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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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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Hybrid Inflatable Pressure Vessel

Figure 1 shows a prototype of a large pressure vessel under development for eventual use as a habitable module for long spaceflight (e.g., for transporting humans to Mars). The vessel is a hybrid that comprises an inflatable shell attached to a rigid central structural core. The inflatable shell is, itself, a hybrid that comprises (1) a pressure bladder restrained against expansion by (2) a web of straps made from high-strength polymeric fabrics. On Earth, pressure vessels like this could be used, for example, as portable habitats that could be set up quickly in remote locations, portable hyperbaric chambers for treatment of decompression sickness, or flotation devices for offshore platforms. In addition, some aspects of the design of the fabric straps could be adapted to such other items as lifting straps, parachute straps, and automotive safety belts. Figure 2 depicts selected aspects of the design of a vessel of this type with a toroidal configuration. The bladder serves as an impermeable layer to keep air within the pressure vessel and, for this purpose, is sealed to the central structural core. The web includes longitudinal and circumferential straps. To help maintain the proper shape upon inflation after storage, longitudinal and circumferential straps are indexed together at several of their intersections. Because the web is not required to provide a pressure seal and the bladder is not required to sustain structural loads, the bladder and the web can be optimized for their respective functions. Thus, the bladder can be sealed directly to the rigid core without having to include the web in the seal substructure, and the web can be designed for strength. The ends of the longitudinal straps are attached to the ends of the rigid structural core by means of clevises. Each clevis pin is surrounded by a roller, around which a longitudinal strap is wrapped to form a lap seam with itself. The roller is of a large diameter chosen to reduce bending of the fibers in the strap. The roller also serves to equalize the load in the portions of the strap on both sides of the clevis pin. The lap seam is formed near the clevis by use of a tapered diamond stitch: This stitch is designed specifically to allow fibers in the stitch and strap to relax under load in such a manner that the load becomes more nearly evenly distributed among all fibers in the stitch region. Thus, the tapered diamond stitch prevents load concentrations that could cause premature failure of the strap and thereby increases the strength of the strap/structural-core joint. The lap seam can be rated at >90 percent of the strength of the strap material.

Raboin, Jasen↗
DOE OSTI2024

Acrylonitrile-butadiene-lignin thermoplastic rubber adhesive for enhanced metal-to-metal joining

With the growing requirement for lightweight structural materials in automotive, aerospace, and infrastructure applications, multi-material joints made with adhesive have attracted intense research interest. Commercial thermoset adhesives are one-time cures, and difficult to disassemble the bonded components for repair and recycling. Our prior work with a thermoplastic acrylonitrile-butadiene-lignin rubber (ABL) addresses this sustainability/recycling challenge, but the adhesive exhibits deficient joining strength compared to standard thermosets. Here, we modify the ABL matrix by loading particulate fillers to enhance its modulus and toughness. Further, the goal is to manufacture a cure-free thermoplastic adhesive system with a simple dispensing protocol and characteristic ductility combined with a high yield stress for improved shear strength of a bonded joint. Fumed silica (FS) and epoxidized glass spheres (EGS) were used as fillers in the ABL to promote the dispersion of lignin particles that tailored the functionalities and free energy components of the adhesive surface. With optimal loading of FS (5 wt%) and EGS (30 wt%) in the ABL adhesive matrix, the lap-shear strength of the bonded aluminum joint was elevated by 128%, compared to the neat ABL, reaching 21 MPa, which is 90% of the performance of a commercial epoxy-based adhesive.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

Jones, C. S.↗
NASA NTRSDate not supplied

Measurement System Analysis of a Novel Phase-Based Ultrasonic NDE Technique for Bond Strength Measurement

Fiber reinforced polymer parts have shown tremendous benefits in aerospace structural applications, but their qualification and certification for use in safety critical areas are currently hindered by the lack of a capable non-destructive evaluation (NDE) method or technique for the inspection of these adhesively bonded parts. Conventional NDE methods and techniques typically detect gross bond defects in a qualitative (Pass/Fail) manner. These techniques struggle to detect weak or kissing bonds. Also, there are no widely adopted NDE methods or techniques for measuring interfacial bond strength or detecting kissing bonds. Bond strength is currently ensured by process control and semi-destructive testing. Results from recent research from other authors, including but not limited to mechanical testing, have shown an excellent correlation between interfacial stiffness of an adhesively bonded joint and the adhesive bond strength of that joint. In this paper, a measurement system analysis (MSA) of a novel phase-based ultrasonic NDE Technique, developed at NASA Langley Research Center, is presented for bond strength measurement to assess at an increased level the measurement process and identify components of variation in that measurement process.

