Engineering topics

Grimsley, Brian W.

Publications and source records attributed to Grimsley, Brian W..

31 records · Page 2

NASA NTRS2012

Materials for Heated Head Automated Thermoplastic Tape Placement

NASA Langley Research Center (LaRC) is currently pursuing multiple paths to develop out of autoclave (OOA) polymeric composite materials and processes. Polymeric composite materials development includes the synthesis of new and/or modified thermosetting and thermoplastic matrix resins designed for specific OOA processes. OOA processes currently under investigation include vacuum bag only (VBO) prepreg/composite fabrication, resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM) and heated head automated thermoplastic tape placement (HHATP). This paper will discuss the NASA Langley HHATP facility and capabilities and recent work on characterizing thermoplastic tape quality and requirements for quality part production. Samples of three distinct versions of APC-2 (AS4/PEEK) thermoplastic dry tape were obtained from two materials vendors, TENCATE, Inc. and CYTEC Engineered Materials** (standard grade and an experimental batch). Random specimens were taken from each of these samples and subjected to photo-microscopy and surface profilometry. The CYTEC standard grade of APC-2 tape had the most voids and splits and the highest surface roughness and/or waviness. Since the APC-2 tape is composed of a thermoplastic matrix, it offers the flexibility of reprocessing to improve quality, and thereby improve final quality of HHATP laminates. Discussions will also include potential research areas and future work that is required to advance the state of the art in the HHATP process for composite fabrication.

Jensen, Brian J.↗

NASA NTRS2009

Resin infusion of layered metal/composite hybrid and resulting metal/composite hybrid laminate

A method of fabricating a metal/composite hybrid laminate is provided. One or more layered arrangements are stacked on a solid base to form a layered structure. Each layered arrangement is defined by a fibrous material and a perforated metal sheet. A resin in its liquid state is introduced along a portion of the layered structure while a differential pressure is applied across the laminate structure until the resin permeates the fibrous material of each layered arrangement and fills perforations in each perforated metal sheet. The resin is cured thereby yielding a metal/composite hybrid laminate.

Cano, Roberto J.↗

NASA NTRS2004

Modeling the VARTM Composite Manufacturing Process

A comprehensive simulation model of the Vacuum Assisted Resin Transfer Modeling (VARTM) composite manufacturing process has been developed. For isothermal resin infiltration, the model incorporates submodels which describe cure of the resin and changes in resin viscosity due to cure, resin flow through the reinforcement preform and distribution medium and compaction of the preform during the infiltration. The accuracy of the model was validated by measuring the flow patterns during resin infiltration of flat preforms. The modeling software was used to evaluate the effects of the distribution medium on resin infiltration of a flat preform. Different distribution medium configurations were examined using the model and the results were compared with data collected during resin infiltration of a carbon fabric preform. The results of the simulations show that the approach used to model the distribution medium can significantly effect the predicted resin infiltration times. Resin infiltration into the preform can be accurately predicted only when the distribution medium is modeled correctly.

Song, Xiao-Lan↗

NASA NTRS2004

Preform Characterization in VARTM Process Model Development

Vacuum-Assisted Resin Transfer Molding (VARTM) is a Liquid Composite Molding (LCM) process where both resin injection and fiber compaction are achieved under pressures of 101.3 kPa or less. Originally developed over a decade ago for marine composite fabrication, VARTM is now considered a viable process for the fabrication of aerospace composites (1,2). In order to optimize and further improve the process, a finite element analysis (FEA) process model is being developed to include the coupled phenomenon of resin flow, preform compaction and resin cure. The model input parameters are obtained from resin and fiber-preform characterization tests. In this study, the compaction behavior and the Darcy permeability of a commercially available carbon fabric are characterized. The resulting empirical model equations are input to the 3- Dimensional Infiltration, version 5 (3DINFILv.5) process model to simulate infiltration of a composite panel.

