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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Ultrasonic Nondestructive Characterization of Adhesive Bonds

Adhesives and adhesive joints are widely used in various industrial applications to reduce weight and costs, and to increase reliability. For example, advances in aerospace technology have been made possible, in part, through the use of lightweight materials and weight-saving structural designs. Joints, in particular, have been and continue to be areas in which weight can be trimmed from an airframe through the use of novel attachment techniques. In order to save weight over traditional riveted designs, to avoid the introduction of stress concentrations associated with rivet holes, and to take full advantage of advanced composite materials, engineers and designers have been specifying an ever-increasing number of adhesively bonded joints for use on airframes. Nondestructive characterization for quality control and remaining life prediction has been a key enabling technology for the effective use of adhesive joints. Conventional linear ultrasonic techniques generally can only detect flaws (delamination, cracks, voids, etc) in the joint assembly. However, more important to structural reliability is the bond strength. Although strength, in principle, cannot be measured nondestructively, a slight change in material nonlinearity may indicate the onset of failure. Furthermore, microstructural variations due to aging or under-curing may also cause changes in the third order elastic constants, which are related to the ultrasonic nonlinear parameter of the polymer adhesive. It is therefore reasonable to anticipate a correlation between changes in the ultrasonic nonlinear acoustic parameter and the remaining bond strength. It has been observed that higher harmonics of the fundamental frequency are generated when an ultrasonic wave passes through a nonlinear material. It seems that such nonlinearity can be effectively used to characterize bond strength. Several theories have been developed to model this nonlinear effect. Based on a microscopic description of the nonlinear interface binding force, a quantitative method was presented. Recently, a comparison between the experimental and simulated results based on a similar theoretical model was presented. A through-transmission setup for water immersion mode-converted shear waves was used to analyze the ultrasonic nonlinear parameter of an adhesive bond. In addition, ultrasonic guided waves have been used to analyze adhesive or diffusion bonded joints. In this paper, the ultrasonic nonlinear parameter is used to characterize the curing state of a polymer/aluminum adhesive joint. Ultrasonic through-transmission tests were conducted on samples cured under various conditions. The magnitude of the second order harmonic was measured and the corresponding ultrasonic nonlinear parameter was evaluated. A fairly good correlation between the curing condition and the nonlinear parameter is observed. The results show that the nonlinear parameter might be used as a good indicator of the cure state for adhesive joints.

Qu, Jianmin↗
NASA NTRS2001

The Transition from Hydrogen Bonding to Ionization in (HCI)n(NH3)n and (HCI)n(H2O)n Clusters: Consequences for Anharmonic Vibrational Spectroscopy

Anharmonic vibrational frequencies and intensities are calculated for 1:1 and 2:2 (HCl)(sub n)(NH3)(sub n) and (HCl)(sub n)(H2O)(sub n) complexes, employing the correlation-corrected vibrational self-consistent field method with ab initio potential surfaces at the MP2/TZP computational level. In this method, the anharmonic coupling between all vibrational modes is included, which is found to be important for the systems studied. For the 4:4 (HCl)(sub n)(H2O)(sub n) complex, the vibrational spectra are calculated at the harmonic level, and anharmonic effects are estimated. Just as the (HCl)(sub n)(NH3)(sub n) structure switches from hydrogen-bonded to ionic for n=2, the (HCl)(sub n)(H2O)(sub n) switches to ionic structure for n=4. For (HCl)2(H2O)2, the lowest energy structure corresponds to the hydrogen-bonded form. However, configurations of the ionic form are separated from this minimum by a barrier of less than an O-H stretching quantum. This suggests the possibility of experiments on ionization dynamics using infrared excitation of the hydrogen-bonded form. The strong cooperative effects on the hydrogen bonding, and concomitant transition to ionic bonding, makes an accurate estimate of the large anharmonicity crucial for understanding the infrared spectra of these systems. The anharmonicity is typically of the order of several hundred wave numbers for the proton stretching motions involved in hydrogen or ionic bonding, and can also be quite large for the intramolecular modes. In addition, the large cooperative effects in the 2:2 and higher order (HCl(sub n)(H2O)(sub n) complexes may have interesting implications for solvation of hydrogen halides at ice surfaces.