Ultrasound↗
NASA NTRS1979

Ultimate strength of high-load-capacity composite bolted joints

Presented are the results of a series of tests initiated to obtain baseline data on the load-carrying capacity of bolted joints designed to carry large loads, specifically up to 222 kN (50 kips). The major testing purposes were to determine the load carrying capacity as a function of the width and thickness of the joint and the diameter and number of bolts, and to observe the failure mode. A total of 100 tests were conducted on three different specimen configurations. The specimens were fabricated from a T300/5208 fiber/resin system in a quasi-isotropic lay-up. The results presented indicate that for a given ratio of specimen width to hole diameter, the specimens with the smaller holes sustained a higher net-section tensile stress before failure. In addition, for a given ratio of specimen width to hole diameter, the thinner specimens withstood a higher net-section stress. No attempt has been made to correlate the results with theoretical predictions.

Hyer, M. W.↗
NASA NTRS1981

Design, fabrication and test of graphite/polyimide composite joints and attachments for advanced aerospace vehicles

The development of several types of graphite/polyimide (GR/PI) bonded and bolted joints is reported. The program consists of two concurrent tasks: (1) design and test of specific built up attachments; and (2) evaluation of standard advanced bonded joint concepts. A data base for the design and analysis of advanced composite joints for use at elevated temperatures (561K (550 deg F)) to design concepts for specific joining applications, and the fundamental parameters controlling the static strength characteristics of such joints are evaluated. Data for design and build GR/PI of lightly loaded flight components for advanced space transportation systems and high speed aircraft are presented. Results for compression and interlaminar shear strengths of Celion 6000/PMR-15 laminates are given. Static discriminator test results for type 3 and type 4 bonded and bolted joints and final joint designs for TASK 1.4 scale up fabrication and testing are presented.

Source record↗
NASA NTRS1986

Measuring Hole Elongation in Bolted Joints

Measurement does not affect joint parameters. Verification of analytical and strength-prediction methods for bolted composite joints based generally on data obtained experimentally from double-lap-joint specimens. In mechanically fastened joints, stresses maximal at fastener holes. Ability to measure accurately hole elongations without affecting joint parameters provides better understanding of elastic and plastic behavior of joint material leading to failure mechanisms in mechanically fastened joints required for design of more-efficient, lightweight composite joints.

Wichorek, G. R.↗
NASA NTRS1996

Role of the micro/macro structure of welds in crack nucleation and propagation in aerospace aluminum-lithium alloy

Al-Li alloys offer the benefits of increased strength, elastic modulus and lower densities as compared to conventional aluminum alloys. Martin Marietta Laboratories has developed an Al-Li alloy designated 2195 which is designated for use in the cryogenic tanks of the space shuttle. The Variable Polarity Plasma Arc (VPPA) welding process is currently being used to produce these welds [1]. VPPA welding utilizes high temperature ionized gas (plasma) to transfer heat to the workpiece. An inert gas, such as Helium, is used to shield the active welding zone to prevent contamination of the molten base metal with surrounding reactive atmospheric gases. [1] In the Space Shuttle application, two passes of the arc are used to complete a butt-type weld. The pressure of the plasma stream is increased during the first pass to force the arc entirely through the material, a practice commonly referred to as keyholing. Molten metal forms on either side of the arc and surface tension draws this liquid together as the arc passes. 2319 Al alloy filler material may also be fed into the weld zone during this pass. During the second pass, the plasma stream pressure is reduced such that only partial penetration of the base material is obtained. Al 2319 filler material is added during this pass to yield a uniform, fully filled welded joint. This additional pass also acts to alter the grain structure of the weld zone to yield a higher strength joint.

Talia, George E.↗
NASA NTRS2007

Effects of Different Braze Materials and Composite Substrates on Composite/Ti Joints

An ever increasing number of applications require robust joining technologies of dissimilar materials. In this study, three types of ceramic composites (C-C, C-SiC, and SiC-SiC) were vacuum brazed to commercially pure Ti using the Cusil-ABA (63 Ag - 35.5 Cu - 1.75 Ti) active metal braze alloy. The study also compared composite specimens as-fabricated and after surface grinding/polishing. A butt-strap tensile shear strength test was used to evaluate the joined structures at room temperature, 270 and 500 C. The elevated temperatures represent possible use temperatures for some heat rejection type applications. Joint strength will be discussed in light of braze wetting and spreading properties, composite properties, and test temperature.

