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At least 235 records · Page 13

Light Microscopy Module: An On-Orbit Microscope Planned for the Fluids and Combustion Facility on the International Space Station

The Light Microscopy Module (LMM) is planned as a fully remotely controllable on-orbit microscope subrack facility, allowing flexible scheduling and control of fluids and biology experiments within NASA Glenn Research Center's Fluids and Combustion Facility on the International Space Station. Within the Fluids and Combustion Facility, four fluids physics experiments will utilize an instrument built around a light microscope. These experiments are the Constrained Vapor Bubble experiment (Peter C. Wayner of Rensselaer Polytechnic Institute), the Physics of Hard Spheres Experiment-2 (Paul M. Chaikin of Princeton University), the Physics of Colloids in Space-2 experiment (David A. Weitz of Harvard University), and the Low Volume Fraction Colloidal Assembly experiment (Arjun G. Yodh of the University of Pennsylvania). The first experiment investigates heat conductance in microgravity as a function of liquid volume and heat flow rate to determine, in detail, the transport process characteristics in a curved liquid film. The other three experiments investigate various complementary aspects of the nucleation, growth, structure, and properties of colloidal crystals in microgravity and the effects of micromanipulation upon their properties. Key diagnostic capabilities for meeting the science requirements of the four experiments include video microscopy to observe sample features including basic structures and dynamics, interferometry to measure vapor bubble thin film thickness, laser tweezers for colloidal particle manipulation and patterning, confocal microscopy to provide enhanced three-dimensional visualization of colloidal structures, and spectrophotometry to measure colloidal crystal photonic properties.

Doherty, Michael P.↗

Soot Aerosol Properties in Laminar Soot-Emitting Microgravity Nonpremixed Flames

The spatial distributions and morphological properties of the soot aerosol are examined experimentally in a series of 0-g laminar gas-jet nonpremixed flames. The methodology deploys round jet diffusion flames of nitrogen-diluted acetylene fuel burning in quiescent air at atmospheric pressure. Full-field laser-light extinction is utilized to determine transient soot spatial distributions within the flames. Thermophoretic sampling is employed in conjunction with transmission electron microscopy to define soot microstructure within the soot-emitting 0-g flames. The microgravity tests indicate that the 0-g flames attain a quasi-steady state roughly 0.7 s after ignition, and sustain their annular structure even beyond their luminous flame tip. The measured peak soot volume fractions show a complex dependence on burner exit conditions, and decrease in a nonlinear fashion with decreasing characteristic flow residence times. Fuel preheat by approximately 140 K appears to accelerate the formation of soot near the flame axis via enhanced fuel pyrolysis rates. The increased soot presence caused by the elevated fuel injection temperatures triggers higher flame radiative losses, which may account for the premature suppression of soot growth observed along the annular region of preheated-fuel flames. Electron micrographs of soot aggregates collected in 0-g reveal the presence of soot precursor particles near the symmetry axis at midflame height, The observations also verify that soot primary particle sizes are nearly uniform among aggregates present at the same flame location, but vary considerably with radius at a fixed distance from the burner. The maximum primary size in 0-g is found to be by 40% larger than in 1-g, under the same burner exit conditions. Estimates of the number concentration of primary particles and surface area of soot particulate phase per unit volume of the combustion gases are also made for selected in-flame locations.

Konsur, Bogdan↗

Efficient Development of High Fidelity Structured Volume Grids for Hypersonic Flow Simulations

A new technique for the control of grid line spacing and intersection angles of a structured volume grid, using elliptic partial differential equations (PDEs) is presented. Existing structured grid generation algorithms make use of source term hybridization to provide control of grid lines, imposing orthogonality implicitly at the boundary and explicitly on the interior of the domain. A bridging function between the two types of grid line control is typically used to blend the different orthogonality formulations. It is shown that utilizing such a bridging function with source term hybridization can result in the excessive use of computational resources and diminishes robustness. A new approach, Anisotropic Lagrange Based Trans-Finite Interpolation (ALBTFI), is offered as a replacement to source term hybridization. The ALBTFI technique captures the essence of the desired grid controls while improving the convergence rate of the elliptic PDEs when compared with source term hybridization. Grid generation on a blunt cone and a Shuttle Orbiter is used to demonstrate and assess the ALBTFI technique, which is shown to be as much as 50% faster, more robust, and produces higher quality grids than source term hybridization.

