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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Optically Enhanced Bonding Workstation for Robust Bonding

Process control is one of the methods recommended by the FAA to reduce risk in fabrication of structurally bonded composite joints for aircraft structure based on guidance provided in circular AC-107B for certification of structurally bonded joints. An Optically Enhanced Bonding Workstation is presented here that reduces the risk in bonded joint fabrication. Results will be presented demonstrating the benefits of process monitoring and its ability to reduce risk in performing pre-bond composite surface preparation steps. This supports reduction in the timeline to certification of bonded composite structures through development of a robust bonding process upstream of any part certification steps. Sanding surface preparation has been identified as a high risk process step that is known to impact bond performance. Control of sanding during surface preparation can be performed using portable surface analysis tools previously identified including included gloss, color, Fourier Transform Infrared spectroscopy (FTIR) and optically stimulated electron emissions (OSEE). Threshold limits for the surface analysis tool measurements were determined based on an example objective bonding system utilizing a common EA9394 paste adhesive measured using standard double cantilever beam fracture toughness testing. The patented Optically Enhanced Bonding Workstation (OEBW), was tailored to monitor and control the epoxy composite surface preparation step. Surface analysis tool threshold limits were incorporated into the OEBW to demonstrate improved composite bond performance through process control. The surface analysis tools investigated here can easily be incorporated into an automated system due to their applicability to rapidly quantify the composite sanded surface treatment and their portability.

Kutscha, Eileen O.↗
NASA NTRS1981

Analysis of interface cracks in adhesively bonded lap shear joints, part 4

Conservation laws of elasticity for nonhomogeneous materials were developed and were used to study the crack behavior in adhesively bonded lap shear joints. By using these laws and the fundamental relationships in fracture mechanics of interface cracks, the problem is reduced to a pair of linear algebraic equations, and stress intensity solutions can be determined directly by information extracted from the far field. The numerical results obtained show that: (1) in the lap-shear joint with a given adherend, the opening-mode stress intensity factor, (K sub 1) is always larger than that of the shearing-mode (K sub 2); (2) (K sub 1) is not sensitive to adherent thickness abut (K sub 2) increases rapidly with increasing thickness; and (3) (K sub 1) and (K sub 2) increase simultaneously as the interfacial crack length increases.

Wang, S. S.↗
NASA NTRS1973

Adhesive-bonded double-lap joints

Explicit analytical solutions are derived for the static load carrying capacity of double-lap adhesive-bonded joints. The analyses extend the elastic solution Volkersen and cover adhesive plasticity, adherend stiffness imbalance and thermal mismatch between the adherends. Both elastic-plastic and bi-elastic adhesive representations lead to the explicit result that the influence of the adhesive on the maximum potential bond strength is defined uniquely by the strain energy in shear per unit area of bond. Failures induced by peel stresses at the ends of the joint are examined. This failure mode is particularly important for composite adherends. The explicit solutions are sufficiently simple to be used for design purposes

Hart-Smith, L. J.↗
NASA NTRS1980

Analysis and test of bonded single lap joints with preformed adherends

A theoretical and experimental study has been conducted to investigate the load transfer of a single lap joint where the adherends have been preformed so that the angle between the line of action of the applied in-plane force and the bond line is reduced. The preforming of the adherend reduces the moment resultant in the adherend at the edge of the overlap region which reduces both the maximum peel and shear stresses in the adhesive, and gives a more uniform shear distribution in the adhesive. An increase in static load transfer of up to 120 percent has been shown, and several orders of magnitude increase in fatigue life have been achieved with modest preform angles. Thus, sizeable benefits can be obtained in the fatigue life or additional load capacity of bonded single lap joints by preforming the adherends.

Sawyer, J. W.↗
NASA NTRS1980

Stress analysis of bonded plates and joints

The paper presents a general numerical method of solution to the transverse normal stress and longitudinal shear stress distributions in the adhesive layers of bonded stiffener plates, double lap joints, and strap joints, all of dissimilar orthotropic adherends. The bending deformations and the transverse shear deformations are included in the analytical model. The present influence of bending deformations of adherends on both the normal and shear stresses in adhesive layers is discussed in detail for practical cases.

