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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.

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NASA NTRS1986

Apparatus for Sizing and Rewinding Graphite Fibers

Equipment ideally suited for research and development of new sizing solutions. Designed expecially for applying thermoplastic sizing solutions to graphite tow consisting of 3,000 to 12,000 filaments per tow, but accommodates other solutions, filament counts, and materials other than graphite. Closed system containing highly volatile methylene chloride vapors. Also ventilation system directly over resin reservoir. Concept used to apply sizing compounds on fiber tows or yarn-type reinforcement materials used in composite technology. Sizing solutions consist of compounds compatible with thermosets as well as thermoplastics.

Wilson, M. L.↗

NASA NTRS1991

Cost-efficient manufacturing of composite structures

The Advanced Composites Technology (ACT) program is seeking research breakthroughs that will allow structures made of graphite epoxy materials to replace metals in the wings and fuselages of future aircrafts. NASA's goals are to reduce acquisition cost by 20 to 25 percent, structural weight for a resized aircraft by 40 to 50 percent, and the number of parts by half compared to current production aluminum aircraft. The innovative structural concepts, materials, and fabrication techniques emerging from the ACT program are described, and the relationship between aerospace developments and industrial, commercial, and sporting goods applications are discussed.

Freeman, W. Tom↗

NASA NTRS1992

Overview of mechanics of materials branch activities in the computational structures area

Base programs and system programs are discussed. The base programs include fundamental research of composites and metals for airframes leading to characterization of advanced materials, models of behavior, and methods for predicting damage tolerance. Results from the base programs support the systems programs, which change as NASA's missions change. The National Aerospace Plane (NASP), Advanced Composites Technology (ACT), Airframe Structural Integrity Program (Aging Aircraft), and High Speed Research (HSR) programs are currently being supported. Airframe durability is one of the key issues in each of these system programs. The base program has four major thrusts, which will be reviewed subsequently. Additionally, several technical highlights will be reviewed for each thrust.

Poe, C. C., Jr.↗

NASA NTRS1992

Resin transfer molding for advanced composite primary wing and fuselage structures

The stitching and resin transfer molding (RTM) processes developed at Douglas Aircraft Co. are successfully demonstrating significant cost reductions with good damage tolerance properties. These attributes were identified as critical to application of advanced composite materials to commercial aircraft primary structures. The RTM/stitching developments, cost analyses, and test results are discussed of the NASA Advanced Composites Technology program.

Markus, Alan↗

NASA NTRS1992

Local design optimization for composite transport fuselage crown panels

Composite transport fuselage crown panel design and manufacturing plans were optimized to have projected cost and weight savings of 18 and 45 percent, respectively. These savings are close to those quoted as overall NASA Advanced Composite Technology (ACT) program goals. Three local optimization tasks were found to influence the cost and weight of fuselage crown panels. The effects are summarized of each task and the task associated with a design cost model is described in detail. Studies were performed to evaluate the relationship between manufacturing cost and design details. A design tool was developed to aid in these studies. The development of the design tool included combining cost and performance constraints with a random search optimization algorithm. The resulting software was used in a series of optimization studies that evaluated the sensitivity of design variables, guidelines, criteria, and material selection on cost. The effect of blending adjacent design points in a full scale panel subjected to changing load distributions and local variations was shown to be important. Technical issues and directions for future work were identified.

Swanson, G. D.↗

NASA NTRS1994

Computational Simulation of the Formation and Material Behavior of Ice

Computational methods are described for simulating the formation and the material behavior of ice in prevailing transient environments. The methodology developed at the NASA Lewis Research Center was adopted. A three dimensional finite-element heat transfer analyzer was used to predict the thickness of ice formed under prevailing environmental conditions. A multi-factor interaction model for simulating the material behavior of time-variant ice layers is presented. The model, used in conjunction with laminated composite mechanics, updates the material properties of an ice block as its thickness increases with time. A sample case of ice formation in a body of water was used to demonstrate the methodology. The results showed that the formation and the material behavior of ice can be computationally simulated using the available composites technology.

Tong, Michael T.↗

NASA NTRS1993

Characterization and development of materials for advanced textile composites

Work ongoing under the NASA Langley - Advanced Composite Technology (ACT) program is discussed. The primary emphasis of the work centers around the development and characterization of graphite fiber that has been impregnated with an epoxy powder. Four epoxies have been characterized in towpreg form as to their weaveability and braidability. Initial mechanical properties have been generated on each resin system. These include unidirectional as well as 8-harness satin cloth. Initial 2D and 3D weaving and braiding trials will be reported on as well as initial efforts to develop towpreg suitable for advanced tow placement.

