Thermal-structural composites for aerospace applications.
Inorganic bonded refractory fiber-based composite materials evaluated for aerospace application
MATERIAL TESTING↗
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CONSTRAINT-INDEPENDENT CONSTANT CTOA DETERMINATION FOR DUCTILE STABLE CRACK GROWTH
Crack tip opening angle (CTOA) has been used as a reliable fracture toughness parameter for decades to characterize stable ductile crack growth for thin-walled aerospace structures in the low-constraint conditions. Recently, the CTOA parameter was also applied to the pipeline industry, and a CTOA test standard ASTM E3039 was thus developed for testing a critical constant CTOA. Research showed that the constant CTOA can reasonably describe fracture toughness required to arrest a dynamic crack propagation for a modern gas pipeline. However, the CTOA fracture criterion requires constraint-independent CTOA toughness against stable ductile crack growth. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen for CTOA testing. Since a shallow crack is used, DWTT measured CTOA may depend on constraint level at the crack tip. To understand if it is the case, this paper evaluates the critical CTOA for a set of fracture toughness tests on single edge notched bend (SENB) specimens with shallow and deep cracks based on four CTOA estimation models. In which, the Ln(P)-LLD linear fit model is similar to that used by ASTM E3039 in the CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel are considered in the CTOA evaluation. The results show that the four CTOA models can determine a crack size-independent constant CTOA over stable ductile crack growth for the SENB specimens. As a result, CTOA determined by ASTM E3039 is constraintindependent and transferable to use for an actual crack propagating in a gas pipeline.
Zhu, Xian-Kui↗
Optimization of Picosecond Laser Parameters for Surface Treatment of Composites Using a Design of Experiments (DOE) Approach
Based on guidelines from the Federal Aviation Administration, research supported by the NASA Advanced Composites Project is investigating methods to improve process control for surface preparation and pre-bond surface characterization on aerospace composite structures. The overall goal is to identify high fidelity, rapid, and reproducible surface treatments and surface characterization methods to reduce the uncertainty associated with the bonding process. The desired outcome is a more reliable bonded airframe structure, and to reduce time to achieve certification. In this work, a design of experiments (DoE) approach was conducted to determine optimum laser ablation conditions using a pulsed laser source with a nominal pulse width of 10 picoseconds. The laser power, frequency, scan speed, and number of passes (1 or 2) were varied within the laser system operating boundaries. Aerospace structural carbon fiber reinforced composites (Torayca® 3900-2/T800H) were laser treated, then characterized for contamination, and finally bonded for mechanical testing. Pre-bond characterization included water contact angle (WCA) using a handheld device, ablation depth measurement using scanning electron microscopy (SEM), and silicone contamination measurement using laser induced breakdown spectroscopy (LIBS). In order to accommodate the large number of specimens in the DoE, a rapid-screening, double cantilever beam (DCB) test specimen configuration was devised based on modifications to ASTM D5528. Specimens were tested to assess the failure modes observed under the various laser surface treatment parameters. The models obtained from this DoE indicated that results were most sensitive to variation in the average laser power. Excellent bond performance was observed with nearly 100% cohesive failure for a wide range of laser parameters. Below about 200 mW, adhesive failure was observed because contamination was left on the surface. For laser powers greater than about 600 mW, large amounts of fiber were exposed, and the failure mode was predominately fiber tear.
Palmieri, Frank L.↗
Latent Cure Epoxy Resins for Reliable Joints in Secondary-Bonded Composite Structures
In high-performance polymer matrix composite assemblies, adhesive bonding is generally superior to mechanical fastening in structural performance and manufacturing efficiency. However, adhesive bonds are susceptible to minute levels of contamination accumulated during assembly that can lead to unpredictable, weak bonds. Current methods of measuring bond strength are all destructive mechanical tests. To overcome these challenges, redundant load paths (e.g., mechanical fasteners) are often implemented in secondary-bonded, primary-structures, which can greatly reduce structural performance. This study investigated reformulated aerospace epoxy matrix resins with stoichiometric offset to inhibit cure of the matrix resin prior to assembly. Inhibited resins can reflow and mix across the joint interface, which eliminates the material discontinuity and forms a homogenous joint with reliable fracture properties. The goal of this study was to develop and demonstrate secondary composite assemblies that are mechanically and microscopically indistinguishable from a co-cured composite joint. This article describes the development of latent epoxy resins, the fabrication of test articles, and the mechanical properties measured from experimental joints compared with conventional, co-cured laminates. Methods of in-line quality control using and infrared spectroscopy and post-assembly forensics are also described. The final mode-II fracture toughness measured from precracked AERoBOND specimens was similar to that measured from co-cured laminates indicating that later cure epoxy materials could be a suitable replacement for secondary bonding.