Morscher, Gregory N.↗
NASA NTRS1989

Explosive Joining

Laurence J. Bement of Langley Research Center invented a technique to permit metal joining operations under hazardous or inaccessible conditions. The process, which provides a joint with double the strength of the parent metal, involves the use of very small quantities of ribbon explosive to create hermetically sealed joints. When the metal plates are slammed together by the explosion's force, joining is accomplished. The collision causes a skin deep melt and ejection of oxide films on the surfaces, allowing a linkup of electrons that produce superstrong, uniform joints. The technique can be used to join metals that otherwise would not join and offers advantages over mechanical fasteners and adhesives. With Langley assistance, Demex International Ltd. refined and commercialized the technology. Applications include plugging leaking tubes in feedwater heaters. Demex produces the small plugs, associated sleeves and detonators. The technology allows faster plugging, reduces downtime, cuts plugging costs and increases reliability.

Source record↗
NASA NTRS1997

Joining of Silicon Carbide-Based Ceramics by Reaction Forming Method

Recently, there has been a surge of interest in the development and testing of silicon-based ceramics and composite components for a number of aerospace and ground based systems. The designs often require fabrication of complex shaped parts which can be quite expensive. One attractive way of achieving this goal is to build up complex shapes by joining together geometrically simple shapes. However, the joints should have good mechanical strength and environmental stability comparable to the bulk materials. These joints should also be able to maintain their structural integrity at high temperatures. In addition, the joining technique should be practical, reliable, and affordable. Thus, joining has been recognized as one of the enabling technologies for the successful utilization of silicon carbide based ceramic components in high temperature applications. Overviews of various joining techniques, i.e., mechanical fastening, adhesive bonding, welding, brazing, and soldering have been provided in recent publications. The majority of the techniques used today are based on the joining of monolithic ceramics with metals either by diffusion bonding, metal brazing, brazing with oxides and oxynitrides, or diffusion welding. These techniques need either very high temperatures for processing or hot pressing (high pressures). The joints produced by these techniques have different thermal expansion coefficients than the ceramic materials, which creates a stress concentration in the joint area. The use temperatures for these joints are around 700 C. Ceramic joint interlayers have been developed as a means of obtaining high temperature joints. These joint interlayers have been produced via pre-ceramic polymers, in-situ displacement reactions, and reaction bonding techniques. Joints produced by the pre-ceramic polymer approach exhibit a large amounts of porosity and poor mechanical properties. On the other hand, hot pressing or high pressures are needed for in-situ displacement reactions and reaction bonding techniques. Due to the equipment required, these techniques are impractical for joining large or complex shaped components.

Singh, M.↗
NASA NTRS1990

Advanced fabrication technology for high speed aircraft structures

An overview of the development of the weld-brazing process for fabricating Ti-6Al-4V skin-stiffened panels, a brazing process for fabricating Bsc/Al titanium honeycomb core panels, and the enhanced diffusion bonding (EDB) process for fabricating Ti-14Al-21Nb titanium aluminide structural elements are presented. Data presented include the shear strengths of full-scale weldbrazed Ti-6Al-4V skin stiffened and Bsc/Al titanium honeycomb core sandwich panels designed to meet the requirements of an upper wing panel on the NASA YF-12. These results verified that the materials, fabrication processes, and structural concepts were qualified for Mach 3 flight. Shear strengths of each of the panel concepts following flight service evaluation are also reported. Comparisons made with the cost and weight of the original wing panel indicated that the weldbrazed titanium panels resulted in a 15-20 percent cost savings and the brazed Bsc/Al panel showed a 30 percent weight savings. It was also shown that the strengths of the EDB joints were sufficient to develop stresses in the Ti-14Al-21Nb face sheets of the sandwich structure which were above the yield strength of the material.

Bales, T. T.↗
NASA NTRS2009

Brazed Joints Design and Allowables: Discuss Margins of Safety in Critical Brazed Structures

This slide presentation tutorial discusses margins of safety in critical brazed structures. It reviews: (1) the present situation (2) definition of strength (3) margins of safety (4) design allowables (5) mechanical testing (6) failure criteria (7) design flowchart (8) braze gap (9) residual stresses and (10) delayed failures. This presentation addresses the strength of the brazed joints, the methods of mechanical testing, and our ability to evaluate the margins of safety of the brazed joints as it applies to the design of critical and expensive brazed assemblies.

