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At least 199 records · Page 11

All sources NASA NTRS DOE OSTI

NASA NTRS2015

Design, Fabrication, and Testing of a Composite Rack Prototype in Support of the Deep Space Habitat Program

In support of the Deep Space Habitat project a number of composite rack prototypes were developed, designed, fabricated and tested to various extents ( with the International Standard Payload Rack configuration, or crew quarters, as a baseline). This paper focuses specifically on a composite rack prototype with a direct tie in to Space Station hardware. The outlined prototype is an all composite construction, excluding metallic fasteners, washers, and their associated inserts. The rack utilizes braided carbon composite tubing for the frame with the sidewalls, backwall and flooring sections utilizing aircraft grade composite honeycomb sandwich panels. Novel additively manufactured thermoplastic joints and tube inserts were also developed in support of this effort. Joint and tube insert screening tests were conducted at a preliminary level. The screening tests allowed for modification, and enhancement, of the fabrication and design approaches, which will be outlined. The initial joint tests did not include mechanical fasteners. Adhesives were utilized at the joint to composite tube interfaces, along with mechanical fasteners during final fabrication (thus creating a stronger joint than the adhesive only variant). In general the prototype was focused on a potential in-space assembly approach, or kit-of-parts construction concept, which would not necessarily require the inclusion of an adhesive in the joint regions. However, given the tie in to legacy Station hardware (and potential flight loads with imbedded hardware mass loadings), the rack was built as stiff and strong as possible. Preliminary torque down tests were also conducted to determine the feasibility of mounting the composite honeycomb panels to the composite tubing sections via the additively manufactured tube inserts. Additional fastener torque down tests were also conducted with inserts (helicoils) imbedded within the joints. Lessons learned are also included and discussed.

Smith, Russ↗

NASA NTRSDate not supplied

Characterization and Modeling of Cell Wall Imperfections in Aluminum Honeycomb Cores using X-ray CT Imaging

Honeycomb cell imperfections may significantly affect the failure of sandwich composites in core crushing and shear modes. Identification and quantification of the different types of imperfections and evaluation of their effects on the mechanical response of honeycomb cores in flatwise compression is presented. X-Ray computed tomography (CT) scans of honeycomb cores in co-cured composite sandwich panels were performed. Image analysis methods are applied to characterize and quantify core cell geometry and cell wall waviness. An approach is developed for extracting cell wall mid surface planes and waviness for constructing finite element models using shell elements. Analysis results from models with the as-manufactured imperfections are compared to results from models with idealized geometries to evaluate the effect of the as-manufactured imperfections on the initiation of cell wall buckling and subsequent core crushing.

aluminum honeycomb↗

NASA NTRS2005

Stainless-Steel-Foam Structures Evaluated for Fan and Rotor Blades

The goal of this project is to use a sandwich structure design, consisting of two stainlesssteel face sheets and a stainless-steel-foam core, to fabricate engine fan and propeller blades. Current fan blades are constructed either of polymer matrix composites (PMCs) or hollow titanium alloys. The PMC blades are expensive and have poor impact resistance on their leading edges, thereby requiring a metallic leading edge to satisfy the Federal Aviation Administration s impact requirements relating to bird strikes. Hollow titanium blades cost more to fabricate because of the intrinsically difficult fabrication issues associated with titanium alloys. However, both these current concepts produce acceptable lightweight fan blades.

Lerch, Bradley A.↗

NASA NTRS1977

Evaluation of structural design concepts for an arrow-wing supersonic cruise aircraft

An analytical study was performed to determine the best structural approach for design of primary wing and fuselage structure of a Mach 2.7 arrow wing supersonic cruise aircraft. Concepts were evaluated considering near term start of design. Emphasis was placed on the complex interactions between thermal stress, static aeroelasticity, flutter, fatigue and fail safe design, static and dynamic loads, and the effects of variations in structural arrangements, concepts and materials on these interactions. Results indicate that a hybrid wing structure incorporating low profile convex beaded and honeycomb sandwich surface panels of titanium alloy 6Al-4V were the most efficient. The substructure includes titanium alloy spar caps reinforced with boron polyimide composites. The fuselage shell consists of hat stiffened skin and frame construction of titanium alloy 6Al-4V. A summary of the study effort is presented, and a discussion of the overall logic, design philosophy and interaction between the analytical methods for supersonic cruise aircraft design are included.