Polymer-matrix composites (PMCs)↗
NASA and ESA Collaboration on Hexavalent Chrome Alternatives: Pretreatments Only Final Test Report
Hexavalent chromium (hex chrome or CR(VI)) is a widely used element within applied coating systems because of its self-healing and corrosion-resistant properties. The replacement of hex chrome in the processing of aluminum for aviation and aerospace applications remains a goal of great significance. Aluminum is the major manufacturing material of structures and components in the space flight arena. The National Aeronautics and Space Administration (NASA) and the European Space Agency (ESA) are engaged in a collaborative effort to test and evaluate alternatives to hexavalent chromium containing corrosion coating systems. NASA and ESA share common risks related to material obsolescence associated with hexavalent chromium used in corrosion-resistant coatings.
RoHS↗
Guidelines for Design and Analysis of Large, Brittle Spacecraft Components
There were two related parts to this work. The first, conducted at The Aerospace Corporation was to develop and define methods for integrating the statistical theory of brittle strength with conventional finite element stress analysis, and to carry out a limited laboratory test program to illustrate the methods. The second part, separately funded at Aerojet Electronic Systems Division, was to create the finite element postprocessing program for integrating the statistical strength analysis with the structural analysis. The second part was monitored by Capt. Jeff McCann of USAF/SMC, as Special Study No.11, which authorized Aerojet to support Aerospace on this work requested by NASA. This second part is documented in Appendix A. The activity at Aerojet was guided by the Aerospace methods developed in the first part of this work. This joint work of Aerospace and Aerojet stemmed from prior related work for the Defense Support Program (DSP) Program Office, to qualify the DSP sensor main mirror and corrector lens for flight as part of a shuttle payload. These large brittle components of the DSP sensor are provided by Aerojet. This document defines rational methods for addressing the structural integrity and safety of large, brittle, payload components, which have low and variable tensile strength and can suddenly break or shatter. The methods are applicable to the evaluation and validation of such components, which, because of size and configuration restrictions, cannot be validated by direct proof test.
Robinson, E. Y.↗
Composite Overwrapped Pressure Vessels: Database Extension Task 3.0 and Impact Damage Effects Control Task 8.0
This document represents efforts accomplished at the NASA Johnson Space Center White Sands Test Facility (WSTF) in support of the Enhanced Technology for Composite Overwrapped Pressure Vessels (COPV) Program, a joint research and technology effort among the U.S. Air Force, NASA, and the Aerospace Corporation. WSTF performed testing for several facets of the program. Testing that contributed to the Task 3.0 COPV database extension objective included baseline structural strength, failure mode and safe-life, impact damage tolerance, sustained load/impact effect, and materials compatibility. WSTF was also responsible for establishing impact protection and control requirements under Task 8.0 of the program. This included developing a methodology for establishing an impact control plan. Seven test reports detail the work done at WSTF. As such, this document contributes to the database of information regarding COPV behavior that will ensure performance benefits and safety are maintained throughout vessel service life.
Beeson, Harold D.↗
There's No There, There--At The CG
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resonance frequency structural qualifications↗
Creep and Environmental Durability of EBC/CMCs Under Imposed Thermal Gradient Conditions
Interest in SiC fiber-reinforced SiC ceramic matrix composite (CMC) environmental barrier coating (EBC) systems for use in high temperature structural applications has prompted the need for characterization of material strength and creep performance under complex aerospace turbine engine environments. Stress-rupture tests have been performed on SiC/SiC composites systems, with varying fiber types and coating schemes to demonstrate material behavior under isothermal conditions. Further testing was conducted under exposure to thermal stress gradients to determine the effect on creep resistance and material durability. In order to understand the associated damage mechanisms, emphasis is placed on experimental techniques as well as implementation of non-destructive evaluation; including electrical resistivity monitoring. The influence of environmental and loading conditions on life-limiting material properties is shown.
