SEARCH · Engineering Papers

Results for “Self-weight stability”

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

SourceResearch connectionFrom yearThrough year

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

5 records

All sources NASA NTRS DOE OSTI

DOE OSTI2022

Structural stability of thin overhanging walls during material extrusion additive manufacturing of thermoset-based ink

Recent developments have enabled material extrusion additive manufacturing of thermoset-based composite inks on the large scale. In addition, printing out-of-plane components is of broad interest to the polymer material extrusion community. Here, we address some of the challenges associated with both large-scale and out-of-plane thermoset material extrusion additive manufacturing by studying the height at which thin overhanging walls collapse. Walls at a range of overhang angles were printed until they collapsed. An optical camera captured the profile of each wall throughout the print, allowing the collapse height to be identified and the geometric fidelity to the programmed angle to be evaluated. Using previously measured rheological properties, predictive models were generated to approximate the collapse height and profile of the deflected walls. First, an analytical model was created to predict the height at which the walls would yield. The analytical model assumes the walls exhibit a perfectly linear profile; however, experiments proved this assumption to be false. Therefore, a finite element simulation was developed to account for the elastic deflection that occurs during printing. The finite element simulation predicts both the yield height and the deflected profile after the deposition of each layer. For the properties of the thermoset ink used here, the yield height predicted by the analytical model and finite element simulation are virtually identical. These predictions match experimental data reasonably well, but minor errors are observed. Accounting for the fully plastic moment appears to explain the small mismatch between experimental data and predictions. Additionally, the finite element simulation provides an excellent prediction of the deflected profile before the wall begins to collapse. Finally, by demonstrating that the collapse height and deflected profile of thin overhanging walls can be predicted, this work illustrates how the soft viscoelastic properties of thermoset-based composite inks limit the scale of a key feature required to print some nonplanar components. It also provides a basis to tailor in-process curing systems to suppress deflection and collapse of thin overhanging walls.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Large-scale reactive thermoset printing: Complex interactions between temperature evolution, viscosity, and cure shrinkage

Thermoset composites are strong candidates for large-scale material extrusion additive manufacturing (AM). However, uncured thermoset composites become unstable as print height increases. Here, chemical initiation of vinyl ester immediately before deposition was used to suppress collapse and enable large-scale thermoset printing. Structural stability was assessed by printing thin walls at various layer times and monitoring thermal gradients with an infrared camera. Stable printing was observed at a layer time of 4.50 min, approximately half the gel time of the material (8 min). Self-weight collapse occurred at short layer time (0.68 min), whereas warpage occurred at long layer time (6.50 min). Here, a new behavior was discovered at intermediate layer time (2.25 min) where the heat generated by the reaction causes new, un-gelled layers to flow. Forced convection eliminates this behavior, stabilizing the 2.25-min layer time print. These findings motivated development of a less exothermic material system, which was used to print a large-scale mold and demonstrate the value of this understanding. By presenting these challenges of large-scale reactive thermoset AM for the first time, this work motivates focused studies of the complex interplay between rheological, thermal, and chemical behaviors to improve the feasibility of large-scale thermoset AM. Tensile properties of the printed material were also measured. Longitudinal and transverse elastic moduli are 3.79 and 2.95 GPa, respectively, and corresponding tensile strengths are 36.11 and 18.83 MPa. The glass transition temperature is 93.13 °C.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Research study to determine critical optical/mechanical properties of materials considered for selection as substrates for the primary mirror on a large telescope

An investigation was conducted to evaluate the stability of a specific low expansion glass-ceramic material relative to its use as a large, lightweight mirror substrate for diffraction-limited spaceborne optical applications. These evaluations were made on a segment (0.44 meter diameter by 0.31 meter thick) of a 2 to 3 meter diameter mirror blank. The dimensional stability of this mirror was measured interferometrically before and after lightweighting, as a function of rough machining, etching, thermal environment, and support configuration. A special computer analysis program was used to plot the coefficients corresponding to aberrations with sixfold symmetry (caused by the mirror's self-weight deflection on a three point support). The objective was to enhance the test sensitivity. Results indicate that any such effects due to self-weight deflection are of the order of 0.015 lambda rms. The rms and peak-to-peak figure changes associated with each processing operation are summarized.

Slomba, A. F.↗

NASA NTRS2019

Technology Development Roadmap for Habitable-Zone Exoplanet Observatory (HabEx) Baseline 4-M Primary Mirror

The Habitable Exoplanet Observatory (HabEx) is one of four mission concepts under study for the 2020 Astrophysics Decadal Survey. Its goal is to directly image and spectroscopically characterize planetary systems in the habitable zone around nearby sun-like stars. Additionally, HabEx will perform a broad range of general astrophysics science enabled by 115 to 2500 nm spectral range and 3 x 3 arc-minute FOV. Critical to achieving the HabEx science goals is a large, ultra-stable UV/Optical/Near-IR (UVOIR) telescope. The baseline HabEx telescope is 4-meter off-axis unobscured, diffraction limited at 400 nm with wavefront stability on the order of a few 10s of picometers. The technology readiness level (TRL) to manufacture and test the HabEx baseline primary mirror is assessed to be at TRL-6 for all but two TRL-4 technologies: 1) non-destructive process to quantify CTE homogeneity of a 4-m mirror substrate with a spatial sampling of at least 100 x 100 to better than +/- 1 ppb/K; and, 2) process to quantify self-weight gravity deflection to better than 4-nm rms over a 100 x 100 spatial sampling. This paper reviews the technology needs to manufacture the HabEx primary mirror, assesses their TRL and proposes a roadmap to mature the two remaining technologies to TRL-6.

Space Telescope Technology↗

NASA NTRS2000

Constitutive and Stability Behavior of Soils in Microgravity Environment

All aspects of soil stability, bearing capacity, slope stability, the supporting capacity of deep foundations, and penetration resistance depend on soil strength. The stress-deformation and stress-deformation-time behavior of soils are of importance in any problem where ground movements are of interest. In most engineering materials, the strength is derived from internal chemical and physico-chemical forces of interaction, which bond the atoms, molecules, and particles together. In soils, the constitutive relations are mainly derived from interparticle friction between particles and particle groups and dilatancy, and to a lesser extent from particle bonding by weak electrostatic, physico-chemical, and coulomb forces. For engineering purposes, soils are classified as cohesive (clays and silts; typical particle sizes range from 10 nm to 10 micrometers) and cohesionless (sand and gravel; typical particle sizes range from 10 micrometers to 75 mm). The mechanical or constitutive properties of cohesionless soils or granular materials are highly fabric-dependent, highly non-linear, and non-conservative with engineering properties primarily depending on the effects of gravity through self-weight and on the tractions or forces applied to the soil mass. Under moderate-to-high stress levels, the influence of gravity on the behavior of laboratory test specimens may not be pronounced and, therefore, the test results in terrestrial (1-g) environment may be sufficiently conclusive. However at low interparticle stresses, which can result either from low applied (confining) stresses or from excess pore fluid pressures developed within the soil mass without corresponding changes in the applied stresses, the presence of gravitational body forces acting on solid particles and interstitial fluids exerts a pronounced influence on movement of individual particles or particle groups. Such motions, in turn, cause changes in soil fabric which results in significant changes in the interparticle friction forces contributing to the soil's strength and deformation characteristics.

Alshibli, Khalid A.↗