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At least 1,333 records · Page 74

Flight service evaluation of composite components on Bell 206L and Sikorsky S-76 helicopters

Progress on two programs to evaluate composite structural components in flight service on commercial helicopters is described. Thirty-six ship sets of composite components that include the litter door, baggage door, forward fairing, and vertical fin were installed on Bell Model 206L helicopters that are operating in widely different climatic areas. Four horizontal stabilizers and ten tail rotor spars that are production components on the S-76 helicopter were tested after prescribed periods of service to determine the effects of the operating environment on their performance. Concurrent with the flight evaluation, specimens from materials used to fabricate the components were exposed in ground racks and tested at specified intervals to determine the effects of outdoor environments. Results achieved from 14,000 hours of accumulated service on the 206L components, tests on a S-76 horizontal stabilizer after 1600 hours of service, tests on a S-76 tail rotor spar after 2300 hours service, and two years of ground based exposure of material coupons are reported.

Baker, D. J.↗

Composition of and Method for Making High Performance Resins for Infusion and Transfer Molding Processes

A composition of and method for making high performance imide resins that are processable by resin transfer molding (RTM) and resin infusion (RI) techniques were developed. Materials with a combination of properties, making them particularly useful for the fabrication of composite parts via RTM and/or RI processes, were prepared, characterized and fabricated into moldings and carbon fiber reinforced composites and their mechanical properties were determined. These materials are particularly useful for the fabrication of structural composite components for aerospace applications. The method for making high performance resins for RTM and RI processes is a multi-faceted approach. It involves the preparation of a mixture of products from a combination of aromatic diamines and aromatic dianhydrides at relatively low calculated molecular weights (i.e. high stoichiometric offsets) and endcapping with latent reactive groups. The combination of these monomers results in a mixture of products, in the imide form, that exhibits a stable melt viscosity of less than approximately 60 poise below approximately 300 C.

John W Connell↗

Structural Integrity Testing Method for PRSEUS Rod-Wrap Stringer Design

NASA Langley Research Center and The Boeing Company are developing an innovative composite structural concept, called PRSEUS, for the flat center section of a future environmentally friendly hybrid wing body (HWB) aircraft. The PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure) concept uses dry textile preforms for the skins, frames, and stiffener webs. The highly loaded stiffeners are made from precured unidirectional carbon/epoxy rods and dry fiber preforms. The rods are wrapped with the dry fiber preforms and a resin infusion process is used to form the rod-wrap stiffeners. The structural integrity of the rod-wrap interface is critical for maintaining the panel s high strength and bending rigidity. No standard testing method exists for testing the strength of the rod-wrap bondline. Recently, Boeing proposed a rod push-out testing method and conducted some preliminary tests using this method. This paper details an analytical study of the rod-wrap bondline. The rod-wrap interface is modeled as a cohesive zone for studying the initiation and growth of interfacial debonding during push-out testing. Based on the correlations of analysis results and Boeing s test data, the adequacy of the rod-wrap testing method is evaluated, and potential approaches for improvement of the test method are proposed.

Wang, John T.↗

Crystal Structure and Chemical Composition of a Presolar Silicate from the Queen Elizabeth Range 99177 Meteorite

Mineral characterization of presolar silicate grains, the most abundant stardust phase, has provided valuable information about the formation conditions in circumstellar environments and in super-nova (SN) outflows. Spectroscopic observations of dust around evolved stars suggest a majority of amor-phous, Mg-rich olivine grains, but crystalline silicates, most of which are pyroxene, have also been observed [1]. The chemical compositions of hundreds of presolar silicates have been determined by Auger spectroscopy and reveal high Fe contents and nonstoichiometric compositions intermediate to olivine and pyroxene [2-6]. The unexpectedly high Fe contents can partly be attributed to secondary alteration on the meteorite parent bodies, as some grains have Fe isotopic anomalies from their parent stellar source [7]. Only about 35 presolar silicates have been studied for their mineral structures and chemical compositions by transmission electron microscopy (TEM). These grains display a wide range of compositions and structures, including crystalline forsterite, crystalline pyroxene, nanocrystalline grains, and a majority of amorphous nonstoichiometric grains. Most of these grains were identified in the primitive Acfer 094 meteorite. Presolar silicates from this meteorite show a wide range of Fe-contents, suggestive of secondary processing on the meteorite parent body. The CR chondrite QUE 99177 has not suffered as much alteration [8] and displays the highest presolar silicate abundance to date among carbonaceous chondrites [3, 6]. However, no mineralogical studies of presolar silicates from this meteorite have been performed. Here we examine the mineralogy of a presolar silicate from QUE 99177.

