Neutron activation analysis of rhenium and osmium in Apollo 11 lunar material
Neutron activation analysis for Re and Os in Apollo 11 volcanic rocks, discussing possible meteoritic contamination of secondary rocks and fines
Butterfield, D.↗
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AERoBOND Project Summary
Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.
Frank Louis Palmieri↗
Regolith Particle Erosion of Material in Aerospace Environments
This paper studies the effect of exposing thermal control S13GP:6N/LO-I white paint, Kapton flex cable, fiber optic cable, HEPA filter, and M55J graphite composite to high-velocity regolith environment that spacecraft landing on Mars are commonly exposed to. Due to the similarity between the Mars 2020 Rover design and Mars Science Laboratory design, it is expected that the Mars 2020 rover will be exposed to a similar high-speed regolith environment that the Mars Science Laboratory was exposed to. This environment is replicated to test the survivability of susceptible materials. The testing is performed at the University of Dayton Research Institute in Dayton, Ohio. The experiments expose different materials to basaltic–like particles ranging in size from approximately 40 μm to 2 cm, at velocities ranging from 19 m/s to 250 m/s, with varied particle fluxes (measured in mg/cm2). Depending on the size of the particle used, the particles can either embed in or erode the material. Posttest analysis shows that all materials tested will survive the expected environment observed during the Mars 2020 landing event. Some materials are tested to failure in order to better characterize material response. Materials that fail in some test scenarios include the paint, fiber optic cable, and the graphite composite. After being exposed to regolith, the α/ε ratio of the paint increased by ~37% due to particles embedding in the paint. Darkening of the paint can negatively affect thermal control of the rover. With high particle mass fluxes, the paint eventually degraded enough to expose the aluminum substrate. When impacted by a 1.5 cm particle traveling at 20 m/s, the fiber optic cable did not sever, but the impact did cause the cable to deform enough to crack the glass, which resulted in a significant increase in attenuation, rendering the cable unable to transmit data. The graphite composite also failed when exposed to high particle fluxes. All of the observed failures occurred for test cases above the expected landing environment with significant margin. Tests performed beyond the requirements help characterize how well these materials will survive in even more extreme environments for future missions.
Abid, Mohamed↗
Nondestructive Evaluation Correlated with Finite Element Analysis
Advanced materials are being developed for use in high-temperature gas turbine applications. For these new materials to be fully utilized, their deformation properties, their nondestructive evaluation (NDE) quality and material durability, and their creep and fatigue fracture characteristics need to be determined by suitable experiments. The experimental findings must be analyzed, characterized, modeled and translated into constitutive equations for stress analysis and life prediction. Only when these ingredients - together with the appropriate computational tools - are available, can durability analysis be performed in the design stage, long before the component is built. One of the many structural components being evaluated by the NDE group at the NASA Lewis Research Center is the flywheel system. It is being considered as an energy storage device for advanced space vehicles. Such devices offer advantages over electrochemical batteries in situations demanding high power delivery and high energy storage per unit weight. In addition, flywheels have potentially higher efficiency and longer lifetimes with proper motor-generator and rotor design. Flywheels made of fiber-reinforced polymer composite material show great promise for energy applications because of the high energy and power densities that they can achieve along with a burst failure mode that is relatively benign in comparison to those of flywheels made of metallic materials Therefore, to help improve durability and reduce structural uncertainties, we are developing a comprehensive analytical approach to predict the reliability and life of these components under these harsh loading conditions. The combination of NDE and two- and three-dimensional finite element analyses (e.g., stress analyses and fracture mechanics) is expected to set a standardized procedure to accurately assess the applicability of using various composite materials to design a suitable rotor/flywheel assembly.
Abdul-Azid, Ali↗
A Materials Compatibility and Thermal Stability Analysis of Common Hydrocarbon Fuels
A materials compatibility and thermal stability investigation was conducted using five common liquid hydrocarbon fuels and two structural materials. The tests were performed at the NASA Glenn Research Center Heated Tube Facility under environmental conditions similar to those encountered in regeneratively cooled rocket engines. Scanning-electron microscopic analysis in conjunction with energy dispersive spectroscopy (EDS) was utilized to characterize the condition of the tube inner wall surface and any carbon deposition or corrosion that was formed during selected runs. Results show that the carbon deposition process in stainless steel tubes was relatively insensitive to fuel type or test condition. The deposition rates were comparable for all fuels and none of the stainless steel test pieces showed any signs of corrosion. For tests conducted with copper tubing, the sulfur content of the fuel had a significant impact on both the condition of the tube wall and carbon deposition rates. Carbon deposition rates for the lowest sulfur fuels (2 ppm) were slightly higher than those recorded in the stainless steel tubes with no corrosion observed on the inner wall surface. For slightly higher sulfur content (25 ppm) fuels, nodules that intruded into the flow area were observed to form on the inner wall surface. These nodules induced moderate tube pressure drop increases. The highest sulfur content fuels (400 ppm) produced extensive wall pitting and dendritic copper sulfide growth that was continuous along the entire tube wall surface. The result of this tube degradation was the inability to maintain flow rate due to rapidly increasing test section pressure drops. Accompanying this corrosion were carbon deposition rates an order of magnitude greater than those observed in comparable stainless steel tests. The results of this investigation indicate that trace impurities in fuels (i.e. sulfur) can significantly impact the carbon deposition process and produce unacceptable corrosion levels in copper based structural materials.
