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This issue contains articles with a special focus on Computer-Aided design and engineering amd a research report on the Ames Research Center. Other subjects in this issue are: Electronic Components and Circuits, Electronic Systems, Physical Sciences, Materials, Computer Programs, Mechanics, Machinery, Manufacturing/Fabrication, Mathematics and Information Sciences and Life Sciences
Composite solid freeform fabrication (C-SFF) or composite layer manufacturing (CLM) is an automated process in which an advanced composite material (a matrix reinforced with continuous fibers) is formed into a freestanding, possibly complex, three-dimensional object. In CLM, there is no need for molds, dies, or other expensive tooling, and there is usually no need for machining to ensure that the object is formed to the desired net size and shape. CLM is a variant of extrusion-type rapid prototyping, in which a model or prototype of a solid object is built up by controlled extrusion of a polymeric or other material through an orifice that is translated to form patterned layers. The second layer is deposited on top of the first layer, the third layer is deposited on top of the second layer, and so forth, until the stack of layers reaches the desired final thickness and shape. The elements of CLM include (1) preparing a matrix resin in a form in which it will solidify subsequently, (2) mixing the fibers and matrix material to form a continuous pre-impregnated tow (also called "towpreg"), and (3) dispensing the pre-impregnated tow from a nozzle onto a base while moving the nozzle to form the dispensed material into a patterned layer of controlled thickness. When the material deposited into a given layer has solidified, the material for the next layer is deposited and patterned similarly, and so forth, until the desired overall object has been built up as a stack of patterned layers. Preferably, the deposition apparatus is controlled by a computer-aided design (CAD) system. The basic CLM concept can be adapted to the fabrication of parts from a variety of matrix materials. It is conceivable that a CLM apparatus could be placed at a remote location on Earth or in outer space where (1) spare parts are expected to be needed but (2) it would be uneconomical or impractical to store a full inventory of spare parts. A wide variety of towpregs could be prepared and stored on spools until needed. Long-shelf-life towpreg materials suitable for such use could include thermoplastic-coated carbon fibers and metal-coated SiC fibers. When a spare part was needed, the part could be fabricated by CLM under control by a CAD data file; thus, the part could be built automatically, at the scene, within hours or minutes.
Small Punch Test (SPT) uses a thin disk of material to predict mechanical properties. While SPT has existed for decades, it has been used largely as a qualitative evaluator of mechanical properties. Recent advances in computational modeling have enabled the extraction of uniaxial stress-strain response from the measured SPT load-displacement data. Due to small sample volumes and unidirectional testing, SPT is conducive to high-throughput automation and ideally suited to extract properties from high-cost materials. Aerospace alloys have been of recent interest to the Additive Manufacturing (AM) community due to AM’s unique ability to fabricate complex designs not possible, or extremely arduous, with conventional manufacturing. In this research, SPT, coupled with Materials Informatics and computational modeling, is used to develop relevant Process-Structure-Property relationships to decrease the cost and time of process optimization for AM aerospace alloys, namely Inconel 718, Inconel 625, and Niobium C103.
A structural analysis, sizing optimization, and weight prediction study was performed by Collier Research Corporation and NASA Glenn on a spherical cryogenic hydrogen tank. The tank consisted of an inner and outer wall separated by a vacuum for thermal insulation purposes. HyperSizer (Collier Research and Development Corporation), a commercial automated structural analysis and sizing software package was used to design the lightest feasible tank for a given overall size and thermomechanical loading environment. Weight trade studies were completed for different panel concepts and metallic and composite material systems. Extensive failure analyses were performed for each combination of dimensional variables, materials, and layups to establish the structural integrity of tank designs. Detailed stress and strain fields were computed from operational temperature changes and pressure loads. The inner tank wall is sized by the resulting biaxial tensile stresses which cause it to be strength driven, and leads to an optimum panel concept that need not be stiffened. Conversely, the outer tank wall is sized by a biaxial compressive stress field, induced by the pressure differential between atmospheric pressure and the vacuum between the tanks, thereby causing the design to be stability driven and thus stiffened to prevent buckling. Induced thermal stresses become a major sizing driver when a composite or hybrid composite/metallic material systems are used for the inner tank wall for purposes such as liners to contain the fuel and reduce hydrogen permeation.
Recent industry and NASA experience with the development of launch vehicle structures have indicated a need for updated monographs for the design of buckling-critical structures that account for state-of-the-art structural configurations, material systems, and computational tools. This monograph provides an update to NASA SP-8007 (circa 1965, and 1968) and was prepared under the cognizance of the NASA Engineering and Safety Center (NESC). It summarizes all significant knowledge and experience accumulated from the NESC Shell Buckling Knockdown Factor (SBKF) Assessment (NESC Assessment #: 07-010-E) to date for use in the design of buckling-critical thin-walled circular cylinders. The format and terminology used in this monograph is similar to previous versions of NASA SP-8007 for ease of understanding and implementation. In addition, as with the design recommendations contained in the previous versions of NASA SP-8007, this monograph is to be regarded as a guideline to design and not as a NASA requirement, unless specified in formal program requirements. Furthermore, it is expected that the guidelines presented in this monograph will be updated as appropriate. Designers are advised to stay abreast of updates in the state-of-the-art and corresponding design criteria.
An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut into individual sheets, which are stacked in the sheet-feeding machine until used. The sheet-feeding machine can hold enough sheets for about 8 hours of continuous operation.
The optimal topology of a two dimensional linear elastic body can be computed by regarding the body as a domain of the plane with a high density of material. Such an optimal topology can then be used as the basis for a shape optimization method that computes the optimal form of the boundary curves of the body. This results in an efficient and reliable design tool, which can be implemented via common FEM mesh generator and CAD type input-output facilities.
The composite materials proposed for use in the Advanced Communications Technology Satellite (ACTS) Program contains a new, high modulus graphite fiber as the reinforcement. A study was conducted to measure certain mechanical properties of the new fiber-reinforced material as well as of a composite-faced aluminum honeycomb sandwich structure. Properties were measured at -157, 22, and 121 C. Complete characterization of this material was not intended. Longitudinal tensile, picture-frame shear, short-beam shear, and flexural tests were performed on specimens of the composite face-sheet materials. Unidirectional, cross-plied, and quasi-isotropic fiber composite ply layup designs were fabricated and tested. These designs had been studied by using NASA's Integrated Composite Analyzer (ICAN) computer program. Flexural tests were conducted on (+/- 60/0 deg) sub s composite-faced sandwich structure material. Resistance strain gages were used to measure strains in the tensile, picture-frame, and sandwich flexural tests. The sandwich flexural strength was limited by the core strength at -157 and 22 C. The adhesive bond strength was the limiting factor at 121 C. Adhesive mechanical properties are reflected in sandwich structure flexural properties when the span-to-depth ratio is great enough to allow a significant shear effect on the load-deflection behavior of the sandwich beam. Most measured properties agreed satisfactorily with the properties predicted by ICAN.
The composite materials proposed for use in the Advanced Communications Technology Satellite (ACTS) program contains a new, high modulus graphite fiber as the reinforcement. A study was conducted to measure certain mechanical properties of the new fiber-reinforced material as well as of a composite-faced aluminum honeycomb sandwich structure. Properties were measured at -157, 22, and 121 C. Complete characterization of this material was not intended. Longitudinal tensile, picture-frame shear, short-beam shear, and flexural tests were performed on specimens of the composite face-sheet materials. Unidirectional, cross-plied, and quasi-isotropic fiber composite ply layup designs were fabricated and tested. These designs had been studied by using NASA's Integrated Composite Analyzer (ICAN) computer program. Flexural tests were conducted on (+/- 60/0 deg) sub s composite-faced sandwich structure material. Resistance strain gages were used to measure strains in the tensile, picture-frame, and sandwich flexural tests. The sandwich flexural strength was limited by the core strength at 157 and 22 c. The adhesive bond strength was the limiting factor at 121 C. Adhesive mechanical properties are reflected in sandwich structure flexural properties when the span-to-depth ratio is great enough to allow a significant shear effect on the load-deflection behavior of the sandwich beam. Most measured properties agreed satisfactorily with the properties predicted by ICAN.
Cyclic Damage Accumulation (CDA) computer program performs high-temperature, low-cycle-fatigue life prediction for materials analysis. Designed to account for effects on creep-fatigue life of complex loadings involving such factors as thermomechanical fatigue, hold periods, wave-shapes, mean stresses, multiaxiality, cumulative damage, coatings, and environmental attack. Several features practical for application to actual component analysis using modern finite-element or boundary-element methods. Although developed for use in predicting crack-initiation lifetimes of gas-turbine-engine materials, also applied to other materials as well. Written in FORTRAN 77.
In spite of great improvements in accuracy through the use of computers, design methods, which can be equally critical in establishing the commercial success of a material, have been treated as afterthoughts. Early investment in design and development technologies can easily reduce manufacturing costs later in the product cycle. To avoid lengthy product development times for ceramic composites, funding agencies for materials research must commit resources to support design and development technologies early in the material life cycle. These technologies need not focus on designing the material, rather, the technology must focus on designing with the material, i. e., developing methods to design components fabricated from the new material. Thus a basic tenet that motivated this research effort is that a persistent need exists for improvements in the analysis of components fabricated from CMC material systems. From an aerospace design engineer's perspective the new generation of ceramic composites offers a significant potential for raising the thrust/weight ratio and reducing NOx emissions of gas turbine engines. Continuous ceramic fiber composites exhibit an increase in work of fracture, which allows for 'graceful' rather than catastrophic failure. When loaded in the fiber direction, these composites retain substantial strength capacity beyond the initiation of transverse matrix cracking despite the fact that neither of its constituents would exhibit such behavior if tested alone. As additional load is applied beyond first matrix cracking, the matrix tends to break in a series of cracks bridged by the ceramic fibers. Thus any additional load is born increasingly by the fibers until the ultimate strength of the composite is reached. Establishing design protocols that enable the engineer to analyze and predict this type of behavior in ceramic composites was the general goal of this project.
Ultrasonic wave methods constitute the leading physical mechanism for nondestructive evaluation (NDE) and structural health monitoring (SHM) of solid composite materials, such as carbon fiber reinforced polymer (CFRP) laminates. Computational models of ultrasonic wave excitation, propagation, and scattering in CFRP composites can be extremely valuable in designing practicable NDE and SHM hardware, software, and methodologies that accomplish the desired accuracy, reliability, efficiency, and coverage. The development and application of ultrasonic simulation approaches for composite materials is an active area of research in the field of NDE. This paper presents comparisons of guided wave simulations for CFRP composites implemented using four different simulation codes: the commercial finite element modeling (FEM) packages ABAQUS, ANSYS, and COMSOL, and a custom code executing the Elastodynamic Finite Integration Technique (EFIT). Benchmark comparisons are made between the simulation tools and both experimental laser Doppler vibrometry data and theoretical dispersion curves. A pristine and a delamination type case (Teflon insert in the experimental specimen) is studied. A summary is given of the accuracy of simulation results and the respective computational performance of the four different simulation tools.