Hartness, J. Timothy↗

NASA NTRS1993

Performance of resin transfer molded multiaxial warp knit composites

Composite materials that are subjected to complex loads have traditionally been fabricated with multidirectionally oriented prepreg tape materials. Some of the problems associated with this type of construction include low delamination resistance, poor out-of-plane strength, and labor intensive fabrication processes. Textile reinforced composites with through-the-thickness reinforcement have the potential to solve some of these problems. Recently, a relatively new class of noncrimp fabrics designated as multiaxial warp knits have been developed to minimize some of the high cost and damage tolerance concerns. Multiple stacks of warp knit fabrics can be knitted or stitched together to reduce layup labor cost. The through-the-thickness reinforcement can provide significant improvements in damage tolerance and out-of-plane strength. Multilayer knitted/stitched preforms, in conjunction with resin transfer molding (RTM), offer potential for significant cost savings in fabrication of primary aircraft structures. The objectives of this investigation were to conduct RTM processing studies and to characterize the mechanical behavior of composites reinforced with three multiaxial warp knit fabrics. The three fabrics investigated were produced by Hexcel and Milliken in the United States, and Saerbeck in Germany. Two resin systems, British Petroleum E9O5L and 3M PR 500, were characterized for RTM processing. The performance of Hexcel and Milliken quasi-isotropic knitted fabrics are compared to conventional prepreg tape laminates. The performance of the Saerbeck fabric is compared to uniweave wing skin layups being investigated by Douglas Aircraft Company in the NASA Advanced Composites Technology (ACT) program. Tests conducted include tension, open hole tension, compression, open hole compression, and compression after impact. The effects of fabric defects, such as misaligned fibers and gaps between tows, on material performance are also discussed. Estimated material and labor cost savings are projected for the Saerbeck fabric as compared to uniweave fabric currently being used by Douglas in the NASA ACT wing development program.

Dexter, H. Benson↗

NASA NTRS1995

Analysis of selected compression splice joint locations in a graphite-epoxy transport wing stub box

Three critical compression splice joint locations in a stitched graphite-epoxy transport wing stub box have been analyzed to determine their expected structural performance. The wing box is representative of a section of a commercial transport wing box and was designed and constructed by McDonnell Douglas Aerospace Company as part of the NASA Advanced Composites Technology (ACT) program. The results of the finite element analyses of the splice joints are presented. The analysis results indicate that failure will not occur in the splice joint regions for loads less than the Design Ultimate Load of the wing box.

Jegley, Dawn C.↗

NASA NTRS1995

Mechanics of Textile Composites Conference

This document is a compilation of papers presented at the Mechanics of Textile Composites Conference in Hampton, Virginia, December 6-8, 1994. This conference was the culmination of a 3-year program that was initiated by NASA late in 1990 to develop mechanics of textile composites in support of the NASA Advance Composites Technology Program (ACT). The goal of the program was to develop mathematical models of textile preform materials and test methods to facilitate structural analysis and design. Participants in the program were from NASA, academia, and industry.

Poe, Clarence C.↗

NASA NTRS1995

Mechanics of Textile Composites Conference

This document is a compilation of papers presented at the Mechanics of Textile Composites Conference in Hampton, Virginia, December 6-8, 1994. This conference was the culmination of a 3-year program that was initiated by NASA late in 1990 to develop mechanics of textile composites in support of the NASA Advanced Composites Technology Program (ACT). The goal of the program was to develop mathematical models of textile preform materials and test methods to facilitate structural analysis and design. Participants in the program were from NASA, academia, and industry.

Poe, Clarence C., Jr.↗

NASA NTRS1996

Correlation of Structural Analysis and Test Results for the McDonnell Douglas Stitched/RFI All-Composite Wing Stub Box

The analytical and experimental results of an all-composite wing stub box are presented in this report. The wing stub box, which is representative of an inboard portion of a commercial transport high-aspect-ratio wing, was fabricated from stitched graphite-epoxy material with a Resin Film Infusion manufacturing process. The wing stub box was designed and constructed by the McDonnell Douglas Aerospace Company as part of the NASA Advanced Composites Technology program. The test article contained metallic load-introduction structures on the inboard and outboard ends of the graphite-epoxy wing stub box. The root end of the inboard load introduction structure was attached to a vertical reaction structure, and an upward load was applied to the outermost tip of the outboard load introduction structure to induce bending of the wing stub box. A finite element model was created in which the center portion of the wing-stub-box upper cover panel was modeled with a refined mesh. The refined mesh was required to represent properly the geometrically nonlinear structural behavior of the upper cover panel and to predict accurately the strains in the stringer webs of the stiffened upper cover panel. The analytical and experimental results for deflections and strains are in good agreement.

Wang, John T.↗

NASA NTRS1997

Global Cost and Weight Evaluation of Fuselage Side Panel Design Concepts

This report documents preliminary design trades conducted under NASA contracts NAS1 18889 (Advanced Technology Composite Aircraft Structures, ATCAS) and NAS1-19349 (Task 3, Pathfinder Shell Design) for a subsonic wide body commercial aircraft fuselage side panel section utilizing composite materials. Included in this effort were (1) development of two complete design concepts, (2) generation of cost and weight estimates, (3) identification of technical issues and potential design enhancements, and (4) selection of a single design to be further developed. The first design concept featured an open-section stringer stiffened skin configuration while the second was based on honeycomb core sandwich construction. The trade study cost and weight results were generated from comprehensive assessment of each structural component comprising the fuselage side panel section from detail fabrication through airplane final assembly. Results were obtained in three phases: (1) for the baseline designs, (2) after global optimization of the designs, and (3) the results anticipated after detailed design optimization. A critical assessment of both designs was performed to determine the risk associated with each concept, that is the relative probability of achieving the cost and weight projections. Seven critical technical issues were identified as the first step towards side panel detailed design optimization.

