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DOE OSTI2020

Supramolecular Energy Materials

Self-assembly is a bioinspired strategy to craft materials for renewable and clean energy technologies. In plants, the alignment and assembly of the light-harvesting protein machinery in the green leaf optimize the ability to efficiently convert light from the sun to form chemical bonds. In artificial systems, strategies based on self-assembly using noncovalent interactions offer the possibility to mimic this functional correlation among molecules to optimize photocatalysis, photovoltaics, and energy storage. Here, one of the long-term objectives of the field described here as supramolecular energy materials is to learn how to design soft materials containing light-harvesting assemblies and catalysts to generate fuels and useful chemicals. Supramolecular energy materials also hold great potential in the design of systems for photovoltaics in which intermolecular interactions in self-assembled structures, for example, in electron donor and acceptor phases, maximize charge transport and avoid exciton recombination. Possible pathways to integrate organic and inorganic structures by templating strategies and electrodeposition to create materials relevant to energy challenges including photoconductors and supercapacitors are also described. The final topic discussed is the synthesis of hybrid perovskites in which organic molecules are used to modify both structure and functions, which may include chemical stability, photovoltaics, and light emission.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Design of a Manufacturing Demonstration Unit for a Composite Lunar Landing Gear Strut

The goal of the current work was to develop an analytical framework for design of composite struts using various levels of model fidelity. Rapid optimization trade studies were performed using low fidelity two-dimensional (2D) axisymmetric models with smeared composite properties. The optimum 2D model was compared with three-dimensional (3D) models with higher levels of fidelity in material property representation. Good agreement was found with all models. The buckling performance of the highest fidelity 3D model was found to be satisfactory for the intended loading conditions. An additional goal of this work was to perform an initial assessment of using automated fiber placement (AFP) and other advanced manufacturing methods to explore their feasibility for the fabrication of struts for lunar landers, strut-braced wings, and other aerospace components. The designs produced during this study are intended to be used to develop manufacturing demonstration units (MDU) that can be fabricated at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility at Langley Research Center (LaRC) and tested in lab facilities at LaRC.

carbon-epoxy↗

NASA NTRSDate not supplied

Design of a Manufacturing Demonstration Unit for a Composite Lunar Landing Gear Strut

carbon-epoxy↗

NASA NTRS1979

Thermal-structural Design Study of an Airframe-integrated Scramjet

Design concepts for the cooled structures assembly for the Langley Scramjet engine, for engine subsystems, and for the aircraft/engine interface were developed and evaluated. Results show that the objectives for the Scramjet engine can be met. A thermal protection system was defined that makes it possible to attain a life of 100 hours and 1000 cycles, which is the specified goal. With stoichiometric combustion, the fuel provides an adequate heat sink for cooling the engine at Mach numbers up to 9 at the minimum fuel flow condition. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six-module engine, the mass per unit capture area is 1328 kg/sq m (259 lb/sq ft). The total mass of a six-module engine assembly including the fuel system is 1577 kg (3477 lb).

Buchmann, O. A.↗

NASA NTRS2014

ISAAC Advanced Composites Research Testbed

The NASA Langley Research Center is acquiring a state-of-art composites fabrication capability to support the Center's advanced research and technology mission. The system introduced in this paper is named ISAAC (Integrated Structural Assembly of Advanced Composites). The initial operational capability of ISAAC is automated fiber placement, built around a commercial system from Electroimpact, Inc. that consists of a multi-degree of freedom robot platform, a tool changer mechanism, and a purpose-built fiber placement end effector. Examples are presented of the advanced materials, structures, structural concepts, fabrication processes and technology development that may be enabled using the ISAAC system. The fiber placement end effector may be used directly or with appropriate modifications for these studies, or other end effectors with different capabilities may either be bought or developed with NASA's partners in industry and academia.

Wu, K. Chauncey↗

NASA NTRS2014

ISAAC - A Testbed for Advanced Composites Research

The NASA Langley Research Center is acquiring a state-of-art composites fabrication environment to support the Center's research and technology development mission. This overall system described in this paper is named ISAAC, or Integrated Structural Assembly of Advanced Composites. ISAAC's initial operational capability is a commercial robotic automated fiber placement system from Electroimpact, Inc. that consists of a multi-degree of freedom commercial robot platform, a tool changer mechanism, and a specialized automated fiber placement end effector. Examples are presented of how development of advanced composite materials, structures, fabrication processes and technology are enabled by utilizing the fiber placement end effector directly or with appropriate modifications. Alternatively, end effectors with different capabilities may either be bought or developed with NASA's partners in industry and academia.