Grimsley, Brian W.↗

NASA NTRS2004

High Temperature VARTM with LaRC Polyimides

Recent work at NASA Langley Research Center (LaRC) has concentrated on developing new polyimide resin systems for advanced aerospace applications that can be processed without the use of an autoclave. Polyimide composites are very attractive for applications that require a high strength to weight ratio and thermal stability. Vacuum assisted resin transfer molding (VARTM) has shown potential to reduce the manufacturing cost of composite structures. In VARTM, the fibrous preform is infiltrated on a rigid tool surface contained beneath a flexible vacuum bag. Both resin injection and fiber compaction are achieved under pressures of 101.3 KPa or less. Recent studies have demonstrated the feasibility of the VARTM process for fabrication of void free structures utilizing epoxy resin systems with fiber volume fractions approaching 60%. In this work, the VARTM process has been extended to the fabrication of composite panels from polyimide systems developed at the Langley Research Center. This work has focused on processing LARC(trademark) PETI-8 (Langley Research Center Phenylethynyl Terminated Imide- 8), an aromatic polyimide based on 3,3',4,4' -biphenyltetracarboxylic dianhydride, a 50:50 molar ratio of 3,4'-oxydianiline and 1,3-bis(3-aminophenoxy)benzene, with 4-phenylethynylphthalic anhydride as the endcapping agent. Various molecular weight versions were investigated to determine their feasibility of being processed by VARTM at elevated temperatures. An injection temperature of approximately 280 C was required to achieve the necessary viscosity (<5 Poise) for flow at VARTM pressures. Laminate quality and initial mechanical properties are presented for LARC(trademark) PETI-8 and 6k IM7 uniweave fabric.

Cano, Roberto J.↗

NASA NTRS2003

VARTM Process Modeling of Aerospace Composite Structures

A three-dimensional model was developed to simulate the VARTM composite manufacturing process. The model considers the two important mechanisms that occur during the process: resin flow, and compaction and relaxation of the preform. The model was used to simulate infiltration of a carbon preform with an epoxy resin by the VARTM process. The model predicted flow patterns and preform thickness changes agreed qualitatively with the measured values. However, the predicted total infiltration times were much longer than measured most likely due to the inaccurate preform permeability values used in the simulation.

Song, Xiao-Lan↗

NASA NTRS2003

Cryopumping in Cryogenic Insulations for a Reusable Launch Vehicle

Testing at cryogenic temperatures was performed to verify the material characteristics and manufacturing processes of reusable propellant tank cryogenic insulations for a Reusable Launch Vehicle (RLV). The unique test apparatus and test methods developed for the investigation of cryopumping in cryogenic insulations are described. Panel level test specimens with various types of cryogenic insulations were subjected to a specific thermal profile where the temperature varied from -262 C to 21 C. Cryopumping occurred if the interior temperature of the specimen exhibited abnormal temperature fluctuations, such as a sudden decrease in temperature during the heating phase.

Johnson, Theodore F.↗

NASA NTRS2002

Dimensional Stability of Complex Shapes Manufactured by the VARTM Process

The vacuum assisted resin transfer molding (VARTM) process is a cost effective, innovative method that is being considered for manufacture of large aircraft-quality components where high mechanical properties and dimensional tolerance are essential. In the present work, carbon fiber SAERTEX fabric/SI-ZG-5A epoxy resin C-shaped laminates were manufactured by VARTM using different cure cycles followed by the same post-cure cycle. The final part thickness was uniform except at the corner were thinning was observed. The cure cycle selected is shown to significantly affect the part spring-in and a long cycle at 66 C followed by a 178 C post-cure produced a part with negligible spring-in.

Hubert, Pascal↗

NASA NTRS2002

Variability Analysis in Vacuum Assisted Resin Transfer Molding

The vacuum assisted resin transfer molding (VARTM) process is a low-cost, innovative method that is being considered for manufacture of large aircraft-quality components where high mechanical properties and dimensional tolerance are essential. In the present work a rigorous science-based approach is used to study the VARTM processing of high performance complex shape components. A process model, COMPRO, is used to simulate the cure of panels produced by VARTM. It was found that the presence of the distribution media significantly affects the magnitude of the exotherm particularly for thick panels. For C-shaped laminates, the part distortion was a function of fiber volume fraction distribution and was affected by the presence of the distribution media.