Polland, D. R.↗

NASA NTRS1997

Structural Test Documentation and Results for the McDonnell Douglas All-Composite Wing Stub Box

The results of a series of tests conducted at the NASA Langley Research Center to evaluate the behavior of an all-composite full-scale wing box are presented. The wing stub box is representative of a section of a commercial transport aircraft wing box and was designed and constructed by McDonnell Douglas Aerospace Company as part of the NASA Advanced Composites Technology (ACT) program. Tests were conducted with and without low-speed impact damage and repairs. The structure with nonvisible impact damage carried 140 percent of Design Limit Load prior to failure through an impact site.

Jegley, Dawn C.↗

NASA NTRS1999

Lockheed Martin Skunk Works Single Stage to Orbit/Reusable Launch Vehicle

Lockheed Martin Skunk Works has compiled an Annual Performance Report of the X-33/RLV Program. This report consists of individual reports from all industry team members, as well as NASA team centers. This portion of the report is comprised of a status report of Lockheed Martin's contribution to the program. The following is a summary of the Lockheed Martin Centers involved and work reviewed under their portion of the agreement: (1) Lockheed Martin Skunk Works - Vehicle Development, Operations Development, X-33 and RLV Systems Engineering, Manufacturing, Ground Operations, Reliability, Maintainability/Testability, Supportability, & Special Analysis Team, and X-33 Flight Assurance; (2) Lockheed Martin Technical Operations - Launch Support Systems, Ground Support Equipment, Flight Test Operations, and RLV Operations Development Support; (3) Lockheed Martin Space Operations - TAEM and A/L Guidance and Flight Control Design, Evaluation of Vehicle Configuration, TAEM and A/L Dispersion Analysis, Modeling and Simulations, Frequency Domain Analysis, Verification and Validation Activities, and Ancillary Support; (4) Lockheed Martin Astronautics-Denver - Systems Engineering, X-33 Development; (5) Sanders - A Lockheed Martin Company - Vehicle Health Management Subsystem Progress, GSS Progress; and (6) Lockheed Martin Michoud Space Systems - X-33 Liquid Oxygen (LOX) Tank, Key Challenges, Lessons Learned, X-33/RLV Composite Technology, Reusable Cyrogenic Insulation (RCI) and Vehicle Health Monitoring, Main Propulsion Systems (MPS), Structural Testing, X-33 System Integration and Analysis, and Cyrogenic Systems Operations.

Source record↗

NASA NTRS2000

[Operation/Maintenance of Fiber Placement Machine]

NASA contract NAS8-39749 was completed in January 2000. The contract period of performance covered six (6) years and included basic program technical support as required by NASA with up to thirty (30) different technical directives identified and issued by NASA for specific Advanced Composite Technology tasks during the course of the contract.

Pelham, L.↗

NASA NTRS2000

Hover Testing of the NASA/Army/MIT Active Twist Rotor Prototype Blade

Helicopter rotor individual blade control promises to provide a mechanism for increased rotor performance and reduced rotorcraft vibrations and noise. Active material methods, such as piezoelectrically actuated trailing-edge flaps and strain-induced rotor blade twisting, provide a means of accomplishing individual blade control without the need for hydraulic power in the rotating system. Recent studies have indicated that controlled strain induced blade twisting can be attained using piezoelectric active fiber composite technology. In order to validate these findings experimentally, a cooperative effort between NASA Langley Research Center, the Army Research Laboratory, and the MIT Active Materials and Structures Laboratory has been developed. As a result of this collaboration an aeroelastically-scaled active-twist model rotor blade has been designed and fabricated for testing in the heavy gas environment of the Langley Transonic Dynamics Tunnel (TDT). The results of hover tests of the active-twist prototype blade are presented in this paper. Comparisons with applicable analytical predictions of active-twist frequency response in hovering flight are also presented.

Matthew L Wilbur↗

NASA NTRS2004

Advances in Structures for Large Space Systems

The development of structural systems for scientific remote sensing and space exploration has been underway for four decades. The seminal work from 1960 to 1980 provided the basis for many of the design principles of modern space systems. From 1980- 2000 advances in active materials and structures and the maturing of composites technology led to high precision active systems such those used in the Space Interferometry Mission. Recently, thin-film membrane or gossamer structures are being investigated for use in large area space systems because of their low mass and high packaging efficiency. Various classes of Large Space Systems (LSS) are defined in order to describe the goals and system challenges in structures and materials technologies. With an appreciation of both past and current technology developments, future technology challenges are used to develop a list of technology investments that can have significant impacts on LSS development.

Belvin, W. Keith↗