Nguyen, A. N.↗

Composite space antenna structures: Properties and environmental effects

The thermal behavior of composite spacecraft antenna reflectors has been investigated with the integrated Composites Analyzer (ICAN) computer code. Parametric studies have been conducted on the face sheets and honeycomb core which constitute the sandwich-type structures. Selected thermal and mechanical properties of the composite faces and sandwich structures are presented graphically as functions of varying fiber volume ratio, temperature, and moisture content. The coefficients of thermal expansion are discussed in detail since these are the critical design parameters. In addition, existing experimental data are presented and compared to the ICAN predictions.

Ginty, Carol A.↗

Composite space antenna structures - Properties and environmental effects

The thermal behavior of composite spacecraft antenna reflectors has been investigated with the integrated Composites Analyzer (ICAN) computer code. Parametric studies have been conducted on the face sheets and honeycomb core which constitute the sandwich-type structures. Selected thermal and mechanical properties of the composite faces and sandwich structures are presented graphically as functions of varying fiber volume ratio, temperature, and moisture content. The coefficients of thermal expansion are discussed in detail since these are the critical design parameters. In addition, existing experimental data are presented and compared to the ICAN predictions.

Ginty, C. A.↗

Bioinspired mineralizing microenvironments generated by liquid-liquid phase coexistence

Biominerals such as bones, teeth and shells exhibit improved mechanical properties and intricate morphologies not seen in nonbiologically-produced minerals of ostensibly the same composition. These remarkable properties of biogenic minerals are thought to arise due to precise local control over the mineral deposition process, including organic and inorganic inclusions. Understanding how Biology controls the local reaction environment during formation of these materials to control their composition, structure, and properties is a grand challenge that promises to enable new routes to high-performance materials. This project developed multi-compartment bioinspired microreactors as artificial mineralizing vesicles, and used them to understand and control formation of inorganic/organic composite solid materials. A major emphasis was on developing all-aqueous emulsions in which each droplet was a structured microreactor with two or more adjacent phases. This approach provided local control over reaction environment including availability of inclusions such as polypeptides and metal ions, while being sufficiently simple to produce large populations of essentially identical multiphase reactor droplets simultaneously within a batch. Organic/inorganic composite materials could be produced with very high organic content that stabilized the inorganic portions as amorphous materials (e.g., amorphous calcium carbonate) by preventing the typical conversion to more thermodynamically crystalline forms (e.g., calcite). These stabilized amorphous composites could be stored indefinitely and converted to crystalline forms later by removal of the organic inclusions via, for example, heating. Compositional gradients in the organic and inorganic components were embedded during synthesis due to the evolution of the reaction microenvironment, and despite the complexity of this process it occurred similarly across the population of reactive droplets and was hence encoded into the population of resulting composite particles. The approach developed here allows pre-structuring of reactive microenvironments to control the spatiotemporal reaction environment, which is an important step towards rational design and on-demand production of complex functional materials with desired composition, optical properties, and mechanical response.

36 MATERIALS SCIENCE↗

Solventless Fabrication of Reinforced Composites

Heat and pressure melt thermoplastic fibers, causing them to flow into voids around graphite reinforcement. On cooling, fiber bundle has been transformed into structural composite. Required temperature and pressure depend on properties of particular thermoplastic used.

Baucom, R. M.↗

Nano-Fiber Reinforced Enhancements in Composite Polymer Matrices

Nano-fibers are used to reinforce polymer matrices to enhance the matrix dependent properties that are subsequently used in conventional structural composites. A quasi isotropic configuration is used in arranging like nano-fibers through the thickness to ascertain equiaxial enhanced matrix behavior. The nano-fiber volume ratios are used to obtain the enhanced matrix strength properties for 0.01,0.03, and 0.05 nano-fiber volume rates. These enhanced nano-fiber matrices are used with conventional fiber volume ratios of 0.3 and 0.5 to obtain the composite properties. Results show that nano-fiber enhanced matrices of higher than 0.3 nano-fiber volume ratio are degrading the composite properties.