Chaban, Galina M.↗
NASA NTRS2002

Mullite+CAS Bond Coat for Environmental Barrier Coatings for Si-Based Ceramics

Current environmental barrier coatings (EBCs) for silicon-based ceramics consist of a bond coat and a top coat. Mullite bond coat modified by adding low CTE glass ceramics, such as BSAS (xBaO.1xSrO.Al2O3.2SiO2) or CAS (CaO.Al2O3.2SiO2), was developed in the NASA Enabling Propulsion Materials (EPM) Program. EBCs based on mullite+CAS bond coat were characterized using high steam thermal cycling test and high steam isothermal thermogravemitry (TGA) at 1225 C - 13,000 C. The Mullite+CAS bond coat showed far superior durability compared to mullite bond coat, due to enhanced crack resistance. A BSAS top coat provided further improved durability compared to EBCs with a yttria-stabilized zirconia (YSZ) top coat. Still further improvement in the durability was achieved by adding a silicon bond coat between the mullite and the substrate. However, the silicon/mullite+CAS/BSAS EBC showed inferior long-term durability compared to the current state-of-the art EBC (silicon/mullite+BSAS/BSAS EBC), presumably due to the higher CAS-silica chemical reactivity.

Lee, Kang N.↗
NASA NTRS2003

Bond Sensitivity to Silicone Contamination

Currently during fabrication of the Space Shuttle booster rocket motors, the use of silicone and silicone-containing products is prohibited in most applications. Many shop aids and other materials containing silicone have the potential, if they make contact with a bond surface, to transfer some of the silicone to the substrates being bonded. Such transfer could result in a reduction of the bond strength or even failure of the subsequent bonds. This concern is driving the need to understand the effect of silicones and the concentration needed to affect a given bond-line strength. Additionally, as silicone detection methods used for materials acceptance improve what may have gone unnoticed earlier is now being detected. Thus, realistic silicone limits for process materials (below which bond performance is satisfactory) are needed rather than having an absolute no silicone permitted policy.

Caldwell, G. A.↗
NASA NTRS2003

Using Bond Graphs for Articulated, Flexible Multi-bodies, Sensors, Actuators, and Controllers with Application to the International Space Station

Conceptually, modeling of flexible, multi-body systems involves a formulation as a set of time-dependent partial differential equations. However, for practical, engineering purposes, this modeling is usually done using the method of Finite Elements, which approximates the set of partial differential equations, thus generalizing the approach to all continuous media. This research investigates the links between the Bond Graph method and the classical methods used to develop system models and advocates the Bond Graph Methodology and current bond graph tools as alternate approaches that will lead to a quick and precise understanding of a flexible multi-body system under automatic control. For long endurance, complex spacecraft, because of articulation and mission evolution the model of the physical system may change frequently. So a method of automatic generation and regeneration of system models that does not lead to implicit equations, as does the Lagrange equation approach, is desirable. The bond graph method has been shown to be amenable to automatic generation of equations with appropriate consideration of causality. Indeed human-interactive software now exists that automatically generates both symbolic and numeric system models and evaluates causality as the user develops the model, e.g. the CAMP-G software package. In this paper the CAMP-G package is used to generate a bond graph model of the International Space Station (ISS) at an early stage in its assembly, Zvezda. The ISS is an ideal example because it is a collection of bodies that are articulated, many of which are highly flexible. Also many reaction jets are used to control translation and attitude, and many electric motors are used to articulate appendages, which consist of photovoltaic arrays and composite assemblies. The Zvezda bond graph model is compared to an existing model, which was generated by the NASA Johnson Space Center during the Verification and Analysis Cycle of Zvezda.

Montgomery, Raymond C.↗
NASA NTRS2003

Automated Modeling and Simulation Using the Bond Graph Method for the Aerospace Industry

Bond graph modeling was originally developed in the late 1950s by the late Prof. Henry M. Paynter of M.I.T. Prof. Paynter acted well before his time as the main advantage of his creation, other than the modeling insight that it provides and the ability of effectively dealing with Mechatronics, came into fruition only with the recent advent of modern computer technology and the tools derived as a result of it, including symbolic manipulation, MATLAB, and SIMULINK and the Computer Aided Modeling Program (CAMPG). Thus, only recently have these tools been available allowing one to fully utilize the advantages that the bond graph method has to offer. The purpose of this paper is to help fill the knowledge void concerning its use of bond graphs in the aerospace industry. The paper first presents simple examples to serve as a tutorial on bond graphs for those not familiar with the technique. The reader is given the basic understanding needed to appreciate the applications that follow. After that, several aerospace applications are developed such as modeling of an arresting system for aircraft carrier landings, suspension models used for landing gears and multibody dynamics. The paper presents also an update on NASA's progress in modeling the International Space Station (ISS) using bond graph techniques, and an advanced actuation system utilizing shape memory alloys. The later covers the Mechatronics advantages of the bond graph method, applications that simultaneously involves mechanical, hydraulic, thermal, and electrical subsystem modeling.