Meyer, M. L.↗
Molecular shield - An orbiting low-density materials laboratory
Analysis of a molecular shield orbited at 200 km utilizes the kinetic theory of a drifting Maxwellian gas, applied to a hemispherical shell geometry containing internal sources. The molecular shield provides very low gas density conditions for materials experiments at low gravity, while the hemispherical geometry minimizes the internal surface/volume ratio. Deployment of the shield in orbit is described. Contributions to density by shield outgassing, by experiment outgassing, and by interaction with the orbiter are discussed separately. A jettisonable closure plate sealing the hemisphere minimizes any risk of experiment contamination during deployment.
Melfi, L. T., Jr.↗
Multispectral analysis of ocean dumped materials
Remotely sensed data were collected in conjunction with sea-truth measurements in three experiments in the New York Bight. Pollution features of primary interest were ocean dumped materials, such as sewage sludge and acid waste. Sewage-sludge and acid-waste plumes, including plumes from sewage sludge dumped by the 'line-dump' and 'spot-dump' methods, were located, identified, and mapped. Previously developed quantitative analysis techniques for determining quantitative distributions of materials in sewage sludge dumps were evaluated, along with multispectral analysis techniques developed to identify ocean dumped materials. Results of these experiments and the associated data analysis investigations are presented and discussed.
Johnson, R. W.↗
DENNIS: a design and analysis tool for dynamic material x-ray diffraction experiments
We present DENNIS (Diffraction Experiment desigN and aNalysiS): a graphical software tool useful for the design and analysis of dynamic x-ray diffraction experiments, such as those performed on the Z Pulsed Power Facility, Thor Pulsed Power Generator, and Dynamic Compression Sector (DCS) of the Advanced Photon Source. DENNIS provides rapid powder and single-crystal diffraction pattern predictions and powder diffraction pattern image integration in three-dimensional geometries. Additional features include crystallographic information file reading, image processing, and synthetic diffraction pattern image generation. We overview the software's capabilities, detail the prediction and integration methodologies, and provide example implementations on Z and DCS experiments.
47 OTHER INSTRUMENTATION↗
Development of chemical analysis techniques for advanced materials research program second quarterly progress report, mar. 1 - may 31, 1965
Impurity analysis of nonconductors and gases by spark-source mass spectrography techniques
GAS↗
Analysis of Microcrafters in Materials Specimens after Long-Term Exposure on ISS Surface
The "Komplast" experiment has been carried out on the ISS by the Khrunichev Space Center jointly with other Russian scientific centers since 1998. The experiment incorporates the "Komplast" cartridges on the FGB exterior, which are fitted with materials specimens and sensors. The cartridges were sent into orbit together with FGB on 20 November 1998. In March 2011, two of the cartridges were taken back from the ISS by the "Discovery" American space shuttle after being exposed in the open space for 12 years. In the framework of this experiment the subject of analysis is the effect of the space environment on the exposed specimens of various materials. This report covers the analysis results of the surface morphology of various materials taken from the "Komplast" cartridges exposed to hits of micrometeors and micronic particles of space debris. Analysis is made of microcraters of 5 to 250 mcm in specimens of polished metals and silicone comprised in the sensor for micrometeoric particles. The report represents optic and scanning electron microscope images of craters formed in the specimens by high-velocity and low-velocity particles impacting the surface. By virtue of the electronic microscope, data on composition of the substance in the craters and of the substance of the low-velocity particles are obtained. The data make it possible to differentiate the particles as the natural-origin particles or anthropogenic-origin space debris particles. Distribution of craters and low-velocity particles in the size range of 5 to 50 mcm is obtained. The data are compared with the existing models of fluxes of natural-origin and artificial-origin microparticles on the ISS orbit. Inhomogeneous particles of complicated configuration are discovered on the surface of the analyzed specimens, whose origin are not uniquely determined and are to be the subject of further study.
