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NASA NTRS1973

Design and fabrication of gas bearings for Brayton cycle rotating unit

Analysis, design, and testing of two types of pivoted pad journal bearings and a spiral-grooved thrust bearing suitable for direct installation into the NASA 2 to 15 KW Brayton Cycle Rotating Unit (BRU) have been accomplished. Both types of tilting pad bearing assemblies are of the preloaded type, consisting of three pads with one pad flexibly mounted. One type utilizes a non-conforming pivot, while the other replaces the conventional spherical pivot with a cruciform flexible member. The thrust bearing is flexure mounted to accommodate static machine mislinement. Test results indicate that both types of journal bearings should satisfy the requirements imposed by the BRU. Hydrostatic tests of the spiral-grooved thrust bearing showed it to be free of pneumatic hammer with as many as 24 orifices over the BRU pressure and load range.

Frost, A.↗

NASA NTRSDate not supplied

Electromagnetic Redesign of NASA’s High Efficiency Megawatt Motor

NASA’s High Efficiency Megawatt Motor (HEMM) is being developed to achieve the performance needed by single aisle class electrified aircraft. It is a 1.4 MW electric machine designed as a generator for NASA’s STARC-ABL concept vehicle. It has performance objectives of greater than 16 kW/kg electromagnetic specific power and efficiency of greater than 98%. A significant flaw in the preliminary electromagnetic design of HEMM was recently discovered. The stator teeth in the preliminary design cause the magnetic flux in the rotating components of HEMM to oscillate at a very high frequency (12,240 Hz). Two independent energy loss analyses are presented to show that the frequency is high enough to cause eddy current losses that significantly exceed the rotor’s loss limit (50 W), despite the very small magnitude of this flux oscillation (<0.01 T). To eliminate these rotor losses, while continuing to meet the target performance, it was determined that the stator teeth needed to be removed and the electromagnetic geometry of the motor needed to be revised. The revised, slotless HEMM motor design is summarized. Sensitivity of the new design to key unknown variables such as the temperature of and number of turns in the superconducting rotor coils and the stator winding’s average temperature.

Thomas T Tallerico↗

NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗

NASA NTRS2010

Stacked Corrugated Horn Rings

This Brief describes a method of machining and assembly when the depth of corrugations far exceeds the width and conventional machining is not practical. The horn is divided into easily machined, individual rings with shoulders to control the depth. In this specific instance, each of the corrugations is identical in profile, and only differs in diameter and outer profile. The horn is segmented into rings that are cut with an interference fit (zero clearance with all machining errors biased toward contact). The interference faces can be cut with a reverse taper to increase the holding strength of the joint. The taper is a compromise between the interference fit and the clearance of the two faces during assembly. Each internal ring is dipped in liquid nitrogen, then nested in the previous, larger ring. The ring is rotated in the nest until the temperature of the two parts equalizes and the pieces lock together. The resulting assay is stable, strong, and has an internal finish that cannot be achieved through other methods.

Sosnowski, John B.↗

NASA NTRS1991

An investigation to determine the producibility of a 3-D braider and bias direction weaving loom

The development of prototype machines for the production of generalized braid patterns is described. Mechanical operating principles and control strategies are presented for two prototype machines which were fabricated and evaluated. Both machines represent advances over current techniques for forming composite material preforms by enabling near ideal control of fiber orientation. Furthermore, they overcome both the lack of general control of produced fiber architectures and the complexity of other weaving processes that were produced for the same purpose. One prototype, the modified Farley braider, consists of an array of turntables which can be rotated 90 degrees and returned; hence, they can form tracks in the x and y axis. Yarn ends are transported about the surface formed by the turntables using motorized tractors. These tractors are controlled using an optical link with a control circuit and host computer. The tractors are powered through electrical contact with the turntables. The necessary relative motions are produced by a series of linear tractor moves combined with a sequence of turntable rotations. The movement of the tractors about the surface causes the yarns to produce the desired braiding pattern. The second device, the shuttle plate braider, consists of a braiding surface formed by an array of square elements, each separated from its neighbor by a gap. Beneath this surface lies a shuttle plate, which reciprocates first in one axis and then in the other. As this movement takes place, yarn carrying shuttles engage and disengage the plate by means of solenoid activated pins. By selective engagement and disengagement, the shuttles can move the yarn ends in any desired pattern, forming the desired braid. Control power, and control signals, are transmitted from the electronic interface circuit and host computer, via the braiding surface through electrical contact with the shuttles. Motive power is proved to the shuttles by motion of the shuttle plate, which is passively driven using pneumatic rams. Each shuttle is a simple device that uses only a solenoid to engage the plate and is a simple device that uses only a solenoid to engage the plate and is independently controllable. When compared with each other, the modified Farley braider has the advantage of speed, and the shuttle plate braider the advantage of mechanical control and simplicity.