Sakata, I. F.↗

NASA NTRS1975

Design study of structural concepts for an arrow-wing supersonic-cruise aircraft

An analytical study was performed to determine the best structural approach for design of primary wing and fuselage structure of a Mach number 2.7 arrow-wing supersonic cruise aircraft. Concepts were evaluated considering near-term start-of-design. Emphasis was placed on the complex interactions between thermal stress, static aeroelasticity, flutter, fatigue and fail-safe design, static and dynamic loads, and the effects of variations in structural arrangements, concepts and materials on these interactions. Results indicate that a hybrid wing structure incorporating low-profile convex-beaded and honeycomb sandwich surface panels of titanium alloy 6Al-4V were the most efficient. The substructure includes titanium alloy spar caps reinforced with Boron-polyimide composites. The fuselage shell is a closed-hat stiffened skin and frame construction of titanium alloy 6Al-4V. This paper presents an executive summary of the study effort, and includes a discussion of the overall study logic, design philosophy and interaction between the analytical methods for supersonic cruise aircraft design.

Sakata, I. F.↗

NASA NTRS2004

Cross Cell Sandwich Core

A sandwich core comprises two faceplates separated by a plurality of cells. The cells are comprised of walls positioned at oblique angles relative to a perpendicular axis extending through the faceplates. The walls preferably form open cells and are constructed from open cells and are constructed from rows of ribbons. The walls may be obliquely angled relative to more than one plane extending through the perpendicular axis.

Donald B Ford↗

NASA NTRS1981

Response of stiffened sandwich panels

An increasingly important part of the design of skin-stringer systems, such as those found in flight vehicles, is the ability to reduce surface vibration levels when they are subjected to the dynamic loads of jet, or propeller noise. One common method of reducing the response of these structures is by layered construction using viscoelastic materials. Thus analytical methods to describe such systems are essential.

Slazak, M.↗

NASA NTRS2020

Investigating Local Buckling and Plastic Collapse in Multifunctional Sandwich Composite Cores using a Unit Cell Method

The primary goal of developing analytical models of composite sandwich cores has been to obtain simple expressions for elastic and failure response to improve the rapid analysis of composite structures. An earlier investigation by the authors was made to verify the accuracy of widely-used analytical models that calculate equivalent elastic moduli of a uniform homogeneous single layer of material in place of the complex honeycomb core properties in sandwich composites. This transformation of elastic properties permits a coarsening of the finite element model (FEM) of the core to a fraction of the computational cost in simulating the original complex core architecture. In addition, the core was assumed constructed of multi-layered isotropic walls to support potential additional functionality beyond simple load-carrying capability.