Granda, Jose J.↗
NASA NTRS2003

The Evaluation of High Temperature Adhesive Bonding Processes for Rocket Engine Combustion Chamber Applications

NASA Glenn Research Center is currently evaluating the possibility of using high- temperature polymer matrix composites to reinforce the combustion chamber of a rocket engine. One potential design utilizes a honeycomb structure composed of a PMR-II- 50/M40J 4HS composite facesheet and titanium honeycomb core to reinforce a stainless steel shell. In order to properly fabricate this structure, adhesive bond PMR-II-50 composite. Proper prebond surface preparation is critical in order to obtain an acceptable adhesive bond. Improperly treated surfaces will exhibit decreased bond strength and durability, especially in metallic bonds where interface are susceptible to degradation due to heat and moisture. Most treatments for titanium and stainless steel alloys require the use of strong chemicals to etch and clean the surface. This processes are difficult to perform due to limited processing facilities as well as safety and environmental risks and they do not consistently yield optimum bond durability. Boeing Phantom Works previously developed sol-gel surface preparations for titanium alloys using a PETI-5 based polyimide adhesive. In support of part of NASA Glenn Research Center, UDRI and Boeing Phantom Works evaluated variations of this high temperature sol-gel surface preparation, primer type, and primer cure conditions on the adhesion performance of titanium and stainless steel using Cytec FM 680-1 polyimide adhesive. It was also found that a modified cure cycle of the FM 680-1 adhesive, i.e., 4 hrs at 370 F in vacuum + post cure, significantly increased the adhesion strength compared to the manufacturer's suggested cure cycle. In addition, the surface preparation of the PMR-II-50 composite was evaluated in terms of surface cleanness and roughness. This presentation will discuss the results of strength and durability testing conducted on titanium, stainless steel, and PMR-II-50 composite adherends to evaluate possible bonding processes.

McCray, Daniel↗
NASA NTRS1990

Design/Analysis of the JWST ISIM Bonded Joints for Survivability at Cryogenic Temperatures

A major design and analysis challenge for the JWST ISIM structure is thermal survivability of metal/composite bonded joints below the cryogenic temperature of 30K (-405 F). Current bonded joint concepts include internal invar plug fittings, external saddle titanium/invar fittings and composite gusset/clip joints all bonded to M55J/954-6 and T300/954-6 hybrid composite tubes (75mm square). Analytical experience and design work done on metal/composite bonded joints at temperatures below that of liquid nitrogen are limited and important analysis tools, material properties, and failure criteria for composites at cryogenic temperatures are sparse in the literature. Increasing this challenge is the difficulty in testing for these required tools and properties at cryogenic temperatures. To gain confidence in analyzing and designing the ISIM joints, a comprehensive joint development test program has been planned and is currently running. The test program is designed to produce required analytical tools and develop a composite failure criterion for bonded joint strengths at cryogenic temperatures. Finite element analysis is used to design simple test coupons that simulate anticipated stress states in the flight joints; subsequently the test results are used to correlate the analysis technique for the final design of the bonded joints. In this work, we present an overview of the analysis and test methodology, current results, and working joint designs based on developed techniques and properties.

Bartoszyk, Andrew↗
NASA NTRS2005

Qualifying a Bonding Process for the Space Interferometry Mission

The Space Interferometry Mission consists of three parallel Michelson interferometers that will be capable of detecting extrasolar planets with a high degree of accuracy and precision. High levels of stability must be met in order to fulfill the scientific requirements of this mission. To attain successful measurements the coefficient of thermal expansion between optics and bonding material must be minimized without jeopardizing the integrity of the bonds. Optic-to-optic bonds have been analyzed to better understand variables such as the effects of the coefficient of thermal expansion differences between optics and bonding materials, and materials have been chosen for the project based on these analyses. A study was conducted to determine if a reliable, repeatable process for bonding by wicking adhesive could be obtained using a low-viscosity epoxy and ultra-low expansion glass. A process of creating a methodology of bonding fused silica optics with Z-6020 silane primer and Epo-Tek 301 epoxy will be discussed.

Joyce, Gretchen P.↗
NASA NTRS2006

Diffusion Bonding of Silicon Carbide Ceramics using Titanium Interlayers

Robust joining approaches for silicon carbide ceramics are critically needed to fabricate leak free joints with high temperature mechanical capability. In this study, titanium foils and physical vapor deposited (PVD) titanium coatings were used to form diffusion bonds between SiC ceramics using hot pressing. Silicon carbide substrate materials used for bonding include sintered SiC and two types of CVD SiC. Microscopy results show the formation of well adhered diffusion bonds. The bond strengths as determined from pull tests are on the order of several ksi, which is much higher than required for a proposed application. Microprobe results show the distribution of silicon, carbon, titanium, and other minor elements across the diffusion bond. Compositions of several phases formed in the joint region were identified. Potential issues of material compatibility and optimal bond formation will also be discussed.