Huey, Cecil O., Jr.↗

NASA NTRS1997

Fan Blade Deflection Measurement and Analyses Correlation

Steady deflection measurements were taken of two identical NASA/Pratt & Whitney-designed fan blades while they were rotating in a vacuum in NASA Lewis Research Center's Dynamic Spin Facility. The one-fifth-scale fan blades, which have a tip diameter of 22 in. and a pinroot retention, are of sparshell construction and were unducted for this test. The purpose of the test was to measure the change of the radial deflection of the blade tip and blade angle at selected radial stations along the blade span with respect to rotational speed. The procedure for radial deflection measurement had no precedent and was newly developed for this test. Radial deflection measurements were made to assure adequate tip clearance existed between the fan blades and the duct for a follow-on wind tunnel test. Also, blade angle deflection measurements were desired before pitchsetting parts for the wind tunnel test were finish machined. During the test, laser beams were aimed across the blade path into photodiodes to give signals that were used to determine blade angle change or tip radial deflection. These laser beams were set parallel to the spin axis at selected radial stations.

Mehmed, Oral↗

NASA NTRS1988

Heat Exchanger For Rotating Modular Structures

Heat exchanger transfers heat from one structure to another while accommodating rotary motion of structures. Flat-panel heat exchanger passes heat from fluid in middle panel to fluid in outer panels. Diaphragm-like outer panels swell to conform to surfaces of middle panel, ensuring thermal contact. Rotary fluid coupling provides connection for both supply fluid and return fluid. Flexible hoses carrying fluid to and from coupling accommodate tilt of one structure with respect to other. Adapted to transfer of fluids and heat across joints of machine tools and robot arms and to flow of coolant through portable electronic equipment.

Clark, William E.↗

NASA NTRSDate not supplied

Space Suit Portable Life Support System Thermal Control Valve Ball Design

A Thermal Control Valve (TCV) has been in development for the Exploration Extravehicular Mobility Unit Portable Life Support System (xEMU PLSS). The xEMU PLSS TCV controls flow going to the liquid cooling and ventilation garment that the crew member wears during extra-vehicular activity to expel waste heat. A previous TCV version with a linear actuator and diverter valve has been tested to attempt to control the flow accurately. The previous valve has a non-linear flow response relative to valve position and has struggled to meet the setpoints desired for precise thermal control. While many diverter valve design variations have been attempted, all previous designs have had difficulty meeting set points. Additionally, high precision machining is required to create a metal-on-metal seal which has its own drawbacks and does not always meet requirements for internal leakage. This metal seal also requires stalling a linear actuator to load the seal in compression or tension which has caused sticking failures when stalled. A new approach and design for a TCV has been developed which uses a rotational ball to control flow and has demonstrated a much more precise and linear flow control. The design functions like a two-way ball valve with two Teflon seats that cradle and compress the ball for sealing. The ball outlet has a unique geometric design to create a set-able orifice like hole which is more predictable at controlling flow. Additionally, the Teflon seat performs much better for preventing internal leakage than the metal seal and prevents sticking by having a large range in which it is sealed without having to stall the actuator. This paper will review a new proposed xEMU PLSS TCV ball design and compare it with previous iterations of the design.

Ryan Ogilvie↗

NASA NTRSDate not supplied

Space Suit Portable Life Support System Thermal Control Valve Ball Design

Ryan Ogilvie↗

NASA NTRS1975

Flexible rotor balancing by the influence coefficient method: Multiple critical speeds with rigid or flexible supports

Experimental tests were conducted to demonstrate the ability of the influence coefficient method to achieve precise balance of flexible rotors of virtually any design for operation through virtually any speed range. Various practical aspects of flexible-rotor balancing were investigated. Tests were made on a laboratory quality machine having a 122 cm (48 in.) long rotor weighing 50 kg (110 lb) and covering a speed range up to 18000 rpm. The balancing method was in every instance effective, practical, and economical and permitted safe rotor operation over the full speed range covering four rotor bending critical speeds. Improved correction weight removal methods for rotor balancing were investigated. Material removal from a rotating disk was demonstrated through application of a commercially available laser.

Tessarzik, J. M.↗

NASA NTRS1999

Computer Modeling of Electrostatic Aggregation of Granular Materials in Planetary and Astrophysical Settings

Electrostatic forces strongly influence the behavior of granular materials in both dispersed (cloud) systems and semi-packed systems. These forces can cause aggregation or dispersion of particles and are important in a variety of astrophysical and planetary settings. There are also many industrial and commercial settings where granular matter and electrostatics become partners for both good and bad. This partnership is important for human exploration on Mars where dust adheres to suits, machines, and habitats. Long-range Coulombic (electrostatic) forces, as opposed to contact-induced dipoles and van der Waals attractions, are generally regarded as resulting from net charge. We have proposed that in addition to net charge interactions, randomly distributed charge carriers on grains will result in a dipole moment regardless of any net charge. If grains are unconfined, or fluidized, they will rotate so that the dipole always induces attraction between grains. Aggregates are readily formed, and Coulombic polarity resulting from the dipole produces end-to-end stacking of grains to form filamentary aggregates. This has been demonstrated in USML experiments on Space Shuttle where microgravity facilitated the unmasking of static forces. It has also been demonstrated in a computer model using grains with charge carriers of both sign. Model results very closely resembled micro-g results with actual sand grains. Further computer modeling of the aggregation process has been conducted to improve our understanding of the aggregation process, and to provide a predictive tool for microgravity experiments slated for Space Station. These experiments will attempt to prove the dipole concept as outlined above. We have considerably enhanced the original computer model: refinements to the algorithm have improved the fidelity of grain behavior during grain contact, special attention has been paid to simulation time steps to enable establishment of a meaningful, quantitative time axis, and calibration of rounding accuracies have been conducted to test cumulative numerical influences in the model. The model has been run for larger grain populations, variable initial cloud densities, and we have introduced random net charging to individual grains, as well as a net charge to the cloud as a whole. The model uses 3 positive and 3 negative charges randomly distributed on each grain, with up to 160 grains contained within various size "boxes" that define the initial number densities in the clouds. Each charge represents localized charged region on a grain, but does not necessarily imply single quantized charge carriers. The Coulomb equations are then allowed to interact for each monopole: dipoles and any higher order charge coupling is a natural product of these "free" interactions over which the modeler exerts no influence. The charges are placed on surfaces of grains at random locations. A series of runs was conducted for neutral grains that had a perfect balance of negative and positive char carriers. Runs were also conducted with grains having additional fractional charges ranging between 0 and 1. By adding fractional charges of one sign, the model created grain populations in which all grains had excess charges the same sign, giving the cloud an overall net charge. This simulates clouds subjected to ionizing radiation (e. protoplanetary debris disk around a protosun), or any other process of charge biasing in a grain population (e.g., volcanic plumes). In another run series, random fractional charges of either sign were added to the grains so th some grains had a slight net positive charge while others had a slight net negative charge. This simulates triboelectrically-charged grain populations in which acquisition of an electron by one surface is at the expense creating a hole elsewhere. This dual sign charging was applied in two ways: in one case the cloud remained neutral by ensuring that all grain excess charges added to zero; in the other case, the cloud was permitted slight net char by not imposing a charge-balance condition. Additional information is contained in the original.

Marshall, J.↗

NASA NTRS2000

Accuracy of Numerical Simulations of Tip Clearance Flow in Transonic Compressor Rotors Improved Dramatically

The tip clearance flows of transonic compressor rotors have a significant impact on rotor and stage performance. Although numerical simulations of these flows are quite sophisticated, they are seldom verified through rigorous comparisons of numerical and measured data because, in high-speed machines, measurements acquired in sufficient detail to be useful are rare. Researchers at the NASA Glenn Research Center at Lewis Field compared measured tip clearance flow details (e.g., trajectory and radial extent) of the NASA Rotor 35 with results obtained from a numerical simulation. Previous investigations had focused on capturing the detailed development of the jetlike flow leaking through the clearance gap between the rotating blade tip and the stationary compressor shroud. However, we discovered that the simulation accuracy depends primarily on capturing the detailed development of a wall-bounded shear layer formed by the relative motion between the leakage jet and the shroud.

VanZante, Dale E.↗

NASA NTRS2021

Modeling of Guided Waves for Aerospace Applications

Advancements in computer hardware has led to new possibilities for rapid modeling and simulation capabilities across many scientific fields. Nondestructive evaluation (NDE) can benefit from increased use of simulation tools to guide optimization of inspection and health monitoring methods, enhance understanding of data, aid in development of defect characterization methods, and generate data sets for use with machine learning and model-assisted probability of detection. Recent work at NASA has entailed development and benchmarking of both custom simulation codes and commercial simulation tools for ultrasonic wave propagation. This paper describes recent work at NASA in modeling of guided waves in composites and other aerospace materials. Results and computational speeds for a composite benchmark case are reported for a custom finite difference Rotated Staggered Grid code and for the commercial finite element software package, Pogo. Recent progress in linking NDE models to parametric analysis tools is also discussed.

Nondestructive evaluation↗

NASA NTRSDate not supplied

Sample Polishing Without Epoxy

In recent years, we have received requests for meteorite sample sections to be prepared without using epoxy impregnation or mounting. The reasoning for these requests ranges from potential contamination of analyses from epoxy chemical components to degradation of instrumental vacuum from epoxy outgassing (e.g., SEM, SIMS, EPMA, etc.). An alternative approach that we employ involves sawing off a 1-5 mm thick wafer of the sample. The wafer is ground using silica carbide lapping media wetted with 190 proof ethyl alcohol to make both sides flat and parallel. The sample is then polished on one or both sides using diamond paste or dry diamond powder on a rotating lap wheel until the desired finish is obtained. The sample is cleaned in between steps using 200 proof ethyl alcohol in an ultrasonic cleaner. Friable and altered samples need to have higher thickness in order for polishing to be attempted. Without epoxy to hold the sample together or a glass slide for backing, the sample needs additional material to provide the necessary support structure. The machining steps of this process need to be undertaken at a much slower speed than in traditional thin or thick section preparation.

Meteorite↗

NASA NTRS1989

Robot Acting on Moving Bodies (RAMBO): Interaction with tumbling objects

Interaction with tumbling objects will become more common as human activities in space expand. Attempting to interact with a large complex object translating and rotating in space, a human operator using only his visual and mental capacities may not be able to estimate the object motion, plan actions or control those actions. A robot system (RAMBO) equipped with a camera, which, given a sequence of simple tasks, can perform these tasks on a tumbling object, is being developed. RAMBO is given a complete geometric model of the object. A low level vision module extracts and groups characteristic features in images of the object. The positions of the object are determined in a sequence of images, and a motion estimate of the object is obtained. This motion estimate is used to plan trajectories of the robot tool to relative locations rearby the object sufficient for achieving the tasks. More specifically, low level vision uses parallel algorithms for image enhancement by symmetric nearest neighbor filtering, edge detection by local gradient operators, and corner extraction by sector filtering. The object pose estimation is a Hough transform method accumulating position hypotheses obtained by matching triples of image features (corners) to triples of model features. To maximize computing speed, the estimate of the position in space of a triple of features is obtained by decomposing its perspective view into a product of rotations and a scaled orthographic projection. This allows use of 2-D lookup tables at each stage of the decomposition. The position hypotheses for each possible match of model feature triples and image feature triples are calculated in parallel. Trajectory planning combines heuristic and dynamic programming techniques. Then trajectories are created using dynamic interpolations between initial and goal trajectories. All the parallel algorithms run on a Connection Machine CM-2 with 16K processors.

Davis, Larry S.↗

NASA NTRSDate not supplied

A Science-Focused Artificial Intelligence (AI) Responding in Real-Time to New Information: Capability Demonstration for Ocean World Missions

Introduction: Artificial intelligence (AI) has long been considered a potential mechanism to explore increasingly challenging environments, including those with extreme temperatures and pressures, limited communication capabilities, or those with demanding terrain. We posit that missions in extreme environments could deploy an onboard AI focused on science observations and goals in order to augment a traditional concept(s) of operations (ConOps). An onboard AI capability could perform functions such as data analysis in order to make high-level decisions, including prioritized data transmission for analysis by ground-based teams or autonomously-guided follow-on analyses that maximize science return. Such a capability would empower missions to respond to scientific data of interest in real-time; a mission could make observations and perform a preliminary analysis to alert ground-based scientists to an observation of interest, enabling an informed, rapid response from Earth-based teams. Enceladus Case Study for Onboard AI: We are developing an onboard AI capability for real-time telemetry response that formulates and carries-out informed decisions in service to established mission goals, enabling increased science return of a mission. We focus our AI development for use on a constellation of SmallSats orbiting Enceladus. Our Enceladus case study tests autonomous decision-making capabilities in scenarios with complex orbital dynamics, plume ejecta, extreme cold environments, power restrictions, and a requirement to maximize science return for a potential positive detection of life, while critically evaluating the potential for false positives. Telemetry includes simulated scientific data, spacecraft onboard operational data (e.g., position, velocity, and rotation), and engineering hardware performance data. Enceladus SmallSat Constellation. Our constellation includes eight SmallSat spacecraft in an 8:35 resonant orbit-based formation, leveraging Saturn’s gravitational forces to maintain stable orbits with global coverage around Enceladus. To our knowledge, we simulate the first stable configuration of multiple spacecraft in closed orbits around Enceladus, using a full ephemeris force model (Russell and Lara, 2009). Each spacecraft’s orbit will precess, causing an eastward ground track shift (from an orbiter’s perspective) of each spacecraft for each orbit. However, all spacecraft return to their original positions relative to Enceladus after eight Enceladus revolutions around Saturn. We model communication pathways between SmallSats to understand how information would need to be transmitted across the constellation to enable AI-driven decision-making and resource allocation across the fleet. Capability Demonstration. Our simulated capability demonstration inputs position, velocity, and rotation telemetry from our Enceladus-focused constellation simulations, and mass spectrometry data collected from abiotic and biotic laboratory-analog ocean world experiments (Theiling et al., 2018; Theiling, 2021; Da Poian et al., 2023). Data from these experiments are used to simulate MS measurements and different scenarios of science observations for onboard analysis performed on each of the eight spacecraft. For these demonstrations, we integrate 24 machine learning (ML) algorithms into an onboard intelligence as a ‘knowledge base’, including algorithms evaluating data quality and those predicting (with % confidence) gas composition, ocean aqueous chemistry, and whether the sample was influenced by microbial life. The onboard AI capability is designed to use the knowledge base to come to a consensus-based decision in the interpretation of the observed data in order to request additional action outside of a pre-defined ConOps. Requested actions could include e.g., prioritized downlink to Earth (for analysis by ground-based teams) or follow-on analyses performed across the constellation. The spacecraft’s intelligent onboard planner must then determine whether sufficient resources (e.g., time, power, etc.) are available and weigh the request with mission priorities. In our simulation, the constellation is able to identify potential biosignatures using onboard ML algorithms, evaluate the confidence of that prediction, and perform follow-on analyses across the fleet to confirm the detection, in order to best prepare a transmission of these data to Earth-based teams.