The thermoviscoelastic characterization of Kevlar 49/Fiberite 7714A epoxy composite lamina and the development of a numerical procedure to predict the viscoelastic response of any general laminate constructed from the same material were studied. The four orthotropic material properties, S sub 11, S sub 12, S sub 22, and S sub 66, were characterized by 20 minute static creep tests on unidirectional (0) sub 8, (10) sub 8, and (90) sub 16 lamina specimens. The Time-Temperature Superposition-Principle (TTSP) was used successfully to accelerate the characterization process. A nonlinear constitutive model was developed to describe the stress dependent viscoelastic response for each of the material properties. A numerical procedure to predict long term laminate properties from lamina properties (obtained experimentally) was developed. Numerical instabilities and time constraints associated with viscoelastic numerical techniques were discussed and solved. The numerical procedure was incorporated into a user friendly microcomputer program called Viscoelastic Composite Analysis Program (VCAP), which is available for IBM PC type computers. The program was designed for ease of use. The final phase involved testing actual laminates constructed from the characterized material, Kevlar/epoxy, at various temperatures and load level for 4 to 5 weeks. These results were compared with the VCAP program predictions to verify the testing procedure and to check the numerical procedure used in the program. The actual tests and predictions agreed for all test cases which included 1, 2, 3, and 4 fiber direction laminates.
Three dimensional simulation of oblique hypervelocity impact on orbital debris shielding places extreme demands on computer resources. Research to date has shown that particle models provide the most accurate and efficient means for computer simulation of shield design problems. In order to employ a particle based modeling approach to the wall plate impact portion of the shield design problem, it is essential that particle codes be augmented to represent strength effects. This report describes augmentation of a Lagrangian particle hydrodynamics code developed by the principal investigator, to include strength effects, allowing for the entire shield impact problem to be represented using a single computer code.
Computer aided design methods are presented for the design and construction of strong, lightweight structures which require complex and precise geometric definition. The first, flexible structures, is a unique system of modeling folded plate structures and space frames. It is possible to continuously vary the geometry of a space frame to produce large, clear spans with curvature. The second method deals with developable surfaces, where both folding and bending are explored with the observed constraint of available building materials, and what minimal distortion result in maximum design capability. Alternative inexpensive fabrication techniques are being developed to achieve computer defined enclosures which are extremely lightweight and mathematically highly precise.
A probabilistic design method is described and demonstrated using a smart composite wing. Probabilistic structural design incorporates naturally occurring uncertainties including those in constituent (fiber/matrix) material properties, fabrication variables, structure geometry and control-related parameters. Probabilistic sensitivity factors are computed to identify those parameters that have a great influence on a specific structural reliability. Two performance criteria are used to demonstrate this design methodology. The first criterion requires that the actuated angle at the wing tip be bounded by upper and lower limits at a specified reliability. The second criterion requires that the probability of ply damage due to random impact load be smaller than an assigned value. When the relationship between reliability improvement and the sensitivity factors is assessed, the results show that a reduction in the scatter of the random variable with the largest sensitivity factor (absolute value) provides the lowest failure probability. An increase in the mean of the random variable with a negative sensitivity factor will reduce the failure probability. Therefore, the design can be improved by controlling or selecting distribution parameters associated with random variables. This can be implemented during the manufacturing process to obtain maximum benefit with minimum alterations.
Full size Tug LO2 and LH2 tank configurations were defined, based on selected tank geometries. These configurations were then locally modeled for computer stress analysis. A large subscale test tank, representing the selected Tug LO2 tank, was designed and analyzed. This tank was fabricated using procedures which represented production operations. An evaluation test program was outlined and a test procedure defined. The necessary test hardware was also fabricated.
The capability of a computer program which can be part of a larger computer program for a fully automated multiaxial testing facility is described. This computer program is designed to process test data from tubular or flat specimens made from isotropic or anisotropic materials including high modulus fiber composites. The program can receive data from a large number of strain gages and combinations of applied loads. Options are provided for single element, 90-degree, rectangular or Delta rosettes, or any combinations of these types of strain gages. Options are provided for strain gage transverse sensitivities. The program outputs include: structural axes strains and stresses, initial and strain dependent elastic constants, shift of principal strain direction with load, and local curvatures from back-to-back strain gages, and either calcomp or microfilm plots. The computer program is described with respect to its flow chart, input/output, embedment or linking with other programs and its possible utility in a fully automated testing system.