher fidelity with improved accuracy of local response is needed. The tool, however, can be used for analyzing polymer matrix composites (PMCs) as well. MAC/GMC 4.0 is a composite material and laminate analysis software developed at NASA Glenn Research Center. The software package has been built around the concept of the generalized method of cells (GMC). The computer code is developed with a user friendly framework, along with a library of local inelastic, damage, and failure models. Further, application of simulated thermomechanical loading, generation of output results, and selection of architectures to represent the composite material have been automated to increase the user friendliness, as well as to make it more robust in terms of input preparation and code execution. Finally, classical lamination theory has been implemented within the software, wherein GMC is used to model the composite material response of each ply. Thus, the full range of GMC composite material capabilities is available for analysis of arbitrary laminate configurations as well. The primary focus of the current effort is to provide a graphical user interface (GUI) capability that generates a number of different user-defined repeating unit cells (RUCs). In addition, the code has provisions for generation of a MAC/GMC-compatible input text file that can be merged with any MAC/GMC input file tailored to analyze composite materials. Although the primary intention was to address the three different constituents and phases that are usually present in CMCs-namely, fibers, matrix, and interphase-it can be easily modified to address two-phase polymer matrix composite (PMC) materials where an interphase is absent. Currently, the tool capability includes generation of RUCs for square packing, hexagonal packing, and random fiber packing as well as RUCs based on actual composite micrographs. All these options have the fibers modeled as having a circular cross-sectional area. In addition, a simplified version of RUC is provided where the fibers are treated as having a square cross section and are distributed randomly. This RUC facilitates a speedy analysis using the higher fidelity version of GMC known as HFGMC. The first four mentioned options above support uniform subcell discretization. The last one has variable subcell sizes due to the primary intention of keeping the RUC size to a minimum to gain the speed ups using the higher fidelity version of MAC. The code is implemented within the MATLAB (The Mathworks, Inc., Natick, MA) developmental framework; however, a standalone application that does not need a priori MATLAB installation is also created with the aid of the MATLAB compiler.

Materials Engineering↗

Making a Metal-Lined Composite-Overwrapped Pressure Vessel

process has been devised for the fabrication of a pressure vessel that comprises a composite-material (matrix/fiber) shell with a metal liner on its inner surface. The use of the composite material makes it possible for the tank to be strong enough to withstand the anticipated operating pressure and yet weigh less than does an equivalent all-metal tank. The metal liner is used as a barrier against permeation: In the absence of such a barrier, the pressurized gas in the tank could leak by diffusing through the composite-material shell. The figure depicts workpieces at four key stages in the process, which consists of the following steps: 1. A mandrel that defines the size and shape of the pressure vessel is made by either molding or machining a piece of tooling wax. 2. Silver paint is applied to the surface of the mandrel to make it electrically conductive. 3. The ends of the mandrel are fitted with metal bosses. 4. The mandrel is put into a plating bath, wherein the metal liner is electrodeposited. Depending on the applications, the liner metal could be copper, nickel, gold, or an alloy. Typical liner thicknesses range from 1 to 10 mils (0.025 to 0.25 mm). 5. The wax is melted from within, leaving the thin metal liner. 6. A hollow shaft that includes holes and fittings through which the liner can be pressurized is sealed to both ends of the liner. The liner is pressurized to stiffen (and hence stabilize) it for the next step. 7. The pressurized liner is placed in a filament-winding machine, which is then operated to cover the liner with multiple layers of an uncured graphite-fiber/epoxy-matrix or other suitable composite material. 8. The composite-overwrapped liner is cured in an oven. 9. The pressure is relieved and the shaft is removed. The tank is then ready for use. The process as described above accommodates variations: a) The mandrel could be made of a wax that melts at a higher temperature and not removed until the tank is cured in the oven. b) The tank need not be cylindrical or axisymmetric, as long as the filament-winding machine can accommodate the chosen shape. c) Shallow grooves could be formed on the surface of the mandrel to give the liner a bellows-like character for reinforcement and/or to accommodate expansion and contraction.

