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All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Low Cost Large Core Vehicle Structures Assessment

Boeing Information, Space, and Defense Systems executed a Low Cost Large Core Vehicle Structures Assessment (LCLCVSA) under contract to NASA Marshall Space Flight Center (MSFC) between November 1997 and March 1998. NASA is interested in a low-cost launch vehicle, code named Magnum, to place heavy payloads into low earth orbit for missions such as a manned mission to Mars, a Next Generation Space Telescope, a lunar-based telescope, the Air Force's proposed space based laser, and large commercial satellites. In this study, structural concepts with the potential to reduce fabrication costs were evaluated in application to the Magnum Launch Vehicle (MLV) and the Liquid Fly Back Booster (LFBB) shuttle upgrade program. Seventeen concepts were qualitatively evaluated to select four concepts for more in-depth study. The four structural concepts selected were: an aluminum-lithium monocoque structure, an aluminum-lithium machined isogrid structure, a unitized composite sandwich structure, and a unitized composite grid structure. These were compared against a baseline concept based on the Space Shuttle External Tank (ET) construction. It was found that unitized composite structures offer significant cost and weight benefits to MLV structures. The limited study of application to LFBB structures indicated lower, but still significant benefits. Technology and facilities development roadmaps to prepare the approaches studied for application to MLV and LFBB were constructed. It was found that the cost and schedule to develop these approaches were in line with both MLV and LFBB development schedules. Current Government and Boeing programs which address elements of the development of the technologies identified are underway. It is recommended that NASA devote resources in a timely fashion to address the specific elements related to MLV and LFBB structures.

Hahn, Steven E.↗
NASA NTRS1983

Characterization of composite materials by means of the ultrasonic stress wave factor

The usual approach to nondestructively evaluating a composite structure involves inspection and mechanical analysis of the inspection results. Such an approach has met with only limited success. On the other hand, the ultrasonic stress wave factor technique directly evaluates the material. Despite requiring access to only one surface of the material, the technique interrogates the material in the directions of applied load. Using the stress wave factor technique it is possible to determine the failure location in the material. The correlation of the stress wave factor with stiffness is shown. In addition, the use of the technique for determining the strength or life of composite material structures is discussed.

Duke, J. C., Jr.↗
NASA NTRS1985

Fuel containment, lightning protection and damage tolerance in large composite primary aircraft structures

The damage-tolerance characteristics of high strain-to-failure graphite fibers and toughened resins were evaluated. Test results show that conventional fuel tank sealing techniques are applicable to composite structures. Techniques were developed to prevent fuel leaks due to low-energy impact damage. For wing panels subjected to swept stroke lightning strikes, a surface protection of graphite/aluminum wire fabric and a fastener treatment proved effective in eliminating internal sparking and reducing structural damage. The technology features developed were incorporated and demonstrated in a test panel designed to meet the strength, stiffness, and damage tolerance requirements of a large commercial transport aircraft. The panel test results exceeded design requirements for all test conditions. Wing surfaces constructed with composites offer large weight savings if design allowable strains for compression can be increased from current levels.

Griffin, Charles F.↗
NASA NTRSDate not supplied

Finite Element Analysis Validation for Stitched, Blade-Stiffened Aerospace Structures

Increased performance and manufacturing rates for aircraft or spacecraft structures may be achieved using stitched and resin infused composite structures. In order to carry out design and analysis of stitched composites, 2-dimensional (2-D) and 3-dimensional (3-D) modeling approaches for stitched and non-stitched carbon fiber vacuum-infused parts were developed. These analysis approaches will be compared with data from previous test specimens tested at the NASA Langley Research Center (LaRC) under tension and bending load conditions. The preliminary results presented herein for the 2-D and 3-D models capture the strain patterns observed in digital image correlation (DIC) data for stitched, blade-stiffened specimens tested in either tension or bending. The analysis method study presented for these specimens is part of a larger analysis development effort planned for stitched composites, with the modeling practices developed here contributing to those that may be applied to a new set of blade- stiffened test specimens that are currently being manufactured for testing as well as the design of a blade stringer pull-off test. These future tests are expected to provide opportunities to validate the developed modeling approaches for predictive purposes, and to provide opportunities for further refinement of the modeling approaches.

HiCAM↗
NASA NTRS2011

Accelerated Aging Experiments for Prognostics of Damage Growth in Composite Materials

Composite structures are gaining importance for use in the aerospace industry. Compared to metallic structures their behavior is less well understood. This lack of understanding may pose constraints on their use. One possible way to deal with some of the risks associated with potential failure is to perform in-situ monitoring to detect precursors of failures. Prognostic algorithms can be used to predict impending failures. They require large amounts of training data to build and tune damage model for making useful predictions. One of the key aspects is to get confirmatory feedback from data as damage progresses. These kinds of data are rarely available from actual systems. The next possible resource to collect such data is an accelerated aging platform. To that end this paper describes a fatigue cycling experiment with the goal to stress carbon-carbon composite coupons with various layups. Piezoelectric disc sensors were used to periodically interrogate the system. Analysis showed distinct differences in the signatures of growing failures between data collected at conditions. Periodic X-radiographs were taken to assess the damage ground truth. Results after signal processing showed clear trends of damage growth that were correlated to damage assessed from the X-ray images.