Yuceoglu, U.↗
DOE OSTI2022

Design and analysis of a segmented blade for a 50 MW wind turbine rotor

Extreme-size wind turbines face logistical challenges due to their sheer size. A solution, segmentation, is examined for an extreme-scale 50 MW wind turbine with 250 m blades using a systematic approach. Segmentation poses challenges regarding minimizing joint mass, transferring loads between segments and logistics. We investigate the feasibility of segmenting a 250 m blade by developing design methods and analyzing the impact of segmentation on the blade mass and blade frequencies. This investigation considers various variables such as joint types (bolted and bonded), adhesive materials, joint locations, number of joints and taper ratios (ply dropping). Segmentation increases blade mass by 4.1%–62% with bolted joints and by 0.4%–3.6% with bonded joints for taper ratios up to 1:10. Cases with large mass growth significantly reduce blade frequencies potentially challenging the control design. We show that segmentation of an extreme-scale blade is possible but mass reduction is necessary to improve its feasibility.

Escalera Mendoza, Alejandra S.↗
NASA NTRS1974

Bonded composite to metal scarf joint performance in an aircraft landing gear drag strut

The structural performance of a boron-epoxy reinforced titanium drag strut, which contains a bonded scarf joint and was designed to the criteria of the Boeing 747 transport, was evaluated. An experimental and analytical investigation was conducted. The strut was exposed to two lifetimes of spectrum loading and was statically loaded to the tensile and compressive design ultimate loads. Throughout the test program no evidence of any damage in the drag strut was detected by strain gage measurements, ultrasonic inspection, or visual observation. An analytical study of the bonded joint was made using the NASA structural analysis computer program NASTRAN. A comparison of the strains predicted by the NASTRAN computer program with the experimentally determined values shows excellent agreement. The NASTRAN computer program is a viable tool for studying, in detail, the stresses and strains induced in a bonded joint.

Howell, W. E.↗
NASA NTRS1998

Microstructure and Mechanical Properties of Reaction-Formed Joints in Reaction Bonded Silicon Carbide Ceramics

A reaction-bonded silicon carbide (RB-SiC) ceramic material (Carborundum's Cerastar RB-SIC) has been joined using a reaction forming approach. Microstructure and mechanical properties of three types of reaction-formed joints (350 micron, 50-55 micron, and 20-25 micron thick) have been evaluated. Thick (approximately 350 micron) joints consist mainly of silicon with a small amount of silicon carbide. The flexural strength of thick joints is about 44 plus or minus 2 MPa, and fracture always occurs at the joints. The microscopic examination of fracture surfaces of specimens with thick joints tested at room temperature revealed the failure mode to be typically brittle. Thin joints (<50-55 micron) consist of silicon carbide and silicon phases. The room and high temperature flexural strengths of thin (<50-55 micron) reaction-formed joints have been found to be at least equal to that of the bulk Cerastar RB-SIC materials because the flexure bars fracture away from the joint regions. In this case, the fracture origins appear to be inhomogeneities inside the parent material. This was always found to be the case for thin joints tested at temperatures up to 1350C in air. This observation suggests that the strength of Cerastar RB-SIC material containing a thin joint is not limited by the joint strength but by the strength of the bulk (parent) materials.

Singh, M.↗
NASA NTRS2015

Adhesively-Bonded Structural Composite Joint Utilizing Shoulder-Centered Sleeves

A composite joint includes a first member having a groove therein, a second member adjacent to the first member, and a connector member disposed between the second member and the first member. The connector member is received in the groove so as to bias a load path between the first member and the second member from a peripheral portion to a central portion of the connector member.

Lukowski, Florian P., Jr.↗
NASA NTRS1975

Weld bonding of titanium with polyimide adhesives

A conductive adhesive primer and a capillary flow adhesive were developed for weld bonding titanium alloy joints. Both formulations contained ingredients considered to be non-carcinogenic. Lap-shear joint test specimens and stringer-stiffened panels were weld bonded using a capillary flow process to apply the adhesive. Static property information was generated for weld bonded joints over the temperature range of 219K (-65 F) to 561K (550 F). The capillary flow process was demonstrated to produce weld bonded joints of equal strength to the weld through weld bonding process developed previously.