DeLay, Tom↗

Simulation of Guided Wave Interaction with In-Plane Fiber Waviness

Reducing the timeline for certification of composite materials and enabling the expanded use of advanced composite materials for aerospace applications are two primary goals of NASA's Advanced Composites Project (ACP). A key a technical challenge area for accomplishing these goals is the development of rapid composite inspection methods with improved defect characterization capabilities. Ongoing work at NASA Langley is focused on expanding ultrasonic simulation capabilities for composite materials. Simulation tools can be used to guide the development of optimal inspection methods. Custom code based on elastodynamic finite integration technique is currently being developed and implemented to study ultrasonic wave interaction with manufacturing defects, such as in-plane fiber waviness (marcelling). This paper describes details of validation comparisons performed to enable simulation of guided wave propagation in composites containing fiber waviness. Simulation results for guided wave interaction with in-plane fiber waviness are also discussed. The results show that the wavefield is affected by the presence of waviness on both the surface containing fiber waviness, as well as the opposite surface to the location of waviness.

Leckey, Cara A. C.↗

MAC/GMC 4.0 User's Manual: Keywords Manual

This document is the second volume in the three volume set of User's Manuals for the Micromechanics Analysis Code with Generalized Method of Cells Version 4.0 (MAC/GMC 4.0). Volume 1 is the Theory Manual, this document is the Keywords Manual, and Volume 3 is the Example Problem Manual. MAC/GMC 4.0 is a composite material and laminate analysis software program developed at the NASA Glenn Research Center. It is based on the generalized method of cells (GMC) micromechanics theory, which provides access to the local stress and strain fields in the composite material. This access grants GMC the ability to accommodate arbitrary local models for inelastic material behavior and various types of damage and failure analysis. MAC/GMC 4.0 has been built around GMC to provide the theory with a user-friendly framework, along with a library of local inelastic, damage, and failure models. Further, applications of simulated thermo-mechanical loading, generation of output results, and selection of architectures to represent the composite material have been automated in MAC/GMC 4.0. Finally, classical lamination theory has been implemented within MAC/GMC 4.0 wherein GMC is used to model the composite material response of each ply. Consequently, the full range of GMC composite material capabilities is available for analysis of arbitrary laminate configurations as well. This volume describes the basic information required to use the MAC/GMC 4.0 software, including a 'Getting Started' section, and an in-depth description of each of the 22 keywords used in the input file to control the execution of the code.

Bednarcyk, Brett A.↗

MAC/GMC 4.0 User's Manual: Example Problem Manual

This document is the third volume in the three volume set of User's Manuals for the Micromechanics Analysis Code with Generalized Method of Cells Version 4.0 (MAC/GMC 4.0). Volume 1 is the Theory Manual, Volume 2 is the Keywords Manual, and this document is the Example Problems Manual. MAC/GMC 4.0 is a composite material and laminate analysis software program developed at the NASA Glenn Research Center. It is based on the generalized method of cells (GMC) micromechanics theory, which provides access to the local stress and strain fields in the composite material. This access grants GMC the ability to accommodate arbitrary local models for inelastic material behavior and various types of damage and failure analysis. MAC/GMC 4.0 has been built around GMC to provide the theory with a user-friendly framework, along with a library of local inelastic, damage, and failure models. Further, application of simulated thermo-mechanical loading, generation of output results, and selection of architectures to represent the composite material, have been automated in MAC/GMC 4.0. Finally, classical lamination theory has been implemented within MAC/GMC 4.0 wherein GMC is used to model the composite material response of each ply. Consequently, the full range of GMC composite material capabilities is available for analysis of arbitrary laminate configurations as well. This volume provides in-depth descriptions of 43 example problems, which were specially designed to highlight many of the most important capabilities of the code. The actual input files associated with each example problem are distributed with the MAC/GMC 4.0 software; thus providing the user with a convenient starting point for their own specialized problems of interest.

Bednarcyk, Brett A.↗

Fiber reinforced ceramic material

A strong and tough SiC/RBSN composite material is comprised of silicon fibers and a reaction bonded silicon nitride (RBSN) matrix. This composite material may be used at elevated temperatures up to at least 1400 C.

Ramakrishna T Bhatt↗

Sequestering compositions and materials

The present disclosure relates to a composition that includes a sequestering material capable of binding a target material, where the sequestering material includes a first component that includes at least one of a functional group, a molecule, an oligomer, or a polymer, and the target material includes at least one of an element, a chemical, and/or a compound. In some embodiments of the present disclosure, the element may include at least one element from at least one of Rows 4, 5, 6, and 7 of the Periodic Table and/or an inner transition metal.