Chamis, Christos C.↗

Unprecedented generation of 3D heterostructures by mechanochemical disassembly and re-ordering of incommensurate metal chalcogenides

Three-dimensional heterostructures are usually created either by assembling two-dimensional building blocks into hierarchical architectures or using stepwise chemical processes that sequentially deposit individual monolayers. Both approaches suffer from a number of issues, including lack of suitable precursors, limited reproducibility, and poor scalability of the preparation protocols. Therefore, development of alternative methods that enable preparation of heterostructured materials is desired. We create heterostructures with incommensurate arrangements of well-defined building blocks using a synthetic approach that comprises mechanical disassembly and simultaneous reordering of layered transition-metal dichalcogenides, MX 2 , and non-layered monochalcogenides, REX, where M = Ta, Nb, RE = Sm, La, and X = S, Se. We show that the discovered solid-state processes are rooted in stochastic mechanochemical transformations directed by electronic interaction between chemically and structurally dissimilar solids toward atomic-scale ordering, and offer an alternative to conventional heterostructuring. Details of composition–structure–properties relationships in the studied materials are also highlighted.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

XANES analysis of phosphate glasses melted with Tb 4 O 7 and SnO: evaluating the impact of valence states on structural, thermal, and luminescent properties

Barium phosphate glasses were prepared with 0.5 mol% Tb 4 O 7 added alongside SnO up to 5 mol% with the purpose of evaluating the resulting terbium and tin oxidation states and their impact on glass structural, thermal, and luminescent properties. In this work, following material synthesis by melt-quenching, the composition-structure–property investigation was pursued encompassing measurements by X-ray diffraction (XRD), X-ray absorption near-edge spectroscopy (XANES), Raman spectroscopy, differential scanning calorimetry (DSC), dilatometry, and photoluminescence (PL) spectroscopy. While XRD confirmed the amorphous nature of the glasses, results from XANES indicated that terbium occurs as terbium(III) with a predisposition for tin to exist as tin(IV) which decreased at high SnO content. The structural as well as the thermal properties appeared to be mostly impacted by the presence of tin(IV). Specifically, glass depolymerization was indicated to be induced by Sn 4+ ions, and their concentration was observed to correlate with glass transition and softening temperatures. On the other hand, the tin(II) remnants were observed to exert an impact on the luminescent properties shifting light emission from the green towards the blue-green (cyan). It is indicated that Tb 4 O 7 reacting to produce Tb 2 O 3 supports the oxidation of tin(II) to tin(IV) which in turn dominates the physical properties. However, this was somewhat circumvented at the highest SnO content wherein tin(IV) appeared to be lower.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Development of an engineering analysis of progressive damage in composites during low velocity impact

A computerized, analytical methodology was developed to study damage accumulation during low velocity lateral impact of layered composite plates. The impact event was modeled as perfectly plastic with complete momentum transfer to the plate structure. A transient dynamic finite element approach was selected to predict the displacement time response of the plate structure. Composite ply and interlaminar stresses were computed at selected time intervals and subsequently evaluated to predict layer and interlaminar damage. The effects of damage on elemental stiffness were then incorporated back into the analysis for subsequent time steps. Damage predicted included fiber failure, matrix ply failure and interlaminar delamination.

Humphreys, E. A.↗

Current research on shear buckling and thermal loads with PASCO - Panel analysis and sizing code

The stiffened composite structural panel analysis and sizing code designated 'PASCO' encompasses both the generality required for the exploitation of composite materials' design flexibility and an accurate buckling analysis for the detection of complex buckling modes. PASCO can accordingly design for buckling, frequency, material strength, and panel stiffness requirements. Attention is given to an additional thermal loading design capability. Design studies illustrate the importance of the multiple load condition capability when thermal loads are present.

Stroud, W. J.↗

Computational simulation of progressive fracture in fiber composites

Computational methods for simulating and predicting progressive fracture in fiber composite structures are presented. These methods are integrated into a computer code of modular form. The modules include composite mechanics, finite element analysis, and fracture criteria. The code is used to computationally simulate progressive fracture in composite laminates with and without defects. The simulation tracks the fracture progression in terms of modes initiating fracture, damage growth, and imminent global (catastrophic) laminate fracture.

Chamis, C. C.↗

Automated fiber placement composite manufacturing: The mission at MSFC's Productivity Enhancement Complex

Automated fiber placement is a manufacturing process used for producing complex composite structures. It is a notable leap to the state-of-the-art in technology for automated composite manufacturing. The fiber placement capability was established at the Marshall Space Flight Center's (MSFC) Productivity Enhancement Complex in 1992 in collaboration with Thiokol Corporation to provide materials and processes research and development, and to fabricate components for many of the Center's Programs. The Fiber Placement System (FPX) was developed as a distinct solution to problems inherent to other automated composite manufacturing systems. This equipment provides unique capabilities to build composite parts in complex 3-D shapes with concave and other asymmetrical configurations. Components with complex geometries and localized reinforcements usually require labor intensive efforts resulting in expensive, less reproducible components; the fiber placement system has the features necessary to overcome these conditions. The mechanical systems of the equipment have the motion characteristics of a filament winder and the fiber lay-up attributes of a tape laying machine, with the additional capabilities of differential tow payout speeds, compaction and cut-restart to selectively place the correct number of fibers where the design dictates. This capability will produce a repeatable process resulting in lower cost and improved quality and reliability.

