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Advanced composite standards, representing potential variations occurring when composites are processed into finished structures, were designed, fabricated and tested. Testing methods utilized were ultrasonic C-scan, radiography, and infrared.
Advanced composite processing techniques for fiber reinforced metal matrix composites require the flexibility to meet several widespread objectives. The development of uniquely desired matrix microstructures and uniformly arrayed fiber spacing with sufficient bonding between fiber and matrix to transmit load between them without degradation to the fiber or matrix are the minimum requirements necessary of any fabrication process. For most applications these criteria can be met by fabricating composite monotapes which are then consolidated into composite panels or more complicated components such as fiber reinforced turbine blades. Regardless of the end component, composite monotapes are the building blocks from which near net shape composite structures can be formed. The most common methods for forming composite monotapes are the powder cloth, foil/fiber, plasma spray, and arc spray processes. These practices, however, employ rapid solidification techniques in processing of the composite matrix phase. Consequently, rapid solidification processes play a vital and yet generally overlooked role in composite fabrication. The future potential of rapid solidification processing is discussed.
Because advanced SiC/SiC composites are projected to be used for aerospace components with large thermal gradients at high temperatures, efforts are on-going at NASA Glenn to develop approaches for modeling the anticipated creep behavior of these materials and its subsequent effects on such key composite properties as internal residual stress, proportional limit stress, ultimate tensile strength, and rupture life. Based primarily on in-plane creep data for 2D panels, this presentation describes initial modeling progress at applied composite stresses below matrix cracking for some high performance SiC/SiC composite systems recently developed at NASA. Studies are described to develop creep and rupture models using empirical, mechanical analog, and mechanistic approaches, and to implement them into finite element codes for improved component design and life modeling
Advanced composites will play a key role in the development of the technology for the design and fabrication of future supersonic vehicles. However, incorporating the material into vehicle usage is contingent on accelerating the demonstration of service capacity and design technology. Because of the added material complexity and lack of extensive data, laboratory replication of the flight service will provide the most rapid method to document the airworthiness of advanced composite systems. Consequently, a laboratory program was conducted to determine the time-temperature-stress capabilities of several high temperature composites. Tests included were thermal aging, environmental aging, fatigue, creep, fracture, tensile, and real-time flight simulation exposure. The program had two phases. The first included all the material property determinations and aging and simulation exposures up through 10,000 hours. The second continued these tests up to 50,000 cumulative hours. This report presents the results of the Phase 1 baseline and 10,000-hr aging and flight simulation studies, the Phase 2 50,000-hr aging studies, and the Phase 2 flight simulation tests, some of which extended to almost 40,000 hours.
A study to define potential benefits of advanced technology propeller for 1985-1990 STAT commuter airplanes was completed. Two baselines, a Convair, 30 passenger, 0.47 Mach number airplane and a Lockheed, 50 passenger, 0.70 Mach number airplane, were selected from NASA-Ames sponsored airframe contracts. Parametric performance, noise level, weight and cost trends for propellers with varying number of blades, activity factor, camber and diameter incorporating blade sweep, tip proplets, advanced composite materials, advanced airfoils, advanced prevision synchrophasing and counter-rotation are presented. The resulting DOC, fuel burned, empty weight and acquisition cost benefits are presented for resizings of the two baseline airplanes. Six-bladed propeller having advanced composite blades, advanced airfoils, tip proplets and advanced prevision synchrophasers provided the maximum DOC improvements for both airplanes. DOC and fuel burned were reduced by 8.3% and 17.0% respectively for the Convair airplane and by 24.9% and 41.2% respectively for the Lockheed airplane. The larger reductions arose from a baseline definition with very heavy fuselage acoustic treatment. An alternate baseline, with a cabin noise 13dB in excess of the objective, was also studied.
Advanced composite cylinders, manufactured by filament winding, provide a cost effective solution to many present structural applications; however, the compressive performance of filament-wound cylinders is lower than comparable shells fabricated from unidirectional tape. The objective of this study was to determine the cause of this reduction in thin filament-wound cylinders by relating the manufacturing procedures to the quality of the cylinder and to its compressive performance. The experiments on cylinder buckling were complemented by eigenvalue buckling analysis using a detailed geometric model in a finite element analysis. The applicability of classical buckling analyses was also investigated as a design tool.
Advanced composite materials are providing notable savings in numerous aerospace and non-aerospace applications by virtue of their uniquely high strength-to-density ratio and high stiffness-to-density ratio. However, their full potential for high performance has yet to be achieved because of the low tolerance of the 'brittle' material to impact, holes, flaws, and localized discontinuities due to relatively low toughness. In the present paper a new and simple merit function is proposed for maximizing the strength performance of flawed composite laminate for different design requirement. This new merit function takes into account the flaw tolerance of a composite laminated as well as its stiffness. After development of the new merit function, an example is presented of its application to a practical laminate family.
Advanced composite components are being considered for a wide variety of demanding applications in aerospace, space exploration, and ground based systems. A number of these applications require robust integration technologies to join dissimilar materials (metalcomposites) into complex structural components. In this study, three types of composites (C-C, C-SiC, and SiC-SiC) were vacuum brazed to commercially pure Ti using the active metal braze alloy Cusil-ABA (63Ag-35.3Cu-1.75Ti). Composite substrates with as fabricated and polished surfaces were used for brazing. The microstructure and composition of the joint, examined using scanning electron microscopy (SEM) coupled with energy dispersive spectroscopy (EDS), showed sound metallurgical bonding in all systems. The butt strap tensile (BST) test was performed on bonded specimens at room and elevated temperatures. Effect of substrate composition, interlaminar properties, and surface roughness on the mechanical properties and failure behavior of joints will be discussed.