Hubert, Pascal↗

NASA NTRS2001

Processing and Testing of Thermoplastic Composite Cylindrical Shells Fabricated by Automated Fiber Placement

Two 61-cm-diameter eight-ply quasi-isotropic IM7/PEEK cylindrical shells were fabricated by automated fiber placement the NASA Langley Research Center using only infrared radiant heat to preheat the substrate and incoming composite uni-tape. The shells were characterized by ultrasonic c-scans for overall consolidation quality, and by optical microscopy and acid digestion for void content. Compression tests were also performed. Although the material used in the study was of generally poor quality due to numerous splits and dry fiber regions, the process was able to achieve a net reduction in void content in the as-placed component. Microscopy of the composite shells revealed well-consolidated, void-free interfaces. The two cylinders were then tested in uni-axial compression in a 1334 kN-capacity hydraulic test machine until buckling occurred. A geometrically nonlinear finite element analysis was conducted, and the differences between the predicted and measured values were 18.0 and 25.8%, respectively. Inclusion of measured imperfections of the cylinder into the analysis is expected to reduce these differences.

Hulcher, Anthony Bruce↗

NASA NTRS2001

Hybrid Composites for LH2 Fuel Tank Structure

The application of lightweight carbon fiber reinforced plastics (CFRP) as structure for cryogenic fuel tanks is critical to the success of the next generation of Reusable Launch Vehicles (RLV). The recent failure of the X-33 composite fuel tank occurred in part due to microcracking of the polymer matrix, which allowed cryogen to permeate through the inner skin to the honeycomb core. As part of an approach to solve these problems, NASA Langley Research Center (LaRC) and Marshall Space Flight Center (MSFC) are working to develop and investigate polymer films that will act as a barrier to the permeation of LH2 through the composite laminate. In this study two commercially available films and eleven novel LaRC films were tested in an existing cryogenics laboratory at MSFC to determine the permeance of argon at room temperature. Several of these films were introduced as a layer in the composite to form an interleaved, or hybrid, composite to determine the effects on permeability. In addition, the effects of the interleaved layer thickness, number, and location on the mechanical properties of the composite laminate were investigated. In this initial screening process, several of the films were found to exhibit lower permeability to argon than the composite panels tested.

Grimsley, Brian W.↗

NASA NTRS2001

Flow and Compaction During the Vacuum Assisted Resin Transfer Molding Process

The flow of an epoxy resin and compaction behavior of carbon fiber preform during vacuum- assisted resin transfer molding (VARTM) infiltration was measured using an instrumented tool. Composite panels were fabricated by the VARTM process using SAERTEX(R)2 multi-axial non- crimp carbon fiber fabric and the A.T.A.R.D. SI-ZG-5A epoxy resin. Resin pressure and preform thickness variation was measured during infiltration. The effects of the resin on the compaction behavior of the preform were measured. The local preform compaction during the infiltration is a combination of wetting and spring-back deformations. Flow front position computed by the 3DINFIL model was compared with the experimental data.

Grimsley, Brian W.↗

NASA NTRS1997

High Temperature Structural Foam

The Aerospace Industry is experiencing growing demand for high performance polymer foam. The X-33 program needs structural foam insulation capable of retaining its strength over a wide range of environmental conditions. The High Speed Research Program has a need for low density core splice and potting materials. This paper reviews the state of the art in foam materials and describes experimental work to fabricate low density, high shear strength foam which can withstand temperatures from -220 C to 220 C. Commercially available polymer foams exhibit a wide range of physical properties. Some with densities as low as 0.066 g/cc are capable of co-curing at temperatures as high as 182 C. Rohacell foams can be resin transfer molded at temperatures up to 180 C. They have moduli of elasticity of 0.19 MPa, tensile strengths of 3.7 Mpa and compressive strengths of 3.6 MPa. The Rohacell foams cannot withstand liquid hydrogen temperatures, however Imi-Tech markets Solimide (trademark) foams which withstand temperatures from -250 C to 200 C, but they do not have the required structural integrity. The research activity at NASA Langley Research Center focuses on using chemical blowing agents to produce polyimide thermoplastic foams capable of meeting the above performance requirements. The combination of blowing agents that decompose at the minimum melt viscosity temperature together with plasticizers to lower the viscosity has been used to produce foams by both extrusion and oven heating. The foams produced exhibit good environmental stability while maintaining structural properties.

Weiser, Erik S.↗