Vaughan, R. W.↗
NASA NTRS2004

Elasto-Plastic Analysis of Tee Joints Using HOT-SMAC

The Higher Order Theory - Structural/Micro Analysis Code (HOT-SMAC) software package is applied to analyze the linearly elastic and elasto-plastic response of adhesively bonded tee joints. Joints of this type are finding an increasing number of applications with the increased use of composite materials within advanced aerospace vehicles, and improved tools for the design and analysis of these joints are needed. The linearly elastic results of the code are validated vs. finite element analysis results from the literature under different loading and boundary conditions, and new results are generated to investigate the inelastic behavior of the tee joint. The comparison with the finite element results indicates that HOT-SMAC is an efficient and accurate alternative to the finite element method and has a great deal of potential as an analysis tool for a wide range of bonded joints.

Arnold, Steve M.↗
NASA NTRS1975

Stress analysis of adhesive bonded stiffener plates and double joints

The general problem of adhesive bonded stiffener plates and double joints of dissimilar orthotropic adherends with transverse shear deformations are analyzed. Adhesive layers are assumed to be of an isotropic, elastic and relatively flexible material. It is shown that the stress distributions in the adhesive layers are very much dependent on the bending deformations in adherends. Also, it is found that, in the adhesive layer, maximum transverse normal stress is, in many cases, larger than the longitudinal shear stress and that both occur at the edge of the joint. The general method of solution developed is applied to several practical examples.

Yuceoglu, U.↗
NASA NTRS2012

Nonlinear Analysis of Bonded Composite Tubular Lap Joints

The present study describes a semi-analytical solution method for predicting the geometrically nonlinear response of a bonded composite tubular single-lap joint subjected to general loading conditions. The transverse shear and normal stresses in the adhesive as well as membrane stress resultants and bending moments in the adherends are determined using this method. The method utilizes the principle of virtual work in conjunction with nonlinear thin-shell theory to model the adherends and a cylindrical shear lag model to represent the kinematics of the thin adhesive layer between the adherends. The kinematic boundary conditions are imposed by employing the Lagrange multiplier method. In the solution procedure, the displacement components for the tubular joint are approximated in terms of non-periodic and periodic B-Spline functions in the longitudinal and circumferential directions, respectively. The approach presented herein represents a rapid-solution alternative to the finite element method. The solution method was validated by comparison against a previously considered tubular single-lap joint. The steep variation of both peeling and shearing stresses near the adhesive edges was successfully captured. The applicability of the present method was also demonstrated by considering tubular bonded lap-joints subjected to pure bending and torsion.

E. Oterkus↗
NASA NTRS1973

Adhesive-bonded scarf and stepped-lap joints

Continuum mechanics solutions are derived for the static load-carrying capacity of scarf and stepped-lap adhesive-bonded joints. The analyses account for adhesive plasticity and adherend stiffness imbalance and thermal mismatch. The scarf joint solutions include a simple algebraic formula which serves as a close lower bound, within a small fraction of a per cent of the true answer for most practical geometries and materials. Digital computer programs were developed and, for the stepped-lap joints, the critical adherend and adhesive stresses are computed for each step. The scarf joint solutions exhibit grossly different behavior from that for double-lap joints for long overlaps inasmuch as that the potential bond shear strength continues to increase with indefinitely long overlaps on the scarf joints. The stepped-lap joint solutions exhibit some characteristics of both the scarf and double-lap joints. The stepped-lap computer program handles arbitrary (different) step lengths and thickness and the solutions obtained have clarified potentially weak design details and the remedies. The program has been used effectively to optimize the joint proportions.

Hart-Smith, L. J.↗
NASA NTRS1976

Boron-epoxy-reinforced titanium aircraft landing-gear drag strut

The structural performance of a boron-epoxy-reinforced titanium drag strut, containing a bonded scarf joint and designed to the criteria of a large commercial transport, has been evaluated experimentally and analytically. The strut was exposed to two lifetimes of fatigue loading and was statically loaded to the tensile and compressive design ultimate loads. Throughout the test program no evidence of any damage in the drag strut was detected by strain-gage measurements, ultrasonic inspection, or visual observation. The bonded joint was analyzed using the NASTRAN computer program. A comparison of the strains predicted by the NASTRAN computer program with the experimentally determined values shows excellent agreement. An analytical study indicated that the nonlinear behavior of a structural spacer at each end of the strut could be explained by the inelastic behavior and possible creep of the adhesive.

Howell, W. E.↗