Erik Saether↗

DOE OSTI2024

Characterizing non-Markovian and coherent errors in quantum simulation

Quantum simulation of many-body systems, particularly using ultracold atoms and trapped ions, presents a unique form of quantum control—it is a direct implementation of a multi-qubit gate generated by the Hamiltonian. As a consequence, it also faces a unique challenge in terms of benchmarking, because the well-established gate benchmarking techniques are unsuitable for this form of quantum control. Here we show that the symmetries of the target many-body Hamiltonian can be used not only to benchmark but to characterize experimental errors in the quantum simulation. We use our results to develop protocols to characterize these errors, which can be implemented using state-of-the-art technology. We consider two forms of errors: (i) unitary errors arising out of systematic errors in the applied Hamiltonian and (ii) canonical non-Markovian errors arising out of random shot-to-shot fluctuations in the applied Hamiltonian. We show that the dynamics of the expectation value of the target Hamiltonian itself, which is ideally constant in time, can be used to characterize these errors. In the presence of errors, the expectation value of the target Hamiltonian shows a characteristic thermalization dynamics, when it satisfies the operator thermalization hypothesis (OTH). That is, an oscillation in the short time followed by relaxation to a steady-state value in the long time limit. We show that while the steady-state value can be used to characterize the coherent errors, the amplitude of the oscillations can be used to estimate the non-Markovian errors. We prove a sandwich theorem to establish a linear relation between the amplitude of the oscillations and the magnitude of the non-Markovian errors. Moreover, by varying the initial state, we show that the steady state values can be used to completely construct the generator of the coherent errors. Using these results, we develop two experimental protocols to characterize the unitary errors based on these results, one of which requires single-qubit addressing and the other one doesn't. We also develop a protocol to characterize non-Markovian errors. Published by the American Physical Society 2024

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS2004

Carbon-Carbon Composite Radiator Development for the EO-1 Spacecraft

The Carbon-Carbon Space Radiator Partnership (CSRP), an informal partnership of Government and industrial personnel, was formed to promote the use of Carbon-carbon composites (C-C) as engineering materials for spacecraft thermal management applications . As a part of this effort the partnership has built a structural radiator for the Earth Orbiter - 1 (EO-1) spacecraft. This radiator, using C-C face-sheets with an aluminum honeycomb core, will demonstrate both the thermal and structural properties of C-C under actual service conditions as well as provide performance data from space flight. This paper will present results from the design of the radiator, the thermal/mechanical tests of the facesheet materials, and sub-component test results on the C-C/Al honeycomb sandwich material. The 29- by 28-inch radiator was designed to support two electronics boxes with a combined heat output of 60 watts maximum and a weight of 58 lbs. The analysis of the radiator design shows that the radiator constructed with 20-mil-thick facesheets of a P30-fiber-reinforced C-C from BFGoodrich is able to meet or exceed all the required thermal and mechanical requirements.

Vaughn, Wallace↗

NASA NTRS1979

Polyimide adhesive bonding

Adhesive systems which could be used to bond composite-to-composite, composite-to-titanium, and honeycomb sandwich structures with operational capability at 589K for a minimum of 125 hours were evaluated. Evaluations were based on mechanical property tests such as lap shear and flatwise tensile and on processability. Quasi-isotropic Celion 6000/PMR-15 composite adherend was used to construct lap shear and flatwise tensile specimens. Hexcel's HRH-327-3/16-6.0 glass polyimide honeycomb core was also utilized in the flatwise tensile specimens. Numerous processing variations were also studied that led to selected cure cycles for each adhesive. Shear specimens having either 12 mm or 75 mm overlaps were used to determine the effect of bond size on processability and lap shear properties. The data indicate that processing of FM-34, FM-34B-18, LARC-13 and NRO56X can be achieved using a cure compatible with the composite adherend. No significant differences in mechanical properties were observed among the three adhesive systems and all three are suitable candidates for 589K/125 hour service.

Progar, D.↗

NASA NTRS1986

Light weight fire resistant graphite composites

Composite structures with a honeycomb core and characterized by lightweight and excellent fire resistance are provided. These sandwich structures employ facesheets made up of bismaleimide-vinyl styrylpyridine copolymers with fiber reinforcement such as carbon fiber reinforcement. In preferred embodiments the facesheets are over layered with a decorative film. The properties of these composites make them attractive materials of construction aircraft and spacecraft.

