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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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At least 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Effect of Buckling Modes on the Fatigue Life and Damage Tolerance of Stiffened Structures

The postbuckling response and the collapse of composite specimens with a co-cured hat stringer are investigated experimentally and numerically. These specimens are designed to evaluate the postbuckling response and the effect of an embedded defect on the collapse load and the mode of failure. Tests performed using controlled conditions and detailed instrumentation demonstrate that the damage tolerance, fatigue life, and collapse loads are closely tied with the mode of the postbuckling deformation, which can be different between two nominally identical specimens. Modes that tend to open skin/stringer defects are the most damaging to the structure. However, skin/stringer bond defects can also propagate under shearing modes. In the proposed paper, the effects of initial shape imperfections on the postbuckling modes and the interaction between different postbuckling deformations and the propagation of skin/stringer bond defects under quasi-static or fatigue loads will be examined.

Davila, Carlos G.↗
NASA NTRS1976

Advanced composites: Fabrication processes for selected resin matrix materials

This design note is based on present state of the art for epoxy and polyimide matrix composite fabrication technology. Boron/epoxy and polyimide and graphite/epoxy and polyimide structural parts can be successfully fabricated. Fabrication cycles for polyimide matrix composites have been shortened to near epoxy cycle times. Nondestructive testing has proven useful in detecting defects and anomalies in composite structure elements. Fabrication methods and tooling materials are discussed along with the advantages and disadvantages of different tooling materials. Types of honeycomb core, material costs and fabrication methods are shown in table form for comparison. Fabrication limits based on tooling size, pressure capabilities and various machining operations are also discussed.

Welhart, E. K.↗
NASA NTRS2000

Composite Flywheels Assessed Analytically by NDE and FEA

As an alternative to expensive and short-lived lead-acid batteries, composite flywheels are being developed to provide an uninterruptible power supply for advanced aerospace and industrial applications. Flywheels can help prevent irregularities in voltage caused by power spikes, sags, surges, burnout, and blackouts. Other applications include load-leveling systems for wind and solar power facilities, where energy output fluctuates with weather. Advanced composite materials are being considered for these components because they are significantly lighter than typical metallic alloys and have high specific strength and stiffness. However, much more research is needed before these materials can be fully utilized, because there is insufficient data concerning their fatigue characteristics and nonlinear behavior, especially at elevated temperatures. Moreover, these advanced types of structural composites pose greater challenges for nondestructive evaluation (NDE) techniques than are encountered with typical monolithic engineering metals. This is particularly true for ceramic polymer and metal matrix composites, where structural properties are tailored during the processing stages. Current efforts involving the NDE group at the NASA Glenn Research Center at Lewis Field are focused on evaluating many important structural components, including the flywheel system. Glenn's in-house analytical and experimental capabilities are being applied to analyze data produced by computed tomography (CT) scans to help assess the damage and defects of high-temperature structural composite materials. Finite element analysis (FEA) has been used extensively to model the effects of static and dynamic loading on aerospace propulsion components. This technique allows the use of complicated loading schemes by breaking the complex part geometry into many smaller, geometrically simple elements.

Abdul-Aziz, Ali↗
NASA NTRS2008

Friction Stir Welding

Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and promises to be an important welding process for any industries where welds of optimal quality are demanded. This article provides an introduction to the FSW process. The chief concern is the physical effect of the tool on the weld metal: how weld seam bonding takes place, what kind of weld structure is generated, potential problems, possible defects for example, and implications for process parameters and tool design. Weld properties are determined by structure, and the structure of friction stir welds is determined by the weld metal flow field in the vicinity of the weld tool. Metal flow in the vicinity of the weld tool is explained through a simple kinematic flow model that decomposes the flow field into three basic component flows: a uniform translation, a rotating solid cylinder, and a ring vortex encircling the tool. The flow components, superposed to construct the flow model, can be related to particular aspects of weld process parameters and tool design; they provide a bridge to an understanding of a complex-at-first-glance weld structure. Torques and forces are also discussed. Some simple mathematical models of structural aspects, torques, and forces are included.

Nunes, Arthur C., Jr.↗
NASA NTRS2003

Low Temperature SQUID for NDE Applications

We have developed a low temperature SuperConducting Quantum Interference Device - SQUID measurement system for detection of defects deep under the surface of aluminum structures using eddy current techniques. The system uses a two dimensional planar inducer with two different excitation frequencies to induce a current in the sample. We have developed a data analysis software program that enabled us to distinguish between round defects (holes), straight defects (slots) and slots close to holes simulating cracks starting from rivets in aluminum structures. We were able to detect defects that are 8mm below the surface. We have also measured the change in phase of the detected signal as a function of depth of the defect. This relationship can be used to determine the depth of hidden flaws. Using this analysis software with the high temperature SQUID system at NASA Langley we were able to detect slots close to holes in layered aluminum sample.