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.
The Advanced Technology Composite Aircraft Structures (ATCAS) program has studied transport fuselage structure with a large potential reduction in the total direct operating costs for wide-body commercial transports. The baseline fuselage section was divided into four 'quadrants', crown, keel, and sides, gaining the manufacturing cost advantage possible with larger panels. Key processes found to have savings potential include (1) skins laminated by automatic fiber placement, (2) braided frames using resin transfer molding, and (3) panel bond technology that minimized mechanical fastening. The cost and weight of the baseline fuselage barrel was updated to complete Phase B of the program. An assessment of the former, which included labor, material, and tooling costs, was performed with the help of design cost models. Crown, keel, and side quadrant cost distributions illustrate the importance of panel design configuration, area, and other structural details. Composite sandwich panel designs were found to have the greatest cost savings potential for most quadrants. Key technical findings are summarized as an introduction to the other contractor reports documenting Phase A and B work completed in functional areas. The current program status in resolving critical technical issues is also highlighted.
Conceptual nacelle designs for wide-bodied and for advanced-technology transports were studied with the objective of achieving significant reductions in community noise with minimum penalties in airplane weight, cost, and in operating expense by the application of advanced composite materials to nacelle structure and sound suppression elements. Nacelle concepts using advanced liners, annular splitters, radial splitters, translating centerbody inlets, and mixed-flow nozzles were evaluated and a preferred concept selected. A preliminary design study of the selected concept, a mixed flow nacelle with extended inlet and no splitters, was conducted and the effects on noise, direct operating cost, and return on investment determined.
The development of advanced composite materials for use in space and propulsion components has seen considerable growth over the past few years. In addition to improvements that have been made in material properties and processing techniques, similar growth must be seen in the development of methods for the detection of flaws, either generated in service or during manufacturing. Thermal imaging techniques have proven to be successful for the nondestructive evaluation (NDE) of composite materials, but their detection capabilities decrease as flaw depth increases. The purpose of this research is to investigate advanced thermal imaging methods and thermal image processing technologies to increase the maximum depth below surface that a flaw can be detected and improve the contrast between flawed regions and sound regions.
Advance in polymer technology yields composites having relatively low dielectric constants. Reduction achieved by reducing interactions between linear polyimide chains and by incorporation of fluorine into polymer backbones. Further reductions obtained by physically incorporating selected diamic acid additives into polyimides. Strong potential for use in microelectronics industry for fabrication of printed-circuit boards and fabrication of components for military aircraft.
Priorities for research in advanced laminated fibrous composite materials are presented. Supporting evidence is presented in two bodies, including a general literature survey and a survey of aerospace composite hardware and service experience. Both surveys were undertaken during 1977-1979. Specific results and conclusions indicate that a significant portion of contemporary published research diverges from recommended priorites.
Work performed during the 25th month on NAS1-18889, Advanced Technology Composite Aircraft Structures, is summarized. The main objective of this program is to develop an integrated technology and demonstrate a confidence level that permits the cost- and weight-effective use of advanced composite materials in primary structures of future aircraft with the emphasis on pressurized fuselages. The period from 1-31 May 1991 is covered.
Advanced fiber-reinforced polymeric matric composites have emerged as strong candidate materials for airframe applications. Favorable aspects include high strength, stiffness, and low density. Temperature and Moisture Analysis in Composites (TMAC) program was developed to study effect of variations in diffusion coefficients, surface properties, panel tilt, ground reflection, and geographical location on moisture-concentration profiles and average moisture contents of composite laminates.
Advanced high-temperature Ceramic Matrix Composites (CMC) hold an enormous potential for use in aerospace propulsion system components and certain land-based applications. However, being relatively new materials, a reliable design properties database of sufficient fidelity does not yet exist. To characterize these materials solely by testing is cost and time prohibitive. Computational simulation then becomes very useful to limit the experimental effort and reduce the design cycle time, Authors have been involved for over a decade in developing micromechanics- based computational simulation techniques (computer codes) to simulate all aspects of CMC behavior including quantification of scatter that these materials exhibit. A brief summary/capability of these computer codes with typical examples along with their use in design/analysis of certain structural components is the subject matter of this presentation.
Braided composite materials has been recognized as a potential cost effective material form for fuselage structural elements. Consequently, there is a strong need for more knowledge in the design, manufacture, test, and analysis of textile structural composites. Advance braided composite technology is advanced towards applications to a large commercial transport fuselage. The mechanics are summarized of materials and manufacturing demonstration results which were obtained in order to acquire an understanding of how braided composites can be applied to a commercial fuselage. Textile composites consisting of 2-D, 2-D triaxial, and 3-D braid patterns with thermoplastic and two resin transfer molding resin systems were studied. The structural performance of braided composites was evaluated through an extensive mechanical test program. Analytical methods were also developed and applied to predict the following: internal fiber architecture; stiffness; fiber stresses; failure mechanisms; notch effects; and the history of failure of the braided composite specimens. The applicability of braided composites to a commercial transport fuselage was further assessed through a manufacturing demonstration.