Zhu, Kai↗

Adaptive materials and systems for manipulation of electromagnetic radiation

Fully artificial, adaptive composite materials and systems, having variable transmittance, reflectance, and/or absorptance to radiation in visible, infrared, or other desired region of the electromagnetic spectrum, and methods of the manufacture and use thereof are provided. The adaptive composite materials and systems possess an unprecedented combination of properties and are, therefore, poised to enable a broad range of practical applications. The adaptive composite material incorporates at least one size-variable active area having a variable transmittance, reflectance, and/or absorptance in at least a portion of the electromagnetic spectrum and comprises at least: an elastomer substrate, a texturizing layer disposed on top of the substrate, and an optional reflective coating disposed on top of the texturizing layer. In operation, the stretching and relaxation of the elastomer substrate causes changes in the surface morphology of the texturized layers (e.g., the change in the size and depth of surface features in the texturizing layer), this in turn results in the increased or decreased transmittivity, reflectivity, and/or absorptivity of the active area.

Gorodetsky, Alon A.↗

Improved Anode for a Direct Methanol Fuel Cell

A modified chemical composition has been devised to improve the performance of the anode of a direct methanol fuel cell. The main feature of the modified composition is the incorporation of hydrous ruthenium oxide into the anode structure. This modification can reduce the internal electrical resistance of the cell and increase the degree of utilization of the anode catalyst. As a result, a higher anode current density can be sustained with a smaller amount of anode catalyst. These improvements can translate into a smaller fuel-cell system and higher efficiency of conversion. Some background information is helpful for understanding the benefit afforded by the addition of hydrous ruthenium oxide. The anode of a direct methanol fuel cell sustains the electro-oxidation of methanol to carbon dioxide in the reaction CH3OH + H2O--->CO2 + 6H(+) + 6e(-). An electrocatalyst is needed to enable this reaction to occur. The catalyst that offers the highest activity is an alloy of approximately equal numbers of atoms of the noble metals platinum and ruthenium. The anode is made of a composite material that includes high-surface-area Pt/Ru alloy particles and a proton-conducting ionomeric material. This composite is usually deposited onto a polymer-electrolyte (proton-conducting) membrane and onto an anode gas-diffusion/current-collector sheet that is subsequently bonded to the proton-conducting membrane by hot pressing. Heretofore, the areal density of noble-metal catalyst typically needed for high performance has been about 8 mg/cm2. However, not all of the catalyst has been utilized in the catalyzed electro-oxidation reaction. Increasing the degree of utilization of the catalyst would make it possible to improve the performance of the cell for a given catalyst loading and/or reduce the catalyst loading (thereby reducing the cost of the cell). The use of carbon and possibly other electronic conductors in the catalyst layer has been proposed for increasing the utilization of the catalyst by increasing electrical connectivity between catalyst particles. However, the relatively low density of carbon results in thick catalyst layers that impede the mass transport of methanol to the catalytic sites. Also, the electrical conductivity of carbon is less than 1/300th of typical metals. Furthermore, the polymer-electrolyte membrane material is acidic and most metals are not chemically stable in contact with it. Finally, a material that conducts electrons (but not protons) does not contribute to the needed transport of protons produced in the electro-oxidation reaction.

Valdez, Thomas↗

Stiffness and Fatigue Life Estimator for Polymer Composite Laminates Using Machine Learning

Machine learning (ML) models are increasingly being used in many engineering fields due to the advancements in ML algorithms and availability of high-speed computing power. One of the most popular ML class of models is artificial neural networks (ANN). ML is increasingly being used in the design and analysis of composite materials and structures, specifically in the constitutive modeling of composite materials with the focus on greatly accelerating multiscale analyses of composite materials and structures through development of surrogate models. Towards that end, Python-based neural nets have been developed to predict initial stiffness and fatigue life of an eight-ply symmetric polymer matrix composite laminate. Two types of neural networks, a Multilayer Perceptron (MLP) and a Recurrent Neural Network (RNN), have been established. Results show that both neural net type algorithms can provide an excellent estimate of initial laminate stiffness as well as fatigue life of eight-ply symmetric polymer matrix composite laminates (PMCs). RNNs are better able to capture the shape of the fatigue curve of a laminate. The resulting tool and GUI can be very useful for system level studies to obtain an estimate of desired properties and life of PMC composite laminates. Further, the associated surrogate models can also be used in composite multiscale analyses to replace the actual physics-based calculations at lower scales and thereby significantly increase the computational efficiency of such analyses and thus make micromechanics-based multiscale analyses a viable industrial tool for large scale structural problems.