Alter, Stephen J.↗

Structural Dynamic Testing Results for Air-Independent Proton Exchange Membrane (PEM) Fuel Cell Technologies for Space Applications

In 2016, the NASA Advanced Exploration Systems (AES) project office funded research at the NASA Glenn Research Center to evaluate the maturity of the Proton Exchange Membrane (PEM) fuel cell technology and its viability for supporting launch vehicle and space applications. This technology evaluation included vibration, reactant purity, and vacuum exposure sensitivity testing. The evaluation process did not include microgravity testing. This paper discusses the vibration sensitivity testing of two air-independent fuel cell stacks provided by different vendors to assess the ability of currently available fuel cell stack hardware to survive the projected random vibrational environment that would be encountered in an upper stage launch vehicle. Baseline performance testing was utilized to quantify stack performance and overboard leak rate at standard atmospheric conditions in order to provide a reference for post-test comparison. Both fuel cell stacks were tested at a random vibration qualification level of 10.4 grms for five minutes in each axis. Low-level sinusoidal sweeps were conducted before and after each random vibration level run to see if any significant change in resonances were detected. Following vibration facility testing, the baseline performance testing was repeated. Test results demonstrated no measurable change in fuel cell electrochemical or mechanical performance, indicating that the two evaluated PEM fuel cell stacks may be suitable for space applications pending microgravity testing.

Gilligan, Ryan P.↗

High data rate modem simulation for the space station multiple-access communications system

The communications system for the space station will require a space based multiple access component to provide communications between the space based program elements and the station. A study was undertaken to investigate two of the concerns of this multiple access system, namely, the issues related to the frequency spectrum utilization and the possibilities for higher order (than QPSK) modulation schemes for use in possible modulators and demodulators (modems). As a result of the investigation, many key questions about the frequency spectrum utilization were raised. At this point, frequency spectrum utilization is seen as an area requiring further work. Simulations were conducted using a computer aided communications system design package to provide a straw man modem structure to be used for both QPSK and 8-PSK channels.

Horan, Stephen↗

Development of a nanostructured DNA delivery scaffold via electrospinning of PLGA and PLA-PEG block copolymers

The present work utilizes electrospinning to fabricate synthetic polymer/DNA composite scaffolds for therapeutic application in gene delivery for tissue engineering. The scaffolds are non-woven, nano-fibered, membranous structures composed predominantly of poly(lactide-co-glycolide) (PLGA) random copolymer and a poly(D,L-lactide)-poly(ethylene glycol) (PLA-PEG) block copolymer. Release of plasmid DNA from the scaffolds was sustained over a 20-day study period, with maximum release occurring at approximately 2 h. Cumulative release profiles indicated amounts released were approximately 68-80% of the initially loaded DNA. Variations in the PLGA to PLA-PEG block copolymer ratio vastly affected the overall structural morphology, as well as both the rate and efficiency of DNA release. Results indicated that DNA released directly from these electrospun scaffolds was indeed intact, capable of cellular transfection, and successfully encoded the protein beta-galactosidase. When tested under tensile loads, the electrospun polymer/DNA composite scaffolds exhibited tensile moduli of approximately 35 MPa, with approximately 45% strain initially. These values approximate those of skin and cartilage. Taken together, this work represents the first successful demonstration of plasmid DNA incorporation into a polymer scaffold using electrospinning.

Non-NASA Center↗

Deep Mapping of Small Solar System Bodies with Galactic Cosmic Ray Secondary Particle Showers

