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Results for “STRETCH FORMING”

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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Effects of Annealing Process on the Formability of Friction Stir Welded Al-Li Alloy 2195 Plates

Large rocket cryogenic tank domes have typically been fabricated using Al-Cu based alloys like Al-Cu alloy 2219. The use of aluminum-lithium based alloys for rocket fuel tank domes can reduce weight because aluminum-lithium alloys have lower density and higher strength than Al-Cu alloy 2219. However, Al-Li alloys have rarely been used to fabricate rocket fuel tank domes because of the inherent low formability characteristic that make them susceptible to cracking during the forming operations. The ability to form metal by stretch forming or spin forming without excessive thinning or necking depends on the strain hardening exponent "n". The stain hardening exponent is a measure of how rapidly a metal becomes stronger and harder. A high strain hardening exponent is beneficial to a material's ability to uniformly distribute the imposed strain. Marshall Space Flight Center has developed a novel annealing process that can achieve a work hardening exponent on the order of 0.27 to 0.29, which is approximately 50% higher than what is typically obtained for Al-Li alloys using the conventional method. The strain hardening exponent of the Al-Li alloy plates or blanks heat treated using the conventional method is typically on the order of 0.17 to 0.19. The effects of this novel annealing process on the formability of friction stir welded Al-Li alloy blanks are being studied at Marshall Space Flight Center. The formability ratings will be generated using the strain hardening exponent, strain rate sensitivity and forming range. The effects of forming temperature on the formability will also be studied. The objective of this work is to study the deformation behavior of the friction stir welded Al-Li alloy 2195 blank and determine the formability enhancement by the new annealing process.

Chen, Po-Shou↗
NASA NTRS2015

Aluminum 2195 T8 Gore Development for Space Launch System Core and Upper Stage

Gores are pie-shaped panels that are welded together to form the dome ends of rocket fuel tanks as shown in figure 1. Replacing aluminum alloy 2219 with aluminum (Al)-lithium (Li) alloy 2195 as the Space Launch System (SLS) cryogenic tank material would save enormous amounts of weight. In fact, it has been calculated that simply replacing Al 2219 gores with Al 2195 gores on the SLS core stage domes could save approximately 3,800 pound-mass. This is because the Al-Li 2195 alloy exhibits both higher mechanical properties and lower density than the SLS baseline Al 2219 alloy. Indeed, the known advantages of Al 2195 led to its use as a replacement for Al 2219 in the shuttle external tank program. The required thicknesses of Al 2195 gores for either SLS core stage tanks or upper stage tanks will depend on the specific design configurations. The required thicknesses or widths may exceed the current experience base in the manufacture of such gores by the stretch-forming process. Accordingly, the primary objective of this project was to enhance the formability of Al 2195 by optimizing the heat treatment and stretch-forming process for gore thicknesses up to 0.75 inches, which envelop the maximum expected gore thicknesses for SLS tank configurations.

Volz, Martin↗
NASA NTRS1985

On the differences in continental rifting at the Earth, Mars and Venus

During the process of continental rifting on Earth, the lower ductile crust stretches, forming a neck, while the upper brittle crust is broken in blocks by faults, and the blocks sink down the thinned lower crust; if the stretching continues, the neck may break and a newly originated oceanic crust is formed at this place. The rift system structure depends on the depth of the boundary surface between the brittle crust and the ductile crust, the litospheric thickness, the tension value, etc.. The rigid brittle rifting when narrow necks form in the lower crust is characteristic of the contemