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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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NASA NTRSDate not supplied

FY22 Superlightweight Aerospace Composites (SAC) Annual Review Presentation

Technology Product Capability - Superlightweight Aerospace Composites (SAC) technology aims to develop a carbon nanotube (CNT) based composite structural material with nearly double the specific strength of state-of-the-art carbon (SOA) fiber composites. The product capability offers a viable technology that can reduce overall vehicle structural mass by ~ 25 % to 50 %. Technical Capabilities (Technical Tall Poles) - High volume manufacturing of high strength CNT - Availability of CNT composite mechanical properties - Multiscale CNT composite modeling - CNT composite prototypes Exploration & Science Applicability - Availability of commercial quantities of high strength CNT enables the fabrication of high strength composites that can influence design paradigms for aerospace structures. - SAC technology will enable missions where high strength lightweight structures are needed.

Mia Siochi↗
NASA NTRS2000

Adhesive Bonding Characterization of Composite Joints for Cryogenic Usage

The development of polymer composite cryogenic tanks is a critical step in creating the next generation of launch vehicles. Future reusable launch vehicles need to minimize the gross liftoff weight (GLOW). This weight reduction is possible due to the large reduction in weight that composite materials can provide over current aluminum technology. In addition to composite technology, adhesively bonded joints potentially have several benefits over mechanically fastened joints, such as weight savings and cryogenic fluid containment. Adhesively bonded joints may be used in several areas of these cryogenic tanks, such as in lobe-to-lobe joints (in a multi-lobe concept), skirt-to-tank joint, strut-to-tank joint, and for attaching stringers and ring frames. The bonds, and the tanks themselves, must be able to withstand liquid cryogenic fuel temperatures that they contain. However, the use of adhesively bonded composite joints at liquid oxygen and hydrogen temperatures is largely unknown and must be characterized. Lockheed Martin Space Systems Company, Michoud Operations performed coupon-level tests to determine effects of material selection, cure process parameters, substrate surface preparation, and other factors on the strength of these composite joints at cryogenic temperatures. This led to the selection of a material and process that would be suitable for a cryogenic tank. KEY WORDS: Composites, Adhesive Bonding, Cryogenics

Graf, Neil A.↗
NASA NTRSDate not supplied

3D Woven Composite End Ring Structure: Design Development and Verification Testing

The National Aeronautics and Space Administration (NASA) Space Technology and Mission Directorate (STMD) is advancing composite technologies for exploration missions. The Composite Technology for Exploration (CTE) project goal is to advance lightweight joint concepts for Space Launch System (SLS) class structures. To this end CTE is developing and demonstrating a 3D woven carbon /epoxy composite joint design co-bonded in a circumferential end ring configuration, applied to a SLS sized conceptual payload attachment structure. This joint is a lightweight alternative to heavy and costly metallic joints. The 3D woven joint development advances lightweight joint technologies through material and structural design, material and joint analyses, and fabrication, as well as demonstration through building block testing. Prior limited building block tests are mentioned. In this paper, new sub-element-scale test results are described that demonstrate the structural capability well beyond design limit load. Then, results for a sub-component test article with a 889 mm joint subjected to combined loads are presented.

Kenneth N Segal↗
NASA NTRS2003

Metal Matrix Composite LOX Turbopump Housing via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites for propulsion components offer high performance and affordability, resulting in low weight and cost. The following sections in this viewgraph presentation describe the pressure infiltration casting of a metal matrix composite LOX turbopump housing: 1) Baseline Pump Design and Stress Analysis; 2) Tool-less Advanced Pressure Infiltration Casting Process; 3) Preform Splicing and Joining for Large Components such as Pump Housing; 4) Fullscale Pump Housing Redesign.

Shah, Sandeep↗
NASA NTRS1985

Critical joints in large composite primary aircraft structures. Volume 2: Technology demonstration test report

A program was conducted to develop the technology for critical structural joints in composite wing structure that meets all the design requirements of a 1990 commercial transport aircraft. The results of four large composite multirow bolted joint tests are presented. The tests were conducted to demonstrate the technology for critical joints in highly loaded composite structure and to verify the analytical methods that were developed throughout the program. The test consisted of a wing skin-stringer transition specimen representing a stringer runout and skin splice on the wing lower surface at the side of the fuselage attachment. All tests were static tension tests. The composite material was Toray T-300 fiber with Ciba-Geigy 914 resin in 10 mil tape form. The splice members were metallic, using combinations of aluminum and titanium. Discussions are given of the test article, instrumentation, test setup, test procedures, and test results for each of the four specimens. Some of the analytical predictions are also included.

Bunin, Bruce L.↗
NASA NTRS1972

NASA technology utilization survey on composite materials

NASA and NASA-funded contractor contributions to the field of composite materials are surveyed. Existing and potential non-aerospace applications of the newer composite materials are emphasized. Economic factors for selection of a composite for a particular application are weight savings, performance (high strength, high elastic modulus, low coefficient of expansion, heat resistance, corrosion resistance,), longer service life, and reduced maintenance. Applications for composites in agriculture, chemical and petrochemical industries, construction, consumer goods, machinery, power generation and distribution, transportation, biomedicine, and safety are presented. With the continuing trend toward further cost reductions, composites warrant consideration in a wide range of non-aerospace applications. Composite materials discussed include filamentary reinforced materials, laminates, multiphase alloys, solid multiphase lubricants, and multiphase ceramics. New processes developed to aid in fabrication of composites are given.

Leeds, M. A.↗
NASA NTRS1992

Intelligent Processing Equipment Developments Within the Navy's Manufacturing Technology Centers of Excellence

The U.S. Navy has had an active Manufacturing Technology (MANTECH) Program aimed at developing advanced production processes and equipment since the late-1960's. During the past decade, however, the resources of the MANTECH program were concentrated in Centers of Excellence. Today, the Navy sponsors four manufacturing technology Centers of Excellence: the Automated Manufacturing Research Facility (AMRF); the Electronics Manufacturing Productivity Facility (EMPF); the National Center for Excellence in Metalworking Technology (NCEMT); and the Center of Excellence for Composites Manufacturing Technology (CECMT). This paper briefly describes each of the centers and summarizes typical Intelligent Equipment Processing (IEP) projects that were undertaken.

Nanzetta, Philip↗
NASA NTRS2002

Application of Interface Technology in Progressive Failure Analysis of Composite Panels

A progressive failure analysis capability using interface technology is presented. The capability has been implemented in the COMET-AR finite element analysis code developed at the NASA Langley Research Center and is demonstrated on composite panels. The composite panels are analyzed for damage initiation and propagation from initial loading to final failure using a progressive failure analysis capability that includes both geometric and material nonlinearities. Progressive failure analyses are performed on conventional models and interface technology models of the composite panels. Analytical results and the computational effort of the analyses are compared for the conventional models and interface technology models. The analytical results predicted with the interface technology models are in good correlation with the analytical results using the conventional models, while significantly reducing the computational effort.

Sleight, D. W.↗
NASA NTRS1986

Performance and loads data from a hover test of a full-scale advanced technology XV-15 rotor

A hover test of a full-scale, composite, advanced technology XV-15 rotor was conducted at the Outdoor Aerodynamic Research Facility at Ames Research Center. The primary objective of the test was to obtain accurate measurements of the hover performance of this rotor system. Data were acquired for rotor tip Mach numbers ranging from 0.35 to 0.73. The rotor was tested with several alternate blade root and blade-tip configurations. Data are presented on rotor performance, rotor-wake downwash velocities, and rotor system loads.

Felker, Fort F.↗
NASA NTRS1988

Hygrothermomechanical fiber composite fatigue: Computational simulation

The technology of advanced composites has matured to the point where these composites are prime contenders for various structural applications. One of the major design considerations for prolonged service of these composites is fatigue due to cyclical hygral (moisture), thermal, and mechanical (hygrothermomechanical) loading conditions. Recent research activities at the NASA Lewis Research Center have led to the development of formal procedures for predicting, using computational simulation, fatigue in fiber composites due to cyclic hygrothermomechanical loading conditions. These formal procedures have subsequently been programmed into a computer module and embedded into the Integrated Composites Analyzer (ICAN) computer code. The objective of this paper is to present and describe results obtained using the augmented ICAN computer code.

Ginty, Carol A.↗
NASA NTRS1991

Improved compression molding technology for continuous fiber reinforced composite laminates. Part 2: AS-4/Polyimidesulfone prepreg system

AS-4/polyimidesulfone (PISO2) composite prepreg was utilized for the improved compression molding technology investigation. This improved technique employed molding stops which advantageously facilitate the escape of volatile by-products during the B-stage curing step, and effectively minimize the neutralization of the consolidating pressure by intimate interply fiber-fiber contact within the laminate in the subsequent molding cycle. Without the modifying the resin matrix properties, composite panels with both unidirectional and angled plies with outstanding C-scans and mechanical properties were successfully molded using moderate molding conditions, i.e., 660 F and 500 psi, using this technique. The size of the panels molded were up to 6.00 x 6.00 x 0.07 in. A consolidation theory was proposed for the understanding and advancement of the processing science. Processing parameters such as vacuum, pressure cycle design, prepreg quality, etc. were explored.

Baucom, Robert M.↗
NASA NTRS2002

Penalty-Based Finite Element Interface Technology for Analysis of Homogeneous and Composite Structures

An effective and robust interface element technology able to connect independently modeled finite element subdomains has been developed. This method is based on the use of penalty constraints and allows coupling of finite element models whose nodes do not coincide along their common interface. Additionally, the present formulation leads to a computational approach that is very efficient and completely compatible with existing commercial software. A significant effort has been directed toward identifying those model characteristics (element geometric properties, material properties, and loads) that most strongly affect the required penalty parameter, and subsequently to developing simple 'formulae' for automatically calculating the proper penalty parameter for each interface constraint. This task is especially critical in composite materials and structures, where adjacent sub-regions may be composed of significantly different materials or laminates. This approach has been validated by investigating a variety of two-dimensional problems, including composite laminates.