Kourtides, D. A.↗

NASA NTRS1992

Core design for use with precision composite reflectors

A uniformly flexible core, and method for manufacturing the same, is disclosed for use between the face plates of a sandwich structure. The core is made of a plurality of thin corrugated strips, the corrugations being defined by a plurality of peaks and valleys connected to one another by a plurality of diagonal risers. The corrugated strips are orthogonally criss-crossed to form the core. The core is particularly suitable for use with high accuracy spherically curved sandwich structures because undesirable stresses in the curved face plates are minimized due to the uniform flexibility characteristics of the core in both the X and Y directions. The core is self venting because of the open geometry of the corrugations. The core can be made from any suitable composite, metal, or polymer. Thermal expansion problems in sandwich structures may be minimized by making the core from the same composite materials that are selected in the manufacture of the curved face plates because of their low coefficients of thermal expansion. Where the strips are made of a composite material, the core may be constructed by first cutting an already cured corrugated sheet into a plurality of corrugated strips and then secondarily bonding the strips to one another or, alternatively, by lying a plurality of uncured strips orthogonally over one another in a suitable jig and then curing and bonding the entire plurality of strips to one another in a single operation.

Porter, Christopher C.↗

NASA NTRS2003

Nonlinear Thermal Analyses of a Liquid Hydrogen Tank Wall

A thermal evaluation of a composite tank wall design for a liquid hydrogen tank was performed in the present study. The primary focus of the current effort was to perform one-dimensional, temperature nonlinear, transient thermal analyses to determine the through-the-thickness temperature profiles. These profiles were used to identify critical points within the flight envelope that could have detrimental effects on the adhesive bondlines used in the construction of the tank wall. Additionally, this paper presents the finite element models, analysis strategies, and thermal analysis results that were determined for several vehicle flight conditions. The basic tank wall configuration used to perform the thermal analyses consisted of carbon-epoxy facesheets and a Korex honeycomb core sandwich that was insulated with an Airex cryogenic foam and an Alumina Enhanced Thermal Barrier (AETB-12). Nonlinear, transient thermal analyses were conducted using the ABAQUS finite element code. Tank wall models at a windward side location on the fuel tank were analyzed for three basic flight conditions: cold-soak (ground-hold), ascent, and re-entry. Additionally, three ambient temperature boundary conditions were applied to the tank wall for the cold-soak condition, which simulated the launch pad cooldown process. Time-dependent heating rates were used in the analyses of the ascent and reentry segments of the flight history along with temperature dependent material properties. The steady-state through-the-thickness temperature profile from the cold-soak condition was used as the initial condition for the ascent analyses. Results from the nonlinear thermal analyses demonstrated very good correlation with results from similar models evaluated by Northrop- Grumman using a different analysis tool. Wall through-the-thickness temperature gradients as a function of flight time were obtained for future incorporation into a full-scale thermostructural analysis to evaluate the adhesive bondlines. As a result of the thermal analyses conducted, a sufficient level of confidence was demonstrated in the thermal modeling and analysis capabilities of ABAQUS to warrant future use as a thermo-structural analysis tool to evaluate cryogenic tank wall designs.

Smeltzer, Stanley S., III↗

NASA NTRS1993

Verification of thermal analysis codes for modeling solid rocket nozzles

One of the objectives of the Solid Propulsion Integrity Program (SPIP) at Marshall Space Flight Center (MSFC) is development of thermal analysis codes capable of accurately predicting the temperature field, pore pressure field and the surface recession experienced by decomposing polymers which are used as thermal barriers in solid rocket nozzles. The objective of this study is to provide means for verifications of thermal analysis codes developed for modeling of flow and heat transfer in solid rocket nozzles. In order to meet the stated objective, a test facility was designed and constructed for measurement of the transient temperature field in a sample composite subjected to a constant heat flux boundary condition. The heating was provided via a steel thin-foil with a thickness of 0.025 mm. The designed electrical circuit can provide a heating rate of 1800 W. The heater was sandwiched between two identical samples, and thus ensure equal power distribution between them. The samples were fitted with Type K thermocouples, and the exact location of the thermocouples were determined via X-rays. The experiments were modeled via a one-dimensional code (UT1D) as a conduction and phase change heat transfer process. Since the pyrolysis gas flow was in the direction normal to the heat flow, the numerical model could not account for the convection cooling effect of the pyrolysis gas flow. Therefore, the predicted values in the decomposition zone are considered to be an upper estimate of the temperature. From the analysis of the experimental and the numerical results the following are concluded: (1) The virgin and char specific heat data for FM 5055 as reported by SoRI can not be used to obtain any reasonable agreement between the measured temperatures and the predictions. However, use of virgin and char specific heat data given in Acurex report produced good agreement for most of the measured temperatures. (2) Constant heat flux heating process can produce a much higher heating rate than the radiative heating process. The results show that heating rates of 125 C/s (225 F/s) can be achieved. (3) The electrical resistance of the FM 5055 samples were about 150 Omega in the virgin state, and decreased to about 35 Omega when charred. A reliable scheme must be developed to electrically insulate the composite from the heater foil in order to prevent any current leakage into the sample which can result in volumetric heating of the char zone of the composite.

Keyhani, M.↗

NASA NTRSDate not supplied

Finite Element Modeling for Compression Strength Prediction of Honeycomb Cores with Geometric Imperfections Measured using X-ray CT Imaging

Aluminum honeycomb cores have been used extensively in composite sandwich panels due to having high bending rigidity while maintaining low density. During manufacturing of the aluminum honeycomb, the thin metal walls are susceptible to imperfections that deviate from an ideal honeycomb shape. Computational tools to quantify imperfections and investigate their effects on quasi-static compression and impact response can inform design criteria to construct safer and lighter launch vehicle structures. This paper presents the results of a study on finite element modeling of metallic honeycomb cores (HCC) with geometric imperfections measured using X-ray Computer Tomography (CT), to predict the compression response. Finite element (FE) models are constructed with measured imperfections with appropriate boundary conditions. It is shown that the average behavior of larger 10x11 cell models can be predicted by sampling single cell models from the larger domain. Amplification of imperfections for cells at the center of sampled specimens are mode switched from the larger out-of-plane imperfection to the mode shape of the adjacent cells resulting in strengthening of the center specimens.

aluminum honeycomb↗

NASA NTRS1996

Analysis of Thick Sandwich Shells with Embedded Ceramic Tiles

The Composite Armored Vehicle (CAV) is an advanced technology demonstrator of an all-composite ground combat vehicle. The CAV upper hull is made of a tough light-weight S2-glass/epoxy laminate with embedded ceramic tiles that serve as armor. The tiles are bonded to a rubber mat with a carefully selected, highly viscoelastic adhesive. The integration of armor and structure offers an efficient combination of ballistic protection and structural performance. The analysis of this anisotropic construction, with its inherent discontinuous and periodic nature, however, poses several challenges. The present paper describes a shell-based 'element-layering' technique that properly accounts for these effects and for the concentrated transverse shear flexibility in the rubber mat. One of the most important advantages of the element-layering technique over advanced higher-order elements is that it is based on conventional elements. This advantage allows the models to be portable to other structural analysis codes, a prerequisite in a program that involves the computational facilities of several manufacturers and government laboratories. The element-layering technique was implemented into an auto-layering program that automatically transforms a conventional shell model into a multi-layered model. The effects of tile layer homogenization, tile placement patterns, and tile gap size on the analysis results are described.

Davila, Carlos G.↗

NASA NTRS1972

Improvements in solid state radiographic converter screens.

Description of two different kinds of solid-state radiographic converter screens which have been developed. After briefly reviewing the working principles of the solid-state image converter - a sandwich type structure consisting of a photoconductive layer and an electroluminescent layer with a semiconductive layer and a black layer between them, two different kinds of radiographic converter screens are described - a radiographic amplifier screen that can be used as a substitute for the fluoroscopic screen, and a radiographic storage screen that can be used instead of radiographic films. The construction of both kinds of converters is fundamentally the same, the only difference being in the sensing photoconductive material. The radiographic amplifier screen has a moderately fast response, while the radiographic storage screen displays the image long after the irradiation is stopped.

Szepesi, Z.↗