Appleby, Matthew↗
F-15B QuietSpike(TradeMark) Aeroservoelastic Flight Test Data Analysis
System identification or mathematical modelling is utilised in the aerospace community for the development of simulation models for robust control law design. These models are often described as linear, time-invariant processes and assumed to be uniform throughout the flight envelope. Nevertheless, it is well known that the underlying process is inherently nonlinear. The reason for utilising a linear approach has been due to the lack of a proper set of tools for the identification of nonlinear systems. Over the past several decades the controls and biomedical communities have made great advances in developing tools for the identification of nonlinear systems. These approaches are robust and readily applicable to aerospace systems. In this paper, we show the application of one such nonlinear system identification technique, structure detection, for the analysis of F-15B QuietSpike(TradeMark) aeroservoelastic flight test data. Structure detection is concerned with the selection of a subset of candidate terms that best describe the observed output. This is a necessary procedure to compute an efficient system description which may afford greater insight into the functionality of the system or a simpler controller design. Structure computation as a tool for black-box modelling may be of critical importance for the development of robust, parsimonious models for the flight-test community. Moreover, this approach may lead to efficient strategies for rapid envelope expansion which may save significant development time and costs. The objectives of this study are to demonstrate via analysis of F-15B QuietSpike(TradeMark) aeroservoelastic flight test data for several flight conditions (Mach number) that (i) linear models are inefficient for modelling aeroservoelastic data, (ii) nonlinear identification provides a parsimonious model description whilst providing a high percent fit for cross-validated data and (iii) the model structure and parameters vary as the flight condition is altered.
Kukreja, Sunil L.↗
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.↗
Laser Surface Preparation for Adhesive 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 pre-bonding surface treatments through optical microscopy, contact angle goniometry, and post-bonding mechanical testing.
Belcher, M. A.↗
Flight Testing of the Gulfstream Quiet Spike(TradeMark) on a NASA F-15B
Gulfstream Aerospace has long been interested in the development of an economically viable supersonic business jet (SBJ). A design requirement for such an aircraft is the ability for unrestricted supersonic flight over land. Although independent studies continue to substantiate that a market for a SBJ exists, regulatory and public acceptance challenges still remain for supersonic operation over land. The largest technical barrier to achieving this goal is sonic boom attenuation. Gulfstream's attention has been focused on fundamental research into sonic boom suppression for several years. This research was conducted in partnership with the NASA Aeronautics Research Mission Directorate (ARMD) supersonic airframe cruise efficiency technical challenge. The Quiet Spike, a multi-stage telescopic nose boom and a Gulfstream-patented design (references 1 and 2), was developed to address the sonic boom attenuation challenge and validate the technical feasibility of a morphing fuselage. The Quiet Spike Flight Test Program represents a major step into supersonic technology development for sonic boom suppression. The Gulfstream Aerospace Quiet Spike was designed to reduce the sonic boom signature of the forward fuselage for an aircraft flying at supersonic speeds. In 2004, the Quiet Spike Flight Test Program was conceived by Gulfstream and NASA to demonstrate the feasibility of sonic boom mitigation and centered on the structural and mechanical viability of the translating test article design. Research testing of the Quiet Spike consisted of numerous ground and flight operations. Each step in the process had unique objectives, and involved numerous test team members from the NASA Dryden Flight Research Center (DFRC) and Gulfstream Aerospace. Flight testing of the Quiet Spike was conducted at the NASA Dryden Flight Research Center on an F-15B aircraft from August, 2006, to February, 2007. During this period, the Quiet Spike was flown at supersonic speeds up to Mach 1.8 at the maximum design dynamic pressure of 685 pounds per square foot. Extension and retraction tests were conducted at speeds up to Mach 1.4. The design of the Quiet Spike to shape the forward shock wave environment of the aircraft was confirmed during near-field shock wave probing at Mach 1.4. Thirty-two flights were performed without incident and all project objectives were achieved. The success of the Quiet Spike Flight Test Program represents an important step towards developing commercial aircraft capable of supersonic flight over land within the continental United States and in international airspace.