Shaevich, S. K.↗
Report of the NASA Ad Hoc Committee on failure of high strength structural materials
An analysis of structural failures that have occurred in NASA programs was conducted. Reports of 231 examples of structural failure were reviewed. Attempts were made to identify those factors which contributed to the failures, and recommendations were formulated for actions which would minimize their effects on future NASA programs. Two classes of factors were identified: (1) those associated with deficiencies in existing materials and structures technology and (2) those attributable to inadequate documentation or communication of that technology.
Brown, W. F., Jr.↗
Critical impact of experimentally-driven strut level anisotropic material models in advanced stress analysis of additively manufactured lattice structures
The rapid acceleration in materials discovery may overshadow the importance of thoroughly understanding the mechanical performance of newly developed materials in demanding environments. The recent interest in combining parametric studies with machine learning techniques to explore how changes in specific processing parameters or model inputs affect the overall behavior of a material system can only be truly beneficial if the governing constitutive relations describing material behavior are accurately established. In this study, we demonstrate the critical impact of accurately representing strut-level anisotropic material behavior in advanced stress analysis of additively manufactured lattice structures (AMLS). We introduce a systematic experimental and modeling approach for developing strut-level anisotropic elastoplastic material models that account for the influence of microstructural features such as porosity, texture, and surface roughness on the development of local anisotropic mechanical properties, which vary with strut orientation relative to the build direction (BD). As a result the presented material model captures and relates the statistics of spatially varying struts’ microstructural features to the local stress distribution. Our findings suggest that incorporating strut-level anisotropic material behavior into unit cell analysis significantly influences the load distribution and evolution of local stresses within the structure. Therefore, accounting for this anisotropy is critical for developing an understanding of unit cell behavior and performance, including subsequent topology/component design optimization based on this analysis.
Sahoo, Subhadip [University of Arizona]↗
Numerical analysis of the Iosipescu specimen for composite materials
A finite element analysis of the Iosipescu shear tests for unidirectional and cross-ply composites is presented. It is shown that an iterative analysis procedure must be used to model the fixture-specimen kinematics. The correction factors which are needed to compensate for the nonuniformity of stress distribution in calculating shear modulus are shown to be dependent on the material orthotropic ratio and the finite element loading models. Test section strain distributions representative of typical graphite-epoxy specimens are also presented.
Ho, H.↗
Numerical analysis of the Iosipescu specimen for composite materials
A finite element analysis of the Iosipescu shear tests for unidirectional and cross-ply composites is presented. It is shown that an iterative analysis procedure must be used to model the fixture-specimen kinematics. The correction factors which are needed to compensate for the nonuniformity of stress distribution in calculating shear modulus are shown to be dependent on the material orthotropic ratio and the finite element loading models. Test section strain distributions representative of typical graphite-epoxy specimens are also presented.
Ho, H.↗
Development of chemical analysis techniques for Advanced Materials Research Program Third quarterly progress report, Jun. 1 - Aug. 31, 1965
Mass spectrographic impurity analysis of magnesium oxide powders and compacts
MAGNESIUM OXIDE↗
Apollo 11 evidence for the differentiation of lunar materials
Comparative analysis of lunar rocks from Apollo 11 flight with respect to terrestrial rocks and meteorites
Mueller, R. F.↗
Analytical and numerical investigation of structural response of compliant wall materials
Theoretical analysis of an electrostatically driven wall system for a compliant wall drag reduction program is reported. The electrostatic wall system is capable of producing deflections of many orders greater than the thicknesses and at small wavelengths. An intermediate large response theory was used for structural analysis. The theoretical predictions were compared to bench test results, and good agreement between the two was obtained. The effects of aerodynamic loads and perturbation electric fields on the theoretical solutions were considered. It was shown that for very small wavelengths (approximately 2mm) the aerodynamic effects can be estimated using potential theory without loss of accuracy, and the perturbation electric fields do not affect solutions as long as the deflections are less than one percent of the wavelength. Resonance effects for this type of structure were shown to be fairly small.
Goglia, G. L.↗
PARCEQ2D heat transfer grid sensitivity analysis
The material presented in this paper is an extension of two-dimensional Aeroassist Flight Experiment (AFE) results shown previously. This study has focused on the heating rate calculations to the AFE obtained from an equilibrium real gas code, with attention placed on the sensitivity of grid dependence and wall temperature. Heat transfer results calculated by the PARCEQ2D code compare well with those computed by other researchers. Temperature convergence in the case of kinetic transport has been accomplished by increasing the wall temperature gradually from 300 K to the wall temperature of 1700 K.
Saladino, Anthony J.↗