Galactic cosmic rays rain steadily from all directions onto asteroids and comets. The interaction of these high-energy ions produces a cascade of secondary particles, including muons, which can penetrate the solid interiors of small solar system bodies. Muons, which are produced in abundance in Earth's atmosphere, have been used to image large structures on Earth, including the Great Pyramids and the interior of volcanoes. In this study, we demonstrate that the transmitted flux of muons is sensitive to the interior density structure of asteroids and comets, less than a few hundred meters in diameter. Muonography has the potential to fill a critical gap in our knowledge of the deep interiors of small bodies, providing information needed for planetary defense, in situ resource utilization, and planetary science. We use Monte Carlo codes (MCNPX and FLUKA), which accurately model galactic cosmic ray showers, to explore systematic variations in the production of muons in solid surfaces. Results of these calculations confirm the scaling of muon production in Earth's atmosphere to solid regolith materials, as predicted by a simple, semi-empirical model. Muons are primarily produced in the top meter of the regoliths of asteroids and comets. Their rate of production is over three orders of magnitude lower than in Earth's atmosphere and depends strongly on regolith density. In practice, the use of muonography to characterize the interiors of small solar system bodies must overcome their low rate of production and their dependence on regolith density, which can vary over the surface of asteroids and comets. We show that interior contrast can be resolved using a muon telescope (hodoscope) with about 1 sq m aperture with integration times ranging from hours to weeks. Design concepts for a practical hodoscope that could be deployed in situ or on an orbiting spacecraft, are described. Regolith density within the top meter of an asteroid can be determined from radar observations. A concept for a pilot mission that combines remote radar measurements with in situ muonography of a near-Earth asteroid is presented. Perceived challenges and next steps for the development of the concept are described.

Prettyman, T. H.↗

Development and Testing of an ISRU Soil Mechanics Vacuum Test Facility

For extraterrestrial missions, earth based testing in relevant environments is key to successful hardware development. This is true for both early component level development and system level integration. For In-Situ Resource Utilization (ISRU) on the moon, hardware must interface with the surface material, or regolith, in a vacuum environment. A relevant test environment will therefore involve a vacuum chamber with a controlled, properly conditioned bed of lunar regolith simulant. However, in earth-based granular media, such as lunar regolith simulant, gases trapped within the material pore structures and water adsorbed to all particle surfaces will release when exposed to vacuum. Early vacuum testing has shown that this gas release can occur violently, which loosens and weakens the simulant, altering the consolidation state. A mid-size chamber (3.66 m tall, 1.5 m inner diameter) at the NASA Glenn Research Center has been modified to create a soil mechanics test facility. A 0.64 m deep by 0.914 m square metric ton bed of lunar simulant was placed under vacuum using a variety of pumping techniques. Both GRC-3 and LHT-3M simulant types were used. Data obtained from an electric cone penetrometer can be used to determine strength properties at vacuum including: cohesion, friction angle, bulk density and shear modulus. Simulant disruptions, caused by off-gassing, affected the strength properties, but could be mitigated by reducing pump rate. No disruptions were observed at pressures below 2.5 Torr, regardless of the pump rate. The slow off-gassing of the soil at low pressure lead to long test times; a full week to reach 10(exp -5) Torr. Robotic soil manipulation would enable multiple ISRU hardware test within the same vacuum cycle. The feasibility of a robotically controlled auger and tamper was explored at vacuum conditions.

lunar regolith↗

Automated Technique for the Detection of Step-Like Solar Wind Dynamic Pressure Changes: Application to the Response of the Transpolar Potential to Solar Wind Dynamic Pressure Fronts

The input from the solar wind (SW) and the accompanying Interplanetary Magnetic Field (IMF) is the defining feature of the solar wind-magnetosphere interactions. One of the most important SW drivers is the solar wind dynamic pressure, and most significantly its sharp changes known as pressure fronts. Sudden enhancements in solar wind dynamic pressure, SWP, have been shown to lead to intensification of the auroral electrojets (and Region 1 field-aligned currents), increase in auroral emissions, and significant enhancement in ionospheric convection and the transpolar potential. Case studies of the interaction between pressure fronts and the terrestrial space environment shed great light on their importance to the structure and dynamics of the system. However, thorough understanding of the interaction requires fully statistical investigations. These statistical studies require a large number of suitable pressure front events. In the past these have been obtained through laborious manual inspection of solar wind data. We present an automated procedure that identifies sudden step enhancements in SWP that satisfy a desired set of limiting step-like characteristics, such as magnitude of the change, sign of the change (positive/negative), and rate of change. The procedure yields a list of suitable events, along with their step features within minutes. The technique is tested for missed events and false positives by direct comparison to manual inspection of the data. Its utility is illustrated by application to the statistical effect of pressure fronts to the transpolar potential as measured by the Assimilative Mapping of Ionospheric Electrodynamics (AMIE) technique.

