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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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195 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Design study of prestressed rotor spar concept

Studies on the Bell Helicopter 540 Rotor System of the AH-1G helicopter were performed. The stiffness, mass and geometric configurations of the Bell blade were matched to give a dynamically similar prestressed composite blade. A multi-tube, prestressed composite spar blade configuration was designed for superior ballistic survivability at low life cycle cost. The composite spar prestresses, imparted during fabrication, are chosen to maintain compression in the high strength cryogenically stretchformed 304-L stainless steel liner and tension in the overwrapped HTS graphite fibers under operating loads. This prestressing results in greatly improved crack propagation and fatigue resistance as well as enhanced fiber stiffness properties. Advantages projected for the prestressed composite rotor spar concept include increased operational life and improved ballistic survivability at low life cycle cost.

Gleich, D.↗
NASA NTRS1999

Composite Nozzle/Thrust Chambers Analyzed for Low-Cost Boosters

The Low Cost Booster Technology Program is an initiative to minimize the cost of future liquid engines by using advanced materials and innovative designs, and by reducing engine complexity. NASA Marshall Space Flight Center s 60K FASTRAC Engine is one example where these design philosophies have been put into practice. This engine burns a liquid kerosene/oxygen mixture. It uses a one-piece, polymer composite thrust chamber/nozzle that is constructed of a tape-wrapped silica phenolic liner, a metallic injector interface ring, and a filament-wound epoxy overwrap. A cooperative effort between NASA Lewis Research Center s Structures Division and Marshall is underway to perform a finite element analysis of the FASTRAC chamber/nozzle under all the loading and environmental conditions that it will experience during its lifetime. The chamber/nozzle is a complex composite structure. Of its three different materials, the two composite components have distinctly different fiber architectures and, consequently, require separate material model descriptions. Since the liner is tape wrapped, it is orthotropic in the nozzle global coordinates; and since the overwrap is filament wound, it is treated as a monoclinic material. Furthermore, the wind angle on the overwrap varies continuously along the length of the chamber/nozzle.

Sullivan, Roy M.↗
NASA NTRS1974

Fabrication and testing of prestressed composite rotor blade spar specimens

Prestressed composite spar specimens were fabricated and evaluated by crack propagation and ballistic penetration tests. The crack propagation tests on flawed specimens showed that the prestressed composite spar construction significantly suppresses crack growth. Damage from three high velocity 30 caliber projectile hits was confined to three small holes in the ballistic test specimen. No fragmentation or crack propagation was observed indicating good ballistic damage resistance. Rotor attachment approaches and improved structural performance configurations were identified. Design theory was verified by tests. The prestressed composite spar configuration consisted of a compressively prestressed high strength ARDEFORM 301 stainless steel liner overwrapped with pretensioned S-994 fiberglass.

Gleich, D.↗
NASA NTRS1976

Filament wound pressure vessels with load sharing liners for Space Shuttle Orbiter applications

It is recognized that the use of overwrapped pressure vessels with load sharing liners may provide significant weight savings for high pressure gas containment in Space Shuttle Orbiter systems. The technology readiness to produce Kevlar wound vessels with load sharing liners of titanium 6Al-4V, Inconel 718 or cryoformed 301 steel has been demonstrated. It has been estimated that about 400 lbs can be saved in the Orbiter by using overwrapped vessels with load sharing liners instead of monolithic metal designs. Total weight of the composite vessels would be about 1350 lbs as opposed to about 1750 lbs for all-metal vessels.

Ecord, G. M.↗
NASA NTRS1974

Filament winding S-glass/polyimide resin composite processing studies

The work performed in selecting a TRW A-type polyimide resin that would be suitable for fabrication of filament wound reinforced plastic structures is described. Several different formulations were evaluated after which the P105AC formulation was selected as the most promising. Procedures then were developed for preparing P105AC/S-glass roving prepreg and for fabricating filament wound structural composites. Composites were fabricated and then tested in order to obtain tensile and shear strength information. Small, closed-end cylindrical pressure vessels then were fabricated using a stainless steel liner and end fittings with a P105AC/S-glass polar wound overwrap. These pressure vessels were cured in an air circulating oven without augmented pressure. It is concluded that the P105AC resin system is suitable for filament winding; that low void content, high strength composites are obtained by the filament winding process; and that augmented pressure is not required to effect the fabrication of filament wound P105AC composites.

Vaughan, R. W.↗
NASA NTRS1974

TRW A-type polyimide resin for filament winding

Studies were conducted to select a TRW A-type polyimide resin that would be suitable for fabrication of filament wound reinforced plastics structures. Several different formulations were evaluated after which the P105AC formulation was selected as the most promising. Procedures were developed for preparing P105AC/S-glass roving prepreg and for fabricating filament wound structural composites. Composites were fabricated and then tested in order to obtain tensile and shear strength information. Small, closed-end cylindrical pressure vessels then were fabricated using a stainless steel liner and end-fittings with a P105AC/S-glass polar-wound overwrap. These pressure vessels were cured in an air circulating oven without augmented pressure. It was concluded upon completion of this study that the P105AC resin system is suitable for filament winding; that low void content, high strength composites are obtained by the filament winding process; and that augmented pressure is not required to effect the fabrication of filament wound P105AC composites.

Vaughan, R. W.↗
NASA NTRS1979

Effect of low-stiffness closeout overwrap on rocket thrust-chamber life

Three rocket thrust chambers with copper liners and a thrust level of 20.9 kN were cyclically test fired to failure. Two of the liners were made from oxygen free, high conductivity (OFHC) copper and from annealed Amzirc. The milled coolant channels were closed out with a thin copper closeout over which a fiberglass composite was wrapped to provide hoop strength only. Experimental data are presented, along with the results of a preliminary analysis that was performed before fabrication to evaluate the life extending potential of a thin copper closeout with a fiberglass overwrap.

Kasper, H. J.↗
NASA NTRS1977

Composite pressure vessels for the Space Shuttle Orbiter

During the development of the Space Shuttle Orbiter propulsion and environmental control subsystems it was recognized that use of composite pressure vessels with load sharing liners could provide significant weight savings for high pressure gas containment. A program is described which was undertaken to assess the utility for orbiter applications of titanium 6Al-4V and Inconel 718 liners overwrapped with Kevlar fibers. Vessel characteristics, design features and test results are presented along with brief descriptions of processes and nondestructive evaluation techniques. The resolutions of anomalies and development of design are also presented. Fracture control as applied to the orbiter composite vessels is briefly discussed. Five of the seven titanium lined vessels in the program experienced premature cyclic failures. These failures were shown to be primarily due to metallurgical anomalies rather than an inherent composite design problem. A nonfragmentary leakage mode of failure was demonstrated at operating pressures. The composite designs will be approximately 25 percent lighter than their all metal counterparts.

Ecord, G. M.↗
NASA NTRS1975

Fracture control method for composite tanks with load sharing liners

The experimental program was based on the premise that the plastic sizing cycle, which each pressure vessel is subjected to prior to operation, acts as an effective proof test of the liner, screening out all flaws or cracks larger than a critical size. In doing so, flaw growth potential is available for cyclic operation at pressures less than the sizing pressure. Static fracture and cyclic life tests, involving laboratory type specimens and filament overwrapped tanks, were conducted on three liner materials: (1) 2219-T62 aluminum, (2) Inconel X750 STA, and (3) cryoformed 301 stainless steel. Variables included material condition, thickness, flaw size, flaw shape, temperature, sizing stress level, operating stress level and minimum-to-maximum operating stress ratio. From the empirical data base obtained, a procedure was established by which the service life of composite tanks with load sharing liners could be guaranteed with a high degree of confidence.

Bixler, W. D.↗
NASA NTRS1989

Sustained load behavior of graphite/epoxy metal-lined pressure vessels for long-life space applications

Tests were performed on candidate graphite yarns for the overwraps to be used on the Space Station Freedom's pressure vessels. The objective was to determine the performance and ranking of these overwraps to ensure that sustained loads would not be a problem during their 30-yr life in space. Tests were conducted at high stress levels for short time periods on subscale composite bottles. The average delivered fiber stresses were determined from the measured burst pressures via SCI analysis that accounts for both geometry and the properties of the resin and yarn.

Babel, H. W.↗
NASA NTRS2000

Computer Tomography Analysis of Fastrac Composite Thrust Chamber Assemblies

Computed tomography (CT) inspection has been integrated into the production process for NASA's Fastrac composite thrust chamber assemblies (TCAs). CT has been proven to be uniquely qualified to detect the known critical flaw for these nozzles, liner cracks that are adjacent to debonds between the liner and overwrap. CT is also being used as a process monitoring tool through analysis of low density indications in the nozzle overwraps. 3d reconstruction of CT images to produce models of flawed areas is being used to give program engineers better insight into the location and nature of nozzle flaws.

Beshears, Ronald D.↗
NASA NTRS1971

Cryogenic glass-filament-wound tank evaluation

High-pressure glass-filament-wound fluid storage vessels with thin aluminum liners were designed, fabricated, and tested at ambient and cryogenic temperatures which demonstrated the feasibility of producing such vessels as well as high performance and light weight. Significant developments and advancements were made in solving problems associated with the thin metal liners in the tanks, including liner bonding to the overwrap and high strain magnification at the vessel polar bosses. The vessels had very high burst strengths, and failed in cyclic fatigue tests by local liner fracture and leakage without structural failure of the composite tank wall. The weight of the tanks was only 40 to 55% of comparable 2219-T87 aluminum and Inconel 718 tanks.

Morris, E. E.↗
NASA NTRS2009

Hypervelocity Impacts on ISS Handrails and Evaluation of Alternative Materials to Prevent Extravehicular Mobility Unit (EMU) Glove Damage During EVA

During post-flight processing of STS-116, damage to crewmember Robert Curbeam's Phase VI Glove Thermal Micrometeoroid Garment was discovered. This damage consisted of: loss of RTV-157 palm pads on the thumb area on the right glove, a 0.75 inch cut in the Vectran adjacent to the seam and thumb pad (single event cut), constituting the worst glove damage ever recorded for the U.S. space program. The underlying bladder and restraint were found not be damaged by this event. Evaluation of glove damage found that the outer Vectran fibers were sliced as a result of contact with a sharp edge or pinch point rather than general wear or abrasion (commonly observed on the RTV pads). Damage to gloves was also noted on STS-118 and STS-120. One potential source of EMU glove damages are sharp crater lips on external handrails, generated by micrometeoroid and orbital debris (MMOD) impacts. In this paper, the results of a hypervelocity impact (HVI) test program on representative and actual ISS handrails are presented. These tests were performed in order to characterize impact damage profiles on ISS handrails and evaluate alternatives for limiting risk to future missions. It was determined that both penetrating and non-penetrating MMOD impacts on aluminum and steel ISS handrails are capable of generating protruding crater profiles which exceed the heights required for EMU glove abrasion risk by an order of magnitude. Testing demonstrated that flexible overwraps attached to the outside of existing handrails are capable of limiting contact between hazardous crater formations and crewmember gloves during extravehicular activity (EVA). Additionally, replacing metallic handrails with high strength, low ductility, fiber reinforced composite materials would limit the formation of protruding crater lips on new ISS modules.

Ryan, Shannon↗
NASA NTRS1990

Design and fabrication of instrumented composite airfoils for a cryogenic wind tunnel model

Two instrumented horizontal stabilizers and one instrumented vertical stabilizer were designed and fabricated for testing on the Pathfinder 1 (PF-1) Transport Model in the NASA Langley Research Center's National Transonic Facility (NTF). Two different designs were employed: the horizontal stabilizer utilized a metal spar and fiberglass overwrap and the vertical stabilizer was made of all fiberglass. All design requirements were met in terms of design loads, airfoil tolerances, surface finish, orifice hole quality, and proof-of-concept tests. Pressure tubing installation was found to be easier for these concepts as compared to methods used in conventional metallic models. Ease of repair was found to be a principal advantage in that some fabrication problems were overcome by reapplying fiberglass cloth and/or epoxy to damaged areas. Also, fabrication costs were judged to be lower when compared to the more conventional design fabrication costs.

Young, Clarence P., Jr.↗
NASA NTRS2009

Mitigation of EMU Glove Cut Hazard by MMOD Impact Craters on Exposed ISS Handrails

Recent cut damages to crewmember extravehicular mobility unit (EMU) gloves during extravehicular activity (EVA) onboard the International Space Station (ISS) has been found to result from contact with sharp edges or pinch points rather than general wear or abrasion. One possible source of cut-hazards are protruding sharp edged crater lips from impact of micrometeoroid and orbital debris (MMOD) particles on external metallic handrails along EVA translation paths. During impact of MMOD particles at hypervelocity an evacuation flow develops behind the shock wave, resulting in the formation of crater lips that can protrude above the target surface. In this study, two methods were evaluated to limit EMU glove cut-hazards due to MMOD impact craters. In the first phase, four flexible overwrap configurations are evaluated: a felt-reusable surface insulation (FRSI), polyurethane polyether foam with beta-cloth cover, double-layer polyurethane polyether foam with beta-cloth cover, and multi-layer beta-cloth with intermediate Dacron netting spacers. These overwraps are suitable for retrofitting ground equipment that has yet to be flown, and are not intended to protect the handrail from impact of MMOD particles, rather to act as a spacer between hazardous impact profiles and crewmember gloves. At the impact conditions considered, all four overwrap configurations evaluated were effective in limiting contact between EMU gloves and impact crater profiles. The multi-layer beta-cloth configuration was the most effective in reducing the height of potentially hazardous profiles in handrail-representative targets. In the second phase of the study, four material alternatives to current aluminum and stainless steel alloys were evaluated: a metal matrix composite, carbon fiber reinforced plastic (CFRP), fiberglass, and a fiber metal laminate. Alternative material handrails are intended to prevent the formation of hazardous damage profiles during MMOD impact and are suitable for flight hardware yet to be constructed. Of the four materials evaluated, only the fiberglass formed a less hazardous damage profile than the baseline metallic target. Although the CFRP laminate did not form any noticeable crater lip, brittle protruding fibers are considered a puncture risk. In parallel with EMU glove redesign efforts, modifications to metallic ISS handrails such as those evaluated in this study provide the means to significantly reduce cut-hazards from MMOD impact craters.

Christiansen, Eric L.↗