Wu, K. Chauncey↗

NASA NTRS2014

TPSAS-NF1676L-18913-DND

Composite materials and structures are enabling technology for modern aerospace vehicles. Numerical-control manufacturing, including automated fiber placement (AFP), is widely used to fabricate these components. However, weight and performance requirements for the next generation of aerospace vehicles will push the state-of-art even further, and require development of more advanced materials, manufacturing, and structures technologies that are both affordable and efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address much of NASA?s critical research needs in advanced composites. The baseline ISAAC system, combining a commercial robot with multiple redundant degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, enables precise and accurate additive manufacturing of composite structures, as well as development of advanced tow-steered structures with tailored load paths. The highly capable baseline system can quickly change end effectors, thus enabling further research for composites manufacturing. This extended system is similar to a high-speed machining center, where interchangeable cutters are used for different operations during metal structures fabrication. This capability enables future development, integration and assessment of new advanced manufacturing technologies, such as in-situ curing and NDE, and through-thickness reinforcements to reduce delaminations. End effectors with these advanced capabilities may be purchased, developed internally or with industry or academia, and then integrated onto the existing robotic platform to perform advanced manufacturing operations and develop new techniques and processes. Technologies, techniques and processes developed using this research-oriented system could then be transitioned to the broader composites industry.

Rob Martin↗

NASA NTRSDate not supplied

TPSAS-NF1676L-26669-DND

The NASA Langley Research Center has acquired a state-of-art composites fabrication environment to support the Center's research and technology development mission. This overall system described in this paper is named ISAAC, or Integrated Structural Assembly of Advanced Composites. ISAAC's initial operational capability is a commercial robotic automated fiber placement system from Electroimpact, Inc. that consists of a multi-degree of freedom commercial robot platform, a tool changer mechanism, and a specialized automated fiber placement end effector. Examples are presented of how development of advanced composite materials, structures, fabrication processes and technology are enabled by utilizing the fiber placement end effector directly or with appropriate modifications. Several advanced capability end effectors have been procured, and alternate processes with different capabilities can be developed with NASA's partners in industry and academia.

K C Wu↗

DOE OSTI2026

EEPD1 evolved a unique DNA clamping dimer protecting reversed replication forks

Exonuclease/endonuclease/phosphatase (EEP)-fold hydrolases are canonically monomeric phosphodiesterases exemplified by APE1, DNase I, and TDP2 nucleases. While EEP family domain containing protein 1 (EEPD1) acts in DNA stress responses, its proposed nuclease activities are enigmatic. Here, we integrate hybrid structural methods, evolution, biochemistry, cancer genomics, plus molecular and cell biology to define EEPD1 structure, assembly, and function at stalled DNA replication forks. Results imply EEPD1 surprisingly requires both unique EEP domain dimer and distinctive tandem Helix-hairpin-Helix [(HhH) 2 ] domains to clamp double-stranded (ds) DNA at reversed DNA replication forks for fork protection. Small-angle X-ray Scattering (SAXS), crystal, and cryo-EM structures unveil an unprecedented tryptophan handshake dimer, conserved interface di-Trp-Pro pocket, and adjustable “wrist” enabling an open-closed conformational switch. EEPD1 dimer cooperatively binds complex dsDNA replication fork intermediates but alone lacks nuclease activity due to loss of key EEP catalytic residues during Metazoan evolution and atmospheric oxygen buildup. Instead, EEPD1 prevents nucleolytic degradation of reversed replication forks by MRE11. Furthermore, cancer bioinformatics support oxidative damage-dependent EEPD1 association as a significant modulator of overall patient survival. Collective findings uncover unexpected EEP dimer and fork protection function in clamping, not cleaving, reversed replication forks for metazoan oxidative stress responses controlling genome stability and cancer outcomes.

Shen, Runze [Univ. of Texas, Houston, TX (United S↗

NASA NTRS2014

TPSAS-NF1676L-19134-DND

Composite materials and structures are state-of-art enabling technology for modern aerospace vehicles, reducing weight and maintenance requirements, and increasing performance and reliability. Numerical-control manufacturing systems, including automated fiber placement (AFP), are widely used to fabricate these components. However, the challenging weight and performance requirements necessary for the next generation of aerospace vehicles will push the composites state-of-art even further, and require development of even more advanced materials, manufacturing, and structures technologies that are more affordable and more efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address many of NASA's critical research needs in the field of advanced composites. The baseline ISAAC system, combining a commercial robot with multiple degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, will enable very precise and accurate additive manufacturing of composite structures. One promising area of research enabled by the ISAAC system is advanced composite tow-steered structures that have tailored structural load paths. Several examples are presented that describe these tow-steered composite structures in more detail.

Brian K Stewart↗

NASA NTRS1979

The use of coherence functions to determine dynamic excitation sources on launch vehicle payloads

The problem of determining the relative contribution of simultaneous acoustic and mechanical inputs to the response of structures under combined dynamic loads was studied. An analytical technique developed by Bendat for calculating ordinary, partial, and multiple coherence functions, using an iterative nonmatrix approach was applied to data obtained from laboratory tests on a complex structural assembly. Testing was performed in an acoustically 'live' room. Up to three random inputs, having similar spectral content and varying degrees of mutual coherence, and a single output were used. Stationary and nonstationary inputs were used. It was concluded that the technique provided an effective method of identifying sources of dynamic excitation and evaluating their relative contributions to the measured output at structural resonances, for stationary random inputs. An attempt to apply the technique to nonstationary inputs did not yield consistent results.