A. Boudouridis↗

"Ultra"-Fast Fracture Strength of Advanced Structural Ceramic Materials Studied at Elevated Temperatures

The accurate determination of inert strength is important in reliable life prediction of structural ceramic components. At ambient temperature, the inert strength of a brittle material is typically regarded as free of the effects of slow crack growth due to stress corrosion. Therefore, the inert strength can be determined either by eliminating active species, especially moisture, with an appropriate inert medium, or by using a very high test rate. However, at elevated temperatures, the concept or definition of the inert strength of brittle ceramic materials is not clear, since temperature itself is a degrading environment, resulting in strength degradation through slow crack growth and/or creep. Since the mechanism to control strength is rate-dependent viscous flow, the only conceivable way to determine the inert strength at elevated temperatures is to utilize a very fast test rate that either minimizes the time for or eliminates slow crack growth. Few experimental studies have measured the elevated-temperature, inert (or "ultra"-fast fracture) strength of advanced ceramics. At the NASA Lewis Research Center, an experimental study was initiated to better understand the "ultra"-fast fracture strength behavior of advanced ceramics at elevated temperatures. Fourteen advanced ceramics - one alumina, eleven silicon nitrides, and two silicon carbides - have been tested using constant stress-rate (dynamic fatigue) testing in flexure with a series of stress rates including the "ultra"-fast stress rate of 33 000 MPa/sec with digitally controlled test frames. The results for these 14 advanced ceramics indicate that, notwithstanding possible changes in flaw populations as well as flaw configurations because of elevated temperatures, the strength at 33 000 MPa/sec approached the room-temperature strength or reached a higher value than that determined at the conventional test rate of 30 MPa/sec. On the basis of the experimental data, it can be stated that the elevated-temperature, inert strength of an advanced ceramic material can be defined as the strength where no slow crack growth takes place at the temperature.

Choi, Sung R.↗

Reversible Colorimetric Sensing of Volatile Analytes By Wicking in Close Proximity to A Photonic Film

Isolation of volatile analytes from environmental or biological fluids is a rate-determining step that can delay the response time for continuous sensing. In this paper, we demonstrate a colorimetric sensing system that enables the rapid detection of gas-phase analytes released from a flowing micro-volume fluid sample. The sensor platform is an analyte-responsive metal-insulator-metal (MIM) thin-film structure integrated with a large area quartz micropillar array. This allows precise planar alignment and microscale separation (310 μm) of the optical and fluidic structures. This configuration offers rapid and homogeneous color changes over large areas that permits detection by low-resolution optics or eye, which is well-suited to portable/wearable devices. For our proof-of-principle demonstration, we utilized a poly(methyl methacrylate) (PMMA) spacer and evaluated the sensor's response (color change) to ethanol vapor. We show that the RGB color value is quantitatively linked to the spacer swelling, which is reversible and repeatable. The optofluidic platform reduces the sensor response time from minutes to seconds compared with experiments using a conventional chamber. The sensor's concentration-dependent response was examined, confirming the potential of the reported sensing platform for continuous, compact, and quantitative colorimetric analysis of volatile analytes in low-volume samples, such as biofluids.

Timothy J. Palinski↗

Large-Scale Flow Structure in Turbulent Nonpremixed Flames under Normal- And Low-Gravity Conditions

It is well known that buoyancy has a major influence on the flow structure of turbulent nonpremixed jet flames. Buoyancy acts by inducing baroclinic torques, which generate large-scale vortical structures that can significantly modify the flow field. Furthermore, some suggest that buoyancy can substantially influence the large-scale structure of even nominally momentum-dominated flames, since the low velocity flow outside of the flame will be more susceptible to buoyancy effects. Even subtle buoyancy effects may be important because changes in the large-scale structure affects the local entrainment and fluctuating strain rate, and hence the structure of the flame. Previous studies that have compared the structure of normal- and micro-gravity nonpremixed jet flames note that flames in microgravity are longer and wider than in normal-gravity. This trend was observed for jet flames ranging from laminar to turbulent regimes. Furthermore, imaging of the flames has shown possible evidence of helical instabilities and disturbances starting from the base of the flame in microgravity. In contrast, these characteristics were not observed in normal-gravity. The objective of the present study is to further advance our knowledge of the effects of weak levels of buoyancy on the structure of transitional and turbulent nonpremixed jet flames. In later studies we will utilize the drop tower facilities at NASA Glenn Research Center (GRC), but the preliminary work described in this paper was conducted using the 1.25-second drop tower located at the University of Texas at Austin. A more detailed description of these experiments can be found in Idicheria et al.