composites↗
NASA NTRS2013

Applying a Stitched, Rod-Stiffened Concept to Heavily Loaded Structure

NASA and the Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft wing structure, first in the NASA Advanced Composites Technology (ACT) program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the labor associated with panel fabrication and assembly can be significantly reduced and the need for mechanical fasteners is almost eliminated. Stitching provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. Stitching also reduces part count, and therefore, cost of the structure. The stitched panel concept used in the ACT program in the 1990's used simple blade-stiffeners as stringers, caps and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. A comparison between the blade-stiffened structure and PRSEUS is presented focusing on highly loaded structure and demonstrating improved weight reduction.

Jegley, Dawn C.↗
NASA NTRS2024

Advances in Thermoplastic Composites Over Three Decades – A Literature Review

Recently, there has been a renewed interest in thermoplastic composites driven mainly by advances in automation which can lead to significant cost reductions by increasing manufacturing rates while simultaneously reducing the part count and energy consumption relative to the manufacturing of thermoset composites. At the same time, new material systems have been developed and the thermoplastic composites prepreg material quality has improved over time. Additionally, thermoplastic composites have nearly infinite room-temperature shelf life and production scraps can be reused and retired parts can be recycled, providing opportunities for more sustainable operations and downstream markets. These factors have contributed to a strong interest in advancing thermoplastic composites for aerospace, automotive, and other industrial applications. The objective of the present study is to assess the state of the art regarding the maturity and performance of thermoplastic composite materials and to document the advances made in manufacturing and assembly of thermoplastic composite structures. Therefore, more than 200 NASA reports, conference proceedings and journal papers spanning three and a half decades (1986-2022) were reviewed and the findings summarized. The current study, however, is limited in scope with a focus on the application of thermoplastic composites to aircraft structures. Further, the study does not provide a comprehensive assessment of the available literature but rather offers an overview of past and present research being conducted in the field of thermoplastic composites. The information provided may be used to identify gaps and help guide future research and development. In this report, the opportunities offered by the use of thermoplastic composites in general and challenges encountered in particular are presented first. Second, an overview of thermoplastic materials is presented, manufacturing methods are discussed, and new methods for fastener-less assembly such as welding are introduced. Third, tests that have been performed on different levels of the building block, ranging from coupon to structural level, are presented. In particular, fracture toughness results for different thermoplastic composite materials are used to demonstrate their performance compared to state-of-the-art thermoset composites. Fourth, several examples of analyses are discussed including process modelling and progressive damage analysis (PDA). An extensive list of references and appendices with tables support the narrative. Lastly, a brief summary with outlook and recommendations for future research is provided.

composites↗
NASA NTRS1976

An advanced structural analysis/synthesis capability - ACCESS 2

An advanced automated design procedure for minimum-weight design of structures (ACCESS 2) is reported. Design variable linking, constraint deletion, and explicit constraint approximation are used to combine effectively finite-element and nonlinear mathematical programming techniques. The approximation-concepts approach to structural synthesis is extended to problems involving fiber composite structure, thermal effects, and natural frequency constraints in addition to the usual static stress and displacement limitations. Sample results illustrating these features are given.

Schmit, L. A.↗
NASA NTRS1978

An advanced structural analysis/synthesis capability - ACCESS 2

An advanced automated design procedure for minimum weight design of structures (ACCESS 2) is reported. Design variable linking, constraint deletion, and explicit constraint approximation are used to effectively combine finite element and nonlinear mathematical programming techniques. The approximation concepts approach to structural synthesis is extended to problems involving fiber composite structure, thermal effects and natural frequency constraints in addition to the usual static stress and displacement limitations. Sample results illustrating these new features are given.

Schmit, L. A.↗
NASA NTRS1983

Advances and trends in structural and solid mechanics; Proceedings of the Symposium, Washington, DC, October 4-7, 1982

The mechanics of materials and material characterization are considered, taking into account micromechanics, the behavior of steel structures at elevated temperatures, and an anisotropic plasticity model for inelastic multiaxial cyclic deformation. Other topics explored are related to advances and trends in finite element technology, classical analytical techniques and their computer implementation, interactive computing and computational strategies for nonlinear problems, advances and trends in numerical analysis, database management systems and CAD/CAM, space structures and vehicle crashworthiness, beams, plates and fibrous composite structures, design-oriented analysis, artificial intelligence and optimization, contact problems, random waves, and lifetime prediction. Earthquake-resistant structures and other advanced structural applications are also discussed, giving attention to cumulative damage in steel structures subjected to earthquake ground motions, and a mixed domain analysis of nuclear containment structures using impulse functions.

Noor, A. K.↗
NASA NTRS1992

NASA advanced design program: Analysis, design, and construction of a solar powered aircraft

Increase in energy demands coupled with rapid depletion of natural energy resources have deemed solar energy as the most logical alternative source of power. The major objective of this project was to build a solar powered remotely controlled aircraft to demonstrate the feasibility of solar energy as an effective, alternate source of power. The final design was optimized for minimum weight and maximum strength of the structure. These design constraints necessitated a carbon fiber composite structure. Surya is a lightweight, durable aircraft capable of achieving level flight powered entirely by solar cells.