astrobiology↗

NASA NTRS1974

The response of rotating machinery to external random vibration

A high-speed turbogenerator employing gas-lubricated hydrodynamic journal and thrust bearings was subjected to external random vibrations for the purpose of assessing bearing performance in a dynamic environment. The pivoted-pad type journal bearings and the step-sector thrust bearing supported a turbine-driven rotor weighing approximately twenty-one pounds at a nominal operating speed of 36,000 rpm. The response amplitudes of both the rigid-supported and flexible-supported bearing pads, the gimballed thrust bearing, and the rotor relative to the machine casing were measured with capacitance type displacement probes. Random vibrations were applied by means of a large electrodynamic shaker at input levels ranging between 0.5 g (rms) and 1.5 g (rms). Vibrations were applied both along and perpendicular to the rotor axis. Response measurements were analyzed for amplitude distribution and power spectral density. Experimental results compare well with calculations of amplitude power spectral density made for the case where the vibrations were applied along the rotor axis. In this case, the rotor-bearing system was treated as a linear, three-mass model.

Tessarzik, J. M.↗

NASA NTRS1994

Sub-ply level scaling approach investigated for graphite-epoxy composite beam columns

Scale model graphite-epoxy composite specimens were fabricated using the 'sub-ply level' approach and tested as beam-columns under an eccentric axial load to determine the effect of specimen size on flexural response and failure. In the current research project, although the fiber diameters are not scaled, the thickness of the pre-preg material itself has been scaled by adjusting the number of fibers through the thickness of a single ply. Three different grades of graphite-epoxy composite material (AS4/3502) were obtained from Hercules, Inc., in which the number of fibers through the thickness of a single ply was reduced (Grade 190 with 12 to 16 fibers, Grade 95 with 6 to 8 fibers, and Grade 48 with 3 to 4 fibers). Thus, using the sub-ply level approach, a baseline eight ply quasi-isotropic laminate could be fabricated using either the Grade 48 or Grade 95 material and the corresponding full-scale laminate would be constructed from Grade 95 or standard Grade 190 material, respectively. Note that in the sub-ply level approach, the number of ply interfaces is constant for the baseline and full-scale laminates. This is not true for the ply level and sublaminate level scaled specimens. The three grades of graphite-epoxy composite material were used to fabricate scale model beam-column specimens with in-plane dimensions of 0.5*n x 5.75*n, where n=1,2,4 corresponsing to 1/4, 1/2, and full-scale factors. Angle ply, cross ply, and quasi-isotropic laminate stacking sequences were chosen for the investigation and the test matrices for each laminate type are given. Specimens in each laminate family with the same in-plane dimensions but different thicknesses were tested to isolate the influence of the thickness dimension on the flexural response and failure. Also, specific lay-ups were chosen with blocked plies and dispersed plies for each laminate type. Specimens were subjected to an eccentric axial load until failure. The load offset was introduced through a set of hinges which were attached to the platens of a standard load test machine. Three sets of geometrically scaled hinges were used to ensure that scaled loading conditions were applied. This loading condition was chosen because it promotes large flexural deformations and specimens fail at the center of the beam, away from the grip supports. Five channels of data including applied vertical load, end shortening displacement, strain from gages applied back-to-back at the midspan of the beam, and rotation of the hinge from a bubble inclinometer were recorded for each specimen. The beam-column test configuration was used previously to study size effects in ply level scaled composite specimens of the same material system, sizes, and stacking sequences. Thus, a direct comparison between the two scaling approaches is possible. Ply level scaled beam-columns with angle ply, cross ply, and quasi-isotropic lay-ups exhibited no size dependencies in the flexural response, but significant size effects in strength. The reduction in strength with increasing specimen size was not predicted successfully by analysis techniques. It is anticipated that results from this investigation will lead to a better understanding of the strength scale effect in composite structures.

Jackson, Karen E.↗