Clemens, N. T.↗

Large Aperture Scanning Lidar Based on Holographic Optical Elements

Lidar remote sensing instruments can make a significant contribution to satisfying many of the required measurements of atmospheric and surface parameters for future spaceborne platforms, including topographic altimeters, atmospheric profiles of, wind, humidity, temperature, trace molecules, aerosols, and clouds. It is highly desirable to have wide measurement swaths for rapid coverage rather than just the narrow ribbon of data that is obtained with a nadir only observation. For most applications global coverage is required, and for wind measurements scanning or pointing is required in order to retrieve the full 3-D wind vector from multiple line-of-sight Doppler measurements. Conventional lidar receivers make up a substantial portion of the instrument's size and weight. Wide angle scanning typically requires a large scanning mirror in front of the receiver telescope, or pointing the entire telescope and aft optics assembly, Either of these methods entails the use of large bearings, motors, gearing and their associated electronics. Spaceborne instruments also need reaction wheels to counter the torque applied to the spacecraft by these motions. NASA has developed simplified conical scanning telescopes using Holographic Optical Elements (HOEs) to reduce the size, mass, angular momentum, and cost of scanning lidar systems. NASA has developed two operating lidar systems based on 40 cm diameter HOEs. The first such system, named Prototype Holographic Atmospheric Scanner for Environmental Remote Sensing (PHASERS) was a joint development between NASA Goddard Space Flight Center (GSFC) and the University of Maryland College Park. PHASERS is based on a reflection HOE for use at the doubled Nd:YAG laser wavelength of 532 nm and has recently undergone a number of design changes in a collaborative effort between GSFC and Saint Anselm College in New Hampshire. The next step was to develop IR transmission HOEs for use with the Nd:YAG fundamental in the Holographic Airborne Rotating Lidar Instrument Experiment (HARLIE). The HOE spins like a compact disk in a large ring ball bearing. In an aircraft the HOE faces down, looking out through a window at an angle of 45 degrees off-nadir. The HOE diffracts 85% of the incident 532 nm light into a 160 micron spot at a focal length of 1 meter. HARLIE is a field deployable lidar measuring aerosol, cloud, and boundary layer backscatter for atmospheric research. It has flown several times and is also used from a ground-based trailer in an upward-looking mode. The HOE generates a 45 degree conical scan pattern by rotating at speeds up to 30 rpm. Like PHASERS, the HOE in HARLIE serves both as the laser collimating lens as well as the receiver telescope primary optic. The telescope is coupled to the receiver package via fiber optic. The transmitter is a diode pumped Nd:YAG laser operating at 1064 nm, delivering 1 mJ pulses at a 5 KHz rep-rate. The receiver has a 200 microradian field-of-view and a 0.5 nm optical bandpass. The photon counting data system utilizes a single Geiger-mode silicon avalanche photodiode detector, This new technology has also presented us with new data visualization challenges as well as new measurement techniques. The backscatter data obtained from a stationary (i.e. ground-based) scanning HOE lidar is on the surface of a cone, which when viewed over many consecutive scans can reveal atmospheric motions on this surface over time as the atmosphere advects over the site. In a moving platform such as an airplane or satellite, the data from consecutive scans cover different areas under the flight path, revealing atmospheric structure in 3-dimensions. An example of a visualization of HARLIE ground-based data is presented, showing aerosol backscatter on a 90 degree conical surface generated from one 360 degree scan of the lidar during the HOLO-1 field campaign on the afternoon of 10 March 1999. Higher backscatter levels are rendered as lighter signal against a dark background. Breaking Kelvin-Helmholtz waves are evident on the north side of the scan at an altitude of 10-11 km. Time series of successive scans made at regular intervals render unique views of atmospheric motions, from which vertical profiles of atmospheric wind vectors can be obtained using a unique data analysis approach. Wind vectors obtained from the lidar were compared with co-located radiosonde wind profiles during an intensive operating period in September-October 2000 at the Atmospheric Radiation Measurement Program's Southern Great Plains Central Facility.