Halbig, Michael C.↗
NASA NTRS2008

Bonding and Integration Technologies for Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding, titanium interlayers (PVD and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness (10, 20, and 50 microns), processing time and temperature, and cooling rates were investigated. Microprobe analysis was used to identify the phases in the bonded region. For bonds that were not fully reacted an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner titanium interlayers and/or longer processing times resulted in stable and compatible phases that did not contribute to microcracking and resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Non-destructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig, Michael C.↗
NASA NTRS2008

Hydroxide-Assisted Bonding of Ultra-Low-Expansion Glass

A process for hydroxide-assisted bonding has been developed as a means of joining optical components made of ultra-low-expansion (ULE) glass, while maintaining sufficiently precise alignment between. The process is intended mainly for use in applications in which (1) bonding of glass optical components by use of epoxy does not enable attainment of the required accuracy and dimensional stability and (2) conventional optical contacting (which affords the required accuracy and stability) does not afford adequate bond strength. The basic concept of hydroxide-assisted bonding is not new. The development of the present process was prompted by two considerations: (1) The expertise in hydroxide-assisted bonding has resided in very few places and the experts have not been willing to reveal the details of their processes and (2) data on the reliability and strength attainable by hydroxide-assisted bonding have been scarce.

Abramovici, Alexander↗
NASA NTRS2010

Laser Surface Preparation and Bonding of Aerospace Structural Composites

Adhesive bonds are critical to the integrity of built-up structures. Disbonds can often be detected but the strength of adhesion between surfaces in contact is not obtainable without destructive testing. Typically the number one problem in a bonded structure is surface contamination, and by extension, surface preparation. Standard surface preparation techniques, including grit blasting, manual abrasion, and peel ply, are not ideal because of variations in their application. Etching of carbon fiber reinforced plastic (CFRP) panels using a neodymium-doped yttrium aluminum garnet (Nd:YAG) laser appears to be a highly precise and promising way to both clean a composite surface prior to bonding and provide a bond-promoting patterned surface akin to peel ply without the inherent drawbacks from the same (i.e., debris and curvature). CFRP surfaces prepared using laser patterns conducive to adhesive bonding were compared to typical prebonding surface treatments through optical microscopy, contact angle goniometry, and post-bonding mechanical testing.

Belcher, M. A.↗
NASA NTRS2012

PRTs and Their Bonding for Long-Duration, Extreme-Temperature Environments

Research was conducted on the qualification of Honeywell platinum resistance thermometer (PRT) bonding for use in the Mars Science Laboratory (MSL). This is the first time these sensors will be used for Mars-related projects. Different types of PRTs were employed for the Mars Exploration Rover (MER) project, and several reliability issues were experienced, even for a shortduration mission like MER compared to MSL. Therefore, the development of a qualification process for the Honeywell PRT bonding was needed for the MSL project. Reliability of the PRT sensors, and their bonding processes, is a key element to understand the health of the hardware during all stages of the project, and particularly during surface operations on Mars. Three extreme temperature summer season cycles and three winter season cycles (total: 1983 thermal cycles) were completed, and no Honeywell PRT failures associated with the bonding process were found. Seventy-eight PRTs were bonded onto six different substrate materials using four different adhesives during the thermal cycling, which included a planetary protection cycle to +125 C for two hours, three protoflight/qualification cycles (-135 to 70 C), 1,384 summer cycles (-105 to 40 C), and 599 winter cycles (-130 to 15 C). There were no observed changes in PRT resistances, bonding characteristics, or damage identified from the package evaluation as a result of the qualification tests.