Wincheski, Buzz↗
NASA NTRS1985

Damage and Repair of Composite Structures

NASA technical memorandum reports on research in damage and repair of composite-material structures of types used in airplane. Research includes: Identifying defect areas, determining whether particular kind of damage weakens structure in manner that degrades performance in intended application, developing repair procedures, and testing to demonstrate given repair procedure enables component to serve during remainder of its design life.

Deaton, J. W.↗
NASA NTRS2004

Superalloy Lattice Block Structures

Initial investigations of investment cast superalloy lattice block suggest that this technology will yield a low cost approach to utilize the high temperature strength and environmental resistance of superalloys in lightweight, damage tolerant structural configurations. Work to date has demonstrated that relatively large superalloy lattice block panels can be successfully investment cast from both IN-718 and Mar-M247. These castings exhibited mechanical properties consistent with the strength of the same superalloys measured from more conventional castings. The lattice block structure also accommodates significant deformation without failure, and is defect tolerant in fatigue. The potential of lattice block structures opens new opportunities for the use of superalloys in future generations of aircraft applications that demand strength and environmental resistance at elevated temperatures along with low weight.

Nathal, M. V.↗
NASA NTRSDate not supplied

Developing Approaches for Certification of Uninspectable Fracture Critical AM Components

Introduction - Human-rated spaceflight hardware is subject to the Fracture Control requirements in NASA-STD5019, which are intended to control the risk of component failure due to undetected cracks or defects. - All hardware in this mission class is classified for Fracture Control – Exempt, Non-fracture Critical, or Fracture Critical - Fracture Critical: A classification that identifies a part where failure due to the presence of a crack is a catastrophic hazard ➔ Pressure vessels, engine components, primary structure, etc. - Axiom 1: Material and manufacturing process produce structures and components with cracks or defects. - Axiom 2: The presence of a crack or defect of sufficient size reduces the strength and life of the structure. - Damage Tolerance: demonstration that a component can survive the service life (with a safety factor) in the presence of an undetected flaw or damage. - Components are manufactured from aerospace quality materials using controlled processes. - Components are inspected for damage (cracks, flaws, defects, etc.). - Components are shown by test or analysis to be tolerant to undetected flaws.

Will Tilson↗
NASA NTRS1996

An Analysis of the Magneto-Optic Imaging System

The Magneto-Optic Imaging system is being used for the detection of defects in airframes and other aircraft structures. The system has been successfully applied to detecting surface cracks, but has difficulty in the detection of sub-surface defects such as corrosion. The intent of the grant was to understand the physics of the MOI better, in order to use it effectively for detecting corrosion and for classifying surface defects. Finite element analysis, image classification, and image processing are addressed.

Nath, Shridhar↗
NASA NTRSDate not supplied

Next Generation Durability and Damage Tolerance to Support Certification of Flight Hardware

Durability and Damage Tolerance (D&DT), as currently applied to flight hardware throughout the Agency, is based on continuum and similitude assumptions and does not consider local material properties, environments and responses. These limitations impact our ability to support certification of new component designs, material systems and manufacturing approaches. The primary concern in this Engineering R&A plan is related to the imminent proliferation of parts produced by additive manufacturing (AM). These parts are being advocated by NASA’s suppliers for use on a myriad of flight hardware because of their design flexibility and cost advantages. AM provides opportunities to reduce part counts through complex geometry and reduce manufacturing costs of low volume parts. However, AM materials have some notable metallurgical and microstructural differences compared to traditionally fabricated materials. One of the challenges for the acceptance of AM is the greater tendency for a deleterious defect state, most commonly in the form of porosity, to exist in AM parts. Though this defect state is typically reduced through a hot isostatic pressing (HIP) processing step, the structural performance risks associated with the remaining defects and HIP-healed features is not known. Potential fracture control issues that must be resolved stem from the real possibility that an unhealed defect or a closed defect with less than pristine strength remains at a fracture critical location after HIP. As a result, NASA and the entire aerospace community have been confronted with the need to develop a robust and relevant certification methodology to enable safe implementation of these components. The present work is an important step toward positioning NASA to credibly respond to vendors’ push to implement this new AM materials technology by improving our understanding of AM processing and performance and transitioning that research-based understanding to next-generation engineering capabilities.

Edward H Glaessgen↗
NASA NTRS1999

Damage Tolerance of Large Shell Structures

Progressive damage and fracture of large shell structures is investigated. A computer model is used for the assessment of structural response, progressive fracture resistance, and defect/damage tolerance characteristics. Critical locations of a stiffened conical shell segment are identified. Defective and defect-free computer models are simulated to evaluate structural damage/defect tolerance. Safe pressurization levels are assessed for the retention of structural integrity at the presence of damage/ defects. Damage initiation, growth, accumulation, and propagation to fracture are included in the simulations. Damage propagation and burst pressures for defective and defect-free shells are compared to evaluate damage tolerance. Design implications with regard to defect and damage tolerance of a large steel pressure vessel are examined.