Vickers, John H.↗

The Coming Paradigm-Shift in Maintenance: From Metals to Composites

The purpose of this study is to examine the current maintenance practices of airline operators in the detection and repair of damage to composite structures, with the aim of learning lessons that will be applicable to the maintenance of future advanced composite airplanes. A process map was created to capture the events and activities that occur from the moment a damage event occurs, through damage detection, assessment and repair. The study is identifying areas where operational risks may negatively impact the process, where personnel are required to make judgments in the absence of procedural guidance, and areas where future tools or techniques may be of assistance.

Hobbs, Alan↗

Hybrid FEA/SEA Assessment for an Orthogrid Cylindrical Panel Section and Periodic Subsystem Modeling Evaluation

In the lower frequency range, where particular boundary conditions can make a significant difference to panel response characteristics Statistical Energy Analysis (SEA) has never been the analytical tool of choice. In addition to boundary condition effects, SEA is not well suited in frequency bands where no modes or less than a few modes exist. The advent of the Hybrid Module has enabled integration of Finite Element Analysis to expand and enhance the capability for response calculations within VA One into the lower frequency range. Exploration of several additional modeling approaches was completed for the cylindrical orthogrid panel test article that was examined in Reference 1. Comparison of the new analytical response predictions with the measured response data from ground test and the pure SEA results from the reference will be presented. One approach that is considered promising is the periodic subsystem capability. Initially, a detailed FEM of just one region of the test article is defined. After evaluating this small region using symmetric boundary conditions, the FEM may be expanded to determine the properties of the entire system using similar connected regions that map over the entire test article. Another approach is the direct use of a very detailed finite element model of the entire panel, explicitly modeling pocket and rib details of the structure. A third approach is to approximate localized structure geometry details with a smeared property generalization using a PCOMP (NASTRAN card used to define layered composite structures) to define skin layer and ribbed layer for the orthogrid panel. The authors expect to demonstrate that the integrated Hybrid/FEM approach increases confidence in response prediction in the lower frequency range (for example from 20-300 Hz for the test article under consideration). In addition the strength and weakness of each additional approach will be highlighted and compared to those reported with those reported in an earlier paper

Smith, Andrew M.↗

Enhanced Schapery Theory Software Development for Modeling Failure of Fiber-Reinforced Laminates

Progressive damage and failure analysis (PDFA) tools are needed to predict the nonlinear response of advanced fiber-reinforced composite structures. Predictive tools should incorporate the underlying physics of the damage and failure mechanisms observed in the composite, and should utilize as few input parameters as possible. The purpose of the Enhanced Schapery Theory (EST) was to create a PDFA tool that operates in conjunction with a commercially available finite element (FE) code (Abaqus). The tool captures the physics of the damage and failure mechanisms that result in the nonlinear behavior of the material, and the failure methodology employed yields numerical results that are relatively insensitive to changes in the FE mesh. The EST code is written in Fortran and compiled into a static library that is linked to Abaqus. A Fortran Abaqus UMAT material subroutine is used to facilitate the communication between Abaqus and EST. A clear distinction between damage and failure is imposed. Damage mechanisms result in pre-peak nonlinearity in the stress strain curve. Four internal state variables (ISVs) are utilized to control the damage and failure degradation. All damage is said to result from matrix microdamage, and a single ISV marks the micro-damage evolution as it is used to degrade the transverse and shear moduli of the lamina using a set of experimentally obtainable matrix microdamage functions. Three separate failure ISVs are used to incorporate failure due to fiber breakage, mode I matrix cracking, and mode II matrix cracking. Failure initiation is determined using a failure criterion, and the evolution of these ISVs is controlled by a set of traction-separation laws. The traction separation laws are postulated such that the area under the curves is equal to the fracture toughness of the material associated with the corresponding failure mechanism. A characteristic finite element length is used to transform the traction-separation laws into stress-strain laws. The ISV evolution equations are derived in a thermodynamically consistent manner by invoking the stationary principle on the total work of the system with respect to each ISV. A novel feature is the inclusion of both pre-peak damage and appropriately scaled, post-peak strain softening failure. Also, the characteristic elements used in the failure degradation scheme are calculated using the element nodal coordinates, rather than simply the square root of the area of the element.

Pineda, Evan J.↗