Ramesham, Rajeshuni↗
NASA NTRS2012

Method of Bonding Optical Elements with Near-Zero Displacement

The International X-ray Project seeks to build an x-ray telescope using thousands of pieces of thin and flexible glass mirror segments. Each mirror segment must be bonded into a housing in nearly perfect optical alignment without distortion. Forces greater than 0.001 Newton, or displacements greater than 0.5 m of the glass, cause unacceptable optical distortion. All known epoxies shrink as they cure. Even the epoxies with the least amount of shrinkage (<0.01%) cause unacceptable optical distortion and misalignment by pulling the mirror segments towards the housing as it cures. A related problem is that the shrinkage is not consistent or predictable so that it cannot be accounted for in the setup (i.e., if all of the bonds shrunk an equal amount, there would be no problem). A method has been developed that allows two components to be joined with epoxy in such a way that reduces the displacement caused by epoxy shrinking as it cures to less than 200 nm. The method involves using ultraviolet-cured epoxy with a displacement sensor and a nanoactuator in a control loop. The epoxy is cured by short-duration exposures to UV light. In between each exposure, the nano-actuator zeroes out the displacement caused by epoxy shrinkage and thermal expansion. After a few exposures, the epoxy has cured sufficiently to prevent further displacement of the two components. Bonding of optical elements has been done for many years, but most optics are thick and rigid elements that resist micro-Newton-level forces without causing distortion. When bonding thin glass optics such as the 0.40-mm thick IXO X-ray mirrors, forces in the micro- and milli-Newton levels cause unacceptable optical figure error. This innovation can now repeatedly and reliably bond a thin glass mirror to a metal housing with less than 0.2 m of displacement (<200 nm). This is an enabling technology that allows the installation of virtually stress-free, undistorted thin optics onto structures. This innovation is applicable to the bonding of thin optical elements, or any thin/flexible structures, that must be attached in an undistorted, consistent, and aligned way.

Robinson, David↗
NASA NTRS2008

Joining of Silicon Carbide: Diffusion Bond Optimization and Characterization

Joining and integration methods are critically needed as enabling technologies for the full utilization of advanced ceramic components in aerospace and aeronautics applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. In the application, several SiC substrates with different hole patterns to form fuel and combustion air channels are bonded to form the injector. Diffusion bonding is a joining approach that offers uniform bonds with high temperature capability, chemical stability, and high strength. Diffusion bonding was investigated with the aid of titanium foils and coatings as the interlayer between SiC substrates to aid bonding. The influence of such variables as interlayer type, interlayer thickness, substrate finish, and processing time were investigated. Optical microscopy, scanning electron microscopy, and electron microprobe analysis were used to characterize the bonds and to identify the reaction formed phases.

Halbig, Michael C.↗
NASA NTRS2015

Lightning Protection and Structural Bonding for the B2 Test Stand

With the privatization of the space industry, NASA has entered a new era. To explore deeper parts of the solar system, NASA is developing a new spacecraft, the Space Launch System (SLS), capable of reaching these destinations, such as an asteroid or Mars. However, the test stand that is capable of testing the stage has been unused for many years. In addition to the updating/repair of the stand, more steel is being added to fully support the SLS. With all these modifications, the lightning protection system must be brought up to code to assure the protection of all personnel and assets. Structural bonding is a part of the lightning protection system. The focus of this project was to assure proper structural bonding. To begin, all relevant technical standards and the construction specifications were reviewed. This included both the specifications for the lightning protection and for general construction. The drawings were reviewed as well. From the drawings, bolted structural joints were reviewed to determine whether bonding was necessary. Several bolted joints were determined to need bonding according to the notes in the drawings. This exceeds the industry standards. The bolted joints are an electrically continuous joint. During tests, the stand experiences heavy vibration that may weaken the continuity of the bolted joint. Therefore, the secondary bonding is implemented to ensure that the structural joint has low resistance. If the structural joint has a high resistance because of corrosion, a potential gradient can occur that can cause a side flash. Damage, injury, or death can occur from a side flash so they are to be prevented. A list of the identified structural joints was compiled and sent to the contractor to be bonded. That covers the scope of this project.

Kinard, Brandon↗
NASA NTRS2016

TEM Analysis of Interfaces in Diffusion-Bonded Silicon Carbide Ceramics Joined Using Metallic Interlayers

Silicon Carbide (SiC) is a promising material for thermo-structural applications due to its excellent high-temperature mechanical properties, oxidation resistance, and thermal stability. However, joining and integration technologies are indispensable for this material in order to fabricate large size and complex shape components with desired functionalities. Although diffusion bonding techniques using metallic interlayers have been commonly utilized to bond various SiC ceramics, detailed microstructural observation by Transmission Electron Microscopy (TEM) of the bonded area has not been carried out due to difficulty in preparing TEM samples. In this study, we tried to prepare TEM samples from joints of diffusion bonded SiC ceramics by Focused Ion Beam (FIB) system and carefully investigated the interfacial microstructure by TEM analysis. The samples used in this study were SiC fiber bonded ceramics (SA-Tyrannohex: SA-THX) diffusion bonded with metallic interlayers such as Ti, TiMo, and Mo-B. In this presentation, the result of microstructural analysis obtained by TEM observations and the influence of metallic interlayers and fiber orientation of SA-THX on the joint microstructure will be discussed.

Silicon Carbide↗