Minnetyan, L.↗
NASA NTRS1979

Evaluation of flawed composite structural components under static and cyclic loading

The effects of initial defects on the fatigue and fracture response of graphite-epoxy composite laminates are presented. The structural laminates investigated were a typical angle ply laminate, a polar/hoop wound pressure vessel laminate, and a typical engine fan blade laminate. Defects investigated were full and half penetration circular holes, full and half penetration slits, and countersink holes. The effects of the defect size and type on the static fracture strength, fatigue performance, and residual static strength are shown as well as the results of loadings on damage propagation in composite laminates. The data obtained were used to define proof test levels as a qualification procedure in composite structure subjected to cyclic loading.

Porter, T. R.↗
NASA NTRS2001

Detection and Characterization of Imperfections in Composite Pressure Vessels

The thermographic evaluation of composite structures for delaminations, disbonds, inclusions, porosity and microcracking has proven to be a valuable asset in the field of nondestructive testing. Coupling large area coverage, variable sensitivity and minimal surface contact with a photographic type image representation of structural anomalies; thermography has become a primary inspection method for composite structures. Thermography works well for locating both surface and subsurface defects in most composite systems ranging in thickness of up to 0.25 inch (0.64 cm) or more. The thermographic method for inspection of composite structures typically involves applying an external source of heat to the structure and then recording the changes in the surface heat profile manifested by embedded defects or by material property variations. If these temperature variations are large enough and an infrared camera with sufficient sensitivity is used, then the material or structural abnormality can be detected and referred back to its source. Interpreting the information given in a thermogram, can be a difficult task under ideal circumstances and extremely challenging in a real world setting. Variables including depth, thermal conductivity, orientation and size of the abnormality can all have a great influence on how its heat pattern will be seen by the imager. The work discussed in this paper illustrates how the microstructure of several commonly found defects in composite structures relate to their thermographic image counterpart. Two test cases are studied herein, including a large graphite/epoxy RP-1 fuel tank and a graphite composite cryogenic fuel feedline. The structures used in this study were designed to serve as manufacturing proof of concept specimens and to undergo hydroburst testing to verify manufacturing practices and structural design. Prior to hydrostatic testing the structures underwent 100% thermographic evaluation to ensure that no manufacturing or handling damage was present. Due to a large inclusion found in the feedline, it was pulled from service and dissected without performing the hydroproof The thermographic indications found in the RP-1 tank were below critical limits so it underwent a complete hydroproof loading series and finally a hydroburst. Following the hydroburst samples were cut from the tank in regions where thermography had located damage before the test. These regions were thermographically and then were cross-sectioned and photomicrographed.

Walker, James L.↗
NASA NTRS1978

Defect distribution near the surface of electron-irradiated silicon

The surface-defect distributions of electron-irradiated n-type silicon have been investigated using a transient capacitance technique. Schottky, p-n junction, and MOS structures were used in profiling the defect distributions. Surface depletions of defects observed were attributed to the vacancy distribution, but not that of oxygen, and other capture centers' distributions. The vacancy diffusion length at 300 K was estimated to be about 3-6 microns.

Wang, K. L.↗
NASA NTRS1984

Defect interactions in GaAs single crystals

The two-sublattice structural configuration of GaAs and deviations from stoichiometry render the generation and interaction of electrically active point defects (and point defect complexes) critically important for device applications and very complex. Of the defect-induced energy levels, those lying deep into the energy band are very effective lifetime ""killers". The level 0.82 eV below the condition band, commonly referred to as EL2, is a major deep level, particularly in melt-grown GaAs. This level is associated with an antisite defect complex (AsGa - VAS). Possible mechanisms of its formation and its annihilation were further developed.

Gatos, H. C.↗
NASA NTRS1978

Effect of copper impurity on polycrystalline silicon solar cells

The presence of copper impurity, up to 10 to the 15th atoms/cc, in single crystal silicon has been shown to have no deleterious effect on the p-n junction solar cell performance. However, in polycrystalline silicon, copper atoms tend to migrate to the defect sites because of the structural sensitive properties of copper. This study was undertaken to investigate the influence of this behavior of copper impurity on the performance of p-n junction solar cells fabricated from structurally imperfect silicon. Two sets of polycrystalline silicon substrates containing copper were examined. In one set of samples, copper was incorporated during growth, whereas in the other, copper was diffused. Solar cells were fabricated on both the sets of substrates by a standard process. Dark and light I-V and spectral response characteristics of the cells were measured and compared with copper-free polycrystalline silicon solar cells. The results and the model are discussed.

Daud, T.↗
NASA NTRS1987

Self-Stabilizing Storage Loops for Magnetic-Bubble Memories

Adjacent, sinusoidal loops provide defect-tolerant, self-stabilizing structures. New technology consists of three components providing self-stabilizing structures. First, apertures positioned so bubbles propagate alternately into hexagonally related positions and directly opposed positions; addition of straight barriers by ion milling or implantation of garnet adds transverse stability but leaves longitudinally metastable postions. Second, modification of barrier to sinusoidal shape provides "energy wells" in longitudinal direction at opposed positions and eliminates metastability. Third, positioning and phasing of counterrotating storage loops, provide stable hexagonal support between adjacent loops.

Nelson, Gary L.↗