Barrett, S.↗

NASA NTRS1975

Centaur Standard Shroud (CSS) static ultimate load structural tests

A series of tests were conducted on the jettisonable metallic shroud used on the Titan/Centaur launch vehicle to verify its structural capabilities and to evaluate its structural interaction with the Centaur stage. A flight configured shroud and the interfacing Titan/Centaur structural assemblies were subjected to tests consisting of combinations of applied axial and shear loads to design ultimate values, including a set of tests on thermal conditions and two dynamic response tests to verify the analytical stiffness model. The strength capabilities were demonstrated at ultimate (125 percent of design limit) loads. It was also verified that the spring rate of the flight configured shroud-to-Centaur forward structural deflections of the specimen became nonlinear, as expected, above limit load values. This test series qualification program verified that the Titan/Centaur shroud and the Centaur and Titan interface components are qualified structurally at design ultimate loads.

Source record↗

NASA NTRS1979

A technology base for near-term space platforms

The paper briefly describes the ongoing Large Space Systems Technology (LSST) Program in platform technology. The program addresses technology issues associated with the near-term science and applications platform, and the more fundamental questions associated with the general class of large space-assembled structural systems. Elements of the technology program are described and preliminary results are discussed. Results to date indicate that potential new capabilities of the Space Shuttle will strongly influence spacecraft design, and that future spacecraft utilizing these new capabilities can provide important new performance capabilities and greater efficiency. The proposed science and applications platform appears to be the earliest envisioned space vehicle which will be of the space-assembled class.

Huckins, E. K., III↗

NASA NTRS1967

Flat pack interconnection structure simplifies modular electronic assemblies

Flat pack interconnection structure composed of stick modules simplifies modular electronic assemblies by allowing a single axis mother board. Two of the wiring planes are located in the stick module, which is the lower level of assembly, with the third wiring plane in the mother board.

Katzin, L.↗

DOE OSTI2025

Supramolecular bending and twisting in the hierarchical self-assembly of monodisperse mesogenic oligomers

Understanding how different forms of supramolecular curvature arise during assembly is crucial to designing and tuning the microstructure of hierarchically self-assembled materials. Here, we show that in crystalline phases of mesogenic oligomers, the oligomer length is a critical parameter that determines the type of curvature (Gaussian or cylindrical) exhibited by the self-assembled structures. We use iterative exponential growth to synthesize monodisperse mesogenic oligomers ranging from dimer to octamer. By analyzing their phase behavior and microstructure, we elucidate how length-dependent thermodynamic and kinetic effects tune their hierarchical degree of ordering. The oligomers’ length-dependent crystalline order drives the formation of scrolled sheets in shorter oligomers and twisted ribbons in longer oligomers. These studies highlight how oligomer length interplays with mesogen geometry and crystalline packing to drive self-assembly, introducing oligomer length as a powerful design parameter toward tailored applications of mesogenic systems.

36 MATERIALS SCIENCE↗

NASA NTRS1985

Structural optimization by generalized, multilevel decomposition

The developments toward a general multilevel optimization capability and results for a three-level structural optimization are described. The method partitions a structure into a number of substructuring levels where each substructure corresponds to a subsystem in the general case of an engineering system. The method is illustrated by a portal framework that decomposes into individual beams. Each beam is a box that can be further decomposed into stiffened plates. Substructuring for this example spans three different levels: (1) the bottom level of finite elements representing the plates; (2) an intermediate level of beams treated as substructures; and (3) the top level for the assembled structure. The three-level case is now considered to be qualitatively complete.

Sobieszczanski-Sobieski, J.↗

NASA NTRS1991

Controls of interaction dynamics of orbital assembly

Building structures and spacecraft in orbit will require technologies for positioning, docking/berthing, and joining orbital structures. A fundamental problem underlying the operation of docking and berthing is that of controlling the contact dynamics of mechanical structures actuated by active mechanisms such as robotic devices. Control systems must be designed to control these active mechanisms so that both the free space motions and contact motions are stable and satisfy specifications on position accuracy and bounds on contact forces. For the large orbital structures of the future, the problem of interactive dynamics and control is fundamentally different in several ways than it was for spacecraft docking in the past. First, future space structures must be treated as flexible structures - the operations of docking, berthing, and assembly will need to respect the vibrations of the structures. Second, the assembly of these structures will require multiple-point contact, rather than the essentially single-point positioning of conventional spacecraft docking. Third, some assembly operations require the subassemblies to be brought and held in contact so that successful joining can be accomplished. A preliminary study of contact stability and compliance control design has resulted in the development of an analytical method and a design method to analyze stability. The analytical method analyzes the problem of stability when an actively-controlled structure contacts a passive structure. This method makes it possible to accurately estimate the stiffness of the passive structures with which the contact motion will become unstable. The analytic results suggest that passivity is neither achievable in practice, nor necessary as a design concept. A contact control system need only be passive up to a certain frequency; beyond that frequency the system can be stabilized with sufficiently small gains. With this concept the Center developed a design methodology for achieving desired compliant contact motions. This design method is based on H-infinity norm optimization, which makes it possible to consider both driving point mechanical impedance and systems robustness to modeling uncertainty. A laboratory facility was set up to verify experimentally the analytical and design theory.

Su, Renjeng↗

NASA NTRS2008

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