Averill, Ronald C.↗
NASA NTRS2001

AST Composite Wing Program: Executive Summary

The Boeing Company demonstrated the application of stitched/resin infused (S/RFI) composite materials on commercial transport aircraft primary wing structures under the Advanced Subsonic technology (AST) Composite Wing contract. This report describes a weight trade study utilizing a wing torque box design applicable to a 220-passenger commercial aircraft and was used to verify the weight savings a S/RFI structure would offer compared to an identical aluminum wing box design. This trade study was performed in the AST Composite Wing program, and the overall weight savings are reported. Previous program work involved the design of a S/RFI-base-line wing box structural test component and its associated testing hardware. This detail structural design effort which is known as the "semi-span" in this report, was completed under a previous NASA contract. The full-scale wing design was based on a configuration for a MD-90-40X airplane, and the objective of this structural test component was to demonstrate the maturity of the S/RFI technology through the evaluation of a full-scale wing box/fuselage section structural test. However, scope reductions of the AST Composite Wing Program pre-vented the fabrication and evaluation of this wing box structure. Results obtained from the weight trade study, the full-scale test component design effort, fabrication, design development testing, and full-scale testing of the semi-span wing box are reported.

Karal, Michael↗
NASA NTRS1976

Composite materials: A compilation

Design, analysis and fabrication techniques for boron-aluminum composite-structure technology is presented and a new method of joining different laminated composites without mechanical fasteners is proposed. Also discussed is a low-cost procedure for rigidifying expanded honeycomb tubing and piping simulations. A brief note on patent information is added.

Source record↗
NASA NTRS1997

Application of Interface Technology in Nonlinear Analysis of a Stitched/RFI Composite Wing Stub Box

A recently developed interface technology was successfully employed in the geometrically nonlinear analysis of a full-scale stitched/RFI composite wing box loaded in bending. The technology allows mismatched finite element models to be joined in a variationally consistent manner and reduces the modeling complexity by eliminating transition meshing. In the analysis, local finite element models of nonlinearly deformed wide bays of the wing box are refined without the need for transition meshing to the surrounding coarse mesh. The COMET-AR finite element code, which has the interface technology capability, was used to perform the analyses. The COMET-AR analysis is compared to both a NASTRAN analysis and to experimental data. The interface technology solution is shown to be in good agreement with both. The viability of interface technology for coupled global/local analysis of large scale aircraft structures is demonstrated.

Wang, John T.↗
NASA NTRS1993

Optimal design of composite hip implants using NASA technology

Using an adaptation of NASA software, we have investigated the use of numerical optimization techniques for the shape and material optimization of fiber composite hip implants. The original NASA inhouse codes, were originally developed for the optimization of aerospace structures. The adapted code, which was called OPORIM, couples numerical optimization algorithms with finite element analysis and composite laminate theory to perform design optimization using both shape and material design variables. The external and internal geometry of the implant and the surrounding bone is described with quintic spline curves. This geometric representation is then used to create an equivalent 2-D finite element model of the structure. Using laminate theory and the 3-D geometric information, equivalent stiffnesses are generated for each element of the 2-D finite element model, so that the 3-D stiffness of the structure can be approximated. The geometric information to construct the model of the femur was obtained from a CT scan. A variety of test cases were examined, incorporating several implant constructions and design variable sets. Typically the code was able to produce optimized shape and/or material parameters which substantially reduced stress concentrations in the bone adjacent of the implant. The results indicate that this technology can provide meaningful insight into the design of fiber composite hip implants.

Blake, T. A.↗
NASA NTRS2013

Integration Science and Technology of Silicon-Based Ceramics and Composites:Technical Challenges and Opportunities

Ceramic integration technologies enable hierarchical design and manufacturing of intricate ceramic and composite parts starting with geometrically simpler units that are subsequently joined to themselves and/or to metals to create components with progressively higher levels of complexity and functionality. However, for the development of robust and reliable integrated systems with optimum performance for high temperature applications, detailed understanding of various thermochemical and thermomechanical factors is critical. Different technical approaches are required for the integration of ceramic to ceramic and ceramic to metal systems. Active metal brazing, in particular, is a simple and cost-effective method to integrate ceramic to metallic components. Active braze alloys usually contain a reactive filler metal (e.g., Ti, Cr, V, Hf etc) that promotes wettability and spreading by inducing chemical reactions with the ceramics and composites. In this presentation, various examples of brazing of silicon nitride to themselves and to metallic systems are presented. Other examples of joining of ceramic composites (C/SiC and SiC/SiC) using ceramic interlayers and the resulting microstructures are also presented. Thermomechanical characterization of joints is presented for both types of systems. In addition, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be presented.

Singh, M.↗