Schwemmer, Geary K.↗

Utility of a finite element solution algorithm for initial-value problems

The Galerkin criterion within a finite element Weighted Residuals formulation is employed to establish an implicit solution algorithm for an initial-value partial differential equation. Numerical solutions of a transient parabolic and a hyperbolic equation, obtained using linear, quadratic and two cubic finite element basis functions, are employed to quantize accuracy and confirm and refine theoretical convergence rate estimates. The linear basis algorithm for the hyperbolic equation displays excellent accuracy on a coarse computational grid and a high-order convergence rate with discretization refinement. Good accuracy and a strong convergence rate in surface flux are determined for a nonhomogeneous Neumann boundary constraint applied to a parabolic equation. The results amply demonstrate the impact of the nondiagonal finite element initial-value matrix structure on solution accuracy and/or convergence rate.

Baker, A. J.↗

Aeroelastic Indicial Response Reduced-Order Modeling for Flexible Flight Vehicles

A reduced-order modeling method capable of providing computationally efficient predictions of the nonlinear, unsteady aerodynamics encountered by flexible flight vehicles under- going forced oscillations is presented. Models are developed using indicial response theory, which characterizes a vehicle’s dynamics through identification of time-accurate aerodynamic responses due to step changes in the vehicle-state parameters, e.g., angle-of-attack, pitch rate. A coupled computational fluid dynamics aeroelastic analysis is proposed for identifying step (indicial) responses of flexible vehicles. In this approach, aeroelastic indicial responses are simulated via prescribed rigid body motions, while fluid-structure interactions are captured at the subiterative level through coupling to a linear modal structural solver. A nonlinear extension of indicial response theory is applied through time-dependent linear interpolation of a database of locally linear aeroelastic step responses. Reduced-order models are then created using the mathematical principle of convolution applied to the interpolated aeroelastic indicial responses to predict the time-dependent aerodynamic response of a flexible vehicle to any arbitrary prescribed flight maneuver. The NASA FUN3D computational fluid dynamics solver is utilized for simulating full-order trajectories and indicial response functions. Aerodynamic predictions were generated for the X-56A aircraft undergoing a series of harmonic forced oscillations. The s are shown to provide a practical option for evaluating the unsteady aerodynamics of flexible vehicles using high-fidelity simulations.

Hiller, Brett↗

The Malemute development program

The Malemute vehicle systems are two-stage systems based on utilizing a new high performance upper stage motor with two existing military boosters. The Malmute development program is described relative to program structure, preliminary design, vehicle subsystems, and the Malemute motor. Two vehicle systems, the Nike-Malemute and Terrier-Malemute, were developed which are capable of transporting comparatively large diameter (16 in.) 200-lb payloads to altitudes of 500 and 700 km, respectively. These vehicles provide relatively low-cost transportation with two-stage reliability and launch simplicity. Flight tests of both vehicle systems revealed their performance capabilities, with the Terrier-Malemute system involving a unique Malemute motor spin sensitivity problem. It is suggested that the vehicles can be successfully flown by lowering the burnout spin rate.

Bolster, W. J.↗

C-SIDE: The control-structure interaction demonstration experiment

The Control-Structure Interaction Demonstration Experiment (C-SIDE) is sponsored by the Electro-Optics and Cryogenics Division of Ball Aerospace Systems Group. Our objective is to demonstrate methods of solution to structure control problems utilizing currently available hardware in a system that is an extension of our corporate experience. The larger space structures with which Ball has been associated are the SEASAT radar antenna, Shuttle Imaging Radar (SIR) -A, -B and -C antennas and the Radarsat spacecraft. The motivation for the C-SIDE configuration is to show that integration of active figure control in the radar's system-level design can relieve antenna mechanical design constraints. This presentation is primarily an introduction to the C-SIDE testbed. Its physical and functional layouts, and major components are described. The sensor is of special interest as it enables direct surface figure measurements from a remote location. The Remote Attitude Measurement System (RAMS) makes high-rate, unobtrusive measurements of many locations, several of which may be collocated easily with actuators. The control processor is a 386/25 executing a reduced order model-based algorithm with provision for residual mode filters to compensate for structure interaction. The actuators for the ground demonstration are non-contacting, linear force devices. Results presented illustrate some basic characteristics of control-structure interaction with this hardware. The testbed will be used for evaluation of current technologies and for research in several areas. A brief indication of the evolution of the C-SIDE is given at the conclusion.

Mohl, James B.↗

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ®†† in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi- isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non- destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Laser↗