multiscale analysis↗

Stiffness and Fatigue Life Estimator for Polymer Composite Laminates Using Machine Learning

Machine learning (ML) models are increasingly being used in many engineering fields due to the advancements in ML algorithms and availability of high-speed computing power. One of the most popular ML class of models is artificial neural networks (ANN). ML is increasingly being used in the design and analysis of composite materials and structures, specifically in the constitutive modeling of composite materials with the focus on greatly accelerating multiscale analyses of composite materials and structures through development of surrogate models. Towards that end, Python-based neural nets have been developed to predict initial stiffness and fatigue life of an eight-ply symmetric polymer matrix composite laminate. Two types of neural networks, a Multilayer Perceptron (MLP) and a Recurrent Neural Network (RNN), have been established. Results show that both neural net type algorithms can provide an excellent estimate of initial laminate stiffness as well as fatigue life of eight-ply symmetric polymer matrix composite laminates (PMCs). RNNs are better able to capture the shape of the fatigue curve of a laminate. The resulting tool and GUI can be very useful for system level studies to obtain an estimate of desired properties and life of PMC composite laminates. Further, the associated surrogate models can also be used in composite multiscale analyses to replace the actual physics-based calculations at lower scales and thereby significantly increase the computational efficiency of such analyses and thus make micromechanics-based multiscale analyses a viable industrial tool for large scale structural problems.

multiscale analysis↗

Prediction of Stiffness and Fatigue Lives of Polymer Matrix Composite Laminates Using Artificial Neural Networks

Machine learning (ML) models are increasingly being used in many engineering fields due to the advancements in ML algorithms and availability of high-speed computing power. One of the most popular ML class of models is artificial neural networks (ANN). ML is increasingly being used in the design and analysis of composite materials and structures, specifically in the constitutive modeling of composite materials with the focus on greatly accelerating multiscale analyses of composite materials and structures through development of surrogate models. Towards that end, both Python and MATLAB-based neural nets have been developed to predict initial stiffness and fatigue life of an eight-ply symmetric polymer matrix composite laminate. Two types of neural networks, a Multilayer Perceptron (MLP) and a Recurrent Neural Network (RNN), have been developed for both platforms. Results show that the both neural net types can provide an excellent estimate of initial stiffness as well as fatigue life of eight-ply symmetric polymer matrix composite laminate. RNNs are better able to capture the shape of the fatigue curve of a laminate. This tool can be very useful for system level studies to obtain an estimate of desired properties and life of PMC composite laminates. The associated surrogate models could also be used in composite multiscale analyses to replace the actual physics-based calculations at lower scales and thereby significantly increase the computational efficiency of such analyses and thus make multiscale analyses a viable industrial tool for large scale structural problems.

Composite↗

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗

Summary results of the Industry Conference on the Commercial Use of Space

The future intentions of the Federal Republic of Germany in the area of the commercialization of space are presented. It is shown that significant advances in microgravity research, particulary in the areas of materials science, composite materials, physical chemistry, crystal growth, biology, and process engineering will have an effect on future plans for establishing sponsoring organizations to guide commercial interests in German space research. An organizational and functional outline of a proposed sponsoring organization to promote space commercialization under German supervision, including the objectives, the target group to be served, and the administrative structure, is presented. The role of the DFVLR (German Aerospace Research Establishment) and the BMFT (German Ministry for Research and Technology) as sponsoring organizations representing the interests of the German government is shown.

REUSE↗

Experimental and analytical study of the effects of floor location on response of composite fuselage frames

Experimental and analytical results are presented of the effects of floor placement on the structural response and strength of I-cross section, semi-circular fuselage frames constructed of graphite-epoxy composite material. The composite frame configuration is representative of current conventional aircraft design. Experimental strain distributions are presented from static loading tests of the composite frames and compared with finite element structural models and closed form solutions. An understanding of floor location effects can aid dynamists in predicting the crash behavior of these conventional structures, and may assist the designer in developing crashworthy structures for future aircraft.

Jones, Lisa E.↗