Chan, Agnes↗
NASA NTRS2005

Atmospheric Hydroperoxides in West Antarctica: Links to Stratospheric Ozone and Atmospheric Oxidation Capacity

The troposphere above the West Antarctic Ice Sheet (WAIS) was sampled for hydroperoxides at 21 locations during 2-month-long summer traverses from 2000 to 2002, as part of US ITASE (International Transantarctic Scientific Expedition). First time quantitative measurements using an HPLC method showed that methylhydroperoxide (MHP) is the only important organic hydroperoxide occurring in the Antarctic troposphere, and that it is found at levels ten times those previously predicted by photochemical models. During three field seasons, means and standard deviations for hydrogen peroxide (H2O2) were 321+/-158 pptv, 650+/-176 pptv and 330+/-147 pptv. While MHP was detected, but not quantified in December 2000, levels in summer 2001 and 2002 were 317+128 pptv and 304+/-172.2 pptv. Results from firn air experiments and diurnal variability of the two species showed that atmospheric H2O2 is significantly impacted by a physical snow pack source between 76 and 90degS, whereas MHP is not. We show strong evidence of a positive feedback between stratospheric ozone and H2O2 at the surface. Between November-27 and December-12 in 2001, when ozone column densities dropped below 220 DU (means in 2000 and 2001 were 318 DU and 334 DU, respectively), H2O2 was 1.7 times that observed in the same period in 2000 and 2002, while MHP was only 80% of the levels encountered in 2002. Photochemical box model runs suggest that NO and OH levels on WAIS are closer to coastal values, while Antarctic Plateau levels are higher, confirming that region to be a highly oxidizing environment. The modeled sensitivity of H2O2 and particularly MHP to NO offers the potential to use atmospheric hydroperoxides to constrain the NO background and thus estimate the past oxidation capacity of the remote atmosphere. Index Terms: 0365 Atmospheric Composition and Structure: Troposphere: composition and chemistry; 0322 Atmospheric Composition and Structure: Constituent sources and sinks; 1610 Global Change: Atmosphere (03 15,0325); 0736 Cryosphere: Snow (1827, 1863); 0724 Cryosphere: Ice Cores (4932) Keywords: hydrogen peroxide, methylhydroperoxide, Antarctica, air-snow exchange, stratospheric ozone, atmospheric oxidation capacity

Frey, Markus M.↗
NASA NTRS2007

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin↗
NASA NTRS2008

Precision Cleaning - Path to Premier

ITT Space Systems Division s new Precision Cleaning facility provides critical cleaning and packaging of aerospace flight hardware and optical payloads to meet customer performance requirements. The Precision Cleaning Path to Premier Project was a 2007 capital project and is a key element in the approved Premier Resource Management - Integrated Supply Chain Footprint Optimization Project. Formerly precision cleaning was located offsite in a leased building. A new facility equipped with modern precision cleaning equipment including advanced process analytical technology and improved capabilities was designed and built after outsourcing solutions were investigated and found lacking in ability to meet quality specifications and schedule needs. SSD cleans parts that can range in size from a single threaded fastener all the way up to large composite structures. Materials that can be processed include optics, composites, metals and various high performance coatings. We are required to provide verification to our customers that we have met their particulate and molecular cleanliness requirements and we have that analytical capability in this new facility. The new facility footprint is approximately half the size of the former leased operation and provides double the amount of throughput. Process improvements and new cleaning equipment are projected to increase 1st pass yield from 78% to 98% avoiding $300K+/yr in rework costs. Cost avoidance of $350K/yr will result from elimination of rent, IT services, transportation, and decreased utility costs. Savings due to reduced staff expected to net $4-500K/yr.

Mackler, Scott E.↗
NASA NTRS2020

On Orbit Flight Testing of the Roll-Out Solar Array

The Roll-Out Solar Array (ROSA) is an innovative, lightweight solar array with a flexible substrate that makes use of the stored strain energy in its composite structural members to provide deployment without the use of motors while still packaging efficiently. The ROSA flight experiment was launched to the International Space Station (ISS)on June 3rd, 2017 as a part of the eleventh SpaceX commercial resupply mission. After two weeks of storage, ROSA was extracted from the Dragon spacecraft, deployed, and put through a week of tests to verify its structural characteristics as well as the performance of photovoltaics. The structural dynamics experiments included active excitation of out-of-plane bending modes, and a study of the thermal-structural interaction of the structure during day-night transitions. Data was gathered from a small number of accelerometers located at key points on the solar array and from cameras observing numerous photogrammetry targets spread out over the structure and the photovoltaic blanket. The goal in this effort was to better understand the performance of ROSA and to improve modeling efforts for future designs of similar solar arrays. Of particular interest are the first few system modes and mode shapes of the array, the amount of structural damping present, and degree of structural-thermal interaction seen during eclipse exit.

ROSA↗