Smolka, James W.↗
Some aspects of algorithm performance and modeling in transient analysis of structures
The status of an effort to increase the efficiency of calculating transient temperature fields in complex aerospace vehicle structures is described. The advantages and disadvantages of explicit algorithms with variable time steps, known as the GEAR package, is described. Four test problems, used for evaluating and comparing various algorithms, were selected and finite-element models of the configurations are described. These problems include a space shuttle frame component, an insulated cylinder, a metallic panel for a thermal protection system, and a model of the wing of the space shuttle orbiter. Results generally indicate a preference for implicit over explicit algorithms for solution of transient structural heat transfer problems when the governing equations are stiff (typical of many practical problems such as insulated metal structures).
Adelman, H. M.↗
A concurrent processing implementation for structural vibration analysis
A concurrent processing algorithm for analysis of large aerospace structures is presented. A general description of the implementation criteria for the algorithm is given, and the results from applications to two vibration test problems are discussed. The test problems included a flexural vibration analysis of a long beam with 16 uniformly spaced supports, and a torsional vibration analysis. The computer system used to implement the algorithm was an experimental MIND system. The concurrent processing speedups for the test problems are given in a table.
Bostic, S. W.↗
The role of structural dynamics in the design and operations of space systems: The history, the lessons, the technical challenges of the future
Structural dynamics and its auxiliary fields are the most progressive and challenging areas space system engineering design and operations face. Aerospace systems are dependent on structural dynamicists for their success. Past experiences (history) are colored with many dynamic issues, some producing ground or flight test failures. The innovation and creativity that was brought to these issues and problems are the aura from the past that lights the path to the future. Using this illumination to guide understanding of the dynamic phenomena and designing for its potential occurrence are the keys to successful space systems. Our great paradox, or challenge, is how we remain in depth specialists, yet become generalists to the degree that we make good team members and set the right priorities. This paper will deal with how we performed with acclaim in the past, the basic characteristics of structural dynamics (loads cycle, for example), and the challenges of the future.
Ryan, Robert S.↗
Wireless Sensing Opportunities for Aerospace Applications
Wireless sensors and sensor networks is an emerging technology area with many applications within the aerospace industry. Integrated vehicle health monitoring (IVHM) of aerospace vehicles is needed to ensure the safety of the crew and the vehicle, yet often high costs, weight, size and other constraints prevent the incorporation of instrumentation onto spacecraft. This paper presents a few of the areas such as IVHM, where new wireless sensing technology is needed on both existing vehicles as well as future spacecraft. From ground tests to inflatable structures to the International Space Station, many applications could receive benefits from small, low power, wireless sensors. This paper also highlights some of the challenges that need to overcome when implementing wireless sensor networks for aerospace vehicles.
Wilson, William↗
An Overview of Air-Breathing Propulsion Efforts for 2015 SBIR Phase I
NASA's Small Business Innovation Research (SBIR) program focuses on technological innovation by investing in development of innovative concepts and technologies to help NASA mission directorates address critical research needs for Agency programs. This report highlights 24 of the innovative SBIR 2015 Phase I projects that emphasize one of NASA Glenn Research Center's six core competencies-Air-Breathing Propulsion. The technologies cover a wide spectrum of applications such as hybrid nanocomposites for efficient aerospace structures; plasma flow control for drag reduction; physics-based aeroanalysis methods for open rotor conceptual designs; vertical lift by series hybrid power; fast pressure-sensitive paint systems for production wind tunnel testing; rugged, compact, and inexpensive airborne fiber sensor interrogators based on monolithic tunable lasers; and high sensitivity semiconductor sensor skins for multi-axis surface pressure characterization. Each featured technology describes an innovation and technical objective and highlights NASA commercial and industrial applications. This report provides an opportunity for NASA engineers, researchers, and program managers to learn how NASA SBIR technologies could help their programs and projects, and lead to collaborations and partnerships between the small SBIR companies and NASA that would benefit both.
aerospace structures↗