FLom, Yury↗
NASA NTRS2009

Development of High Temperature Dissimilar Joint Technology for Fission Surface Power Systems

NASA is developing fission surface power (FSP) system technology as a potential option for use on the surface of the moon or Mars. The goal is to design a robust system that takes full advantage of existing materials data bases. One of the key components of the power conversion system is the hot-side Heat Exchanger (HX). One possible design for this heat exchanger requires a joint of the dissimilar metals 316L stainless steel and Inconel 718, which must sustain extended operation at high temperatures. This study compares two joining techniques, brazing and diffusion bonding, in the context of forming the requisite stainless steel to superalloy joint. The microstructures produced by brazing and diffusion bonding, the effect of brazing cycle on the mechanical tensile properties of the alloys, and the strength of several brazed joints will be discussed.

Locci, Ivan E.↗
NASA NTRS1983

Critical joints in large composite aircraft structure

A program was conducted at Douglas Aircraft Company to develop the technology for critical structural joints of composite wing structure that meets design requirements for a 1990 commercial transport aircraft. The prime objective of the program was to demonstrate the ability to reliably predict the strength of large bolted composite joints. Ancillary testing of 180 specimens generated data on strength and load-deflection characteristics which provided input to the joint analysis. Load-sharing between fasteners in multirow bolted joints was computed by the nonlinear analysis program A4EJ. This program was used to predict strengths of 20 additional large subcomponents representing strips from a wing root chordwise splice. In most cases, the predictions were accurate to within a few percent of the test results. In some cases, the observed mode of failure was different than anticipated. The highlight of the subcomponent testing was the consistent ability to achieve gross-section failure strains close to 0.005. That represents a considerable improvement over the state of the art.

Nelson, W. D.↗
NASA NTRS1992

Tensile properties of impact ices

A special test apparatus was developed to measure the tensile strength of impact ices perpendicular to the direction of growth. The apparatus consists of a split tube carefully machined to minimize the effect of the joint on impact ice strength. The tube is supported in the wind tunnel by two carefully aligned bearings. During accretion the tube is turned slowly in the icing cloud to form a uniform coating of ice on the split tube specimen. The two halves of the split tube are secured firmly by a longitudinal bolt to prevent relative motion between the two halves during ice accretion and handling. Tensile test strength results for a variety of icing conditions were obtained. Both glaze and rime ice conditions were investigated. In general, the tensile strength of impact ice was significantly less than refrigerator ice. Based on the limited data taken, the median strength of rime ice was less than glaze ice. However, the mean values were similar.

Chu, M. L.↗
NASA NTRS2004

Design/Analysis of Metal/Composite Bonded Joints for Survivability at Cryogenic Temperatures

A major design and analysis challenge for the JWST ISM structure is the metal/composite bonded joints that will be required to survive down to an operational ultra-low temperature of 30K (-405 F). The initial and current baseline design for the plug-type joint consists of a titanium thin walled fitting (1-3mm thick) bonded to the interior surface of an M555/954-6 composite truss square tube with an axially stiff biased lay-up. Metallic fittings are required at various nodes of the truss structure to accommodate instrument and lift-point bolted interfaces. Analytical experience and design work done on metal/composite bonded joints at temperatures below liquid nitrogen are limited and important analysis tools, material properties, and failure criteria for composites at cryogenic temperatures are virtually nonexistent. Increasing the challenge is the difficulty in testing for these required tools and parameters at 30K. A preliminary finite element analysis shows that failure due to CTE mismatch between the biased composite and titanium or aluminum is likely. Failure is less likely with Invar, however an initial mass estimate of Invar fittings demonstrates that Invar is not an automatic alternative. In order to gain confidence in analyzing and designing the ISM joints, a comprehensive joint development testing program has been planned and is currently running. The test program is designed for the correlation of the analysis methodology, including tuning finite element model parameters, and developing a composite failure criterion for the effect of multi-axial composite stresses on the strength of a bonded joint at 30K. The testing program will also consider stress mitigation using compliant composite layers and potential strength degradation due to multiple thermal cycles. Not only will the finite element analysis be correlated to the test data, but the FEA will be used to guide the design of the test. The first phase of the test program has been completed and the preliminary analysis has been revisited based on the test data In this work, we present an overview of the test plan, results today, and resulting design improvements.

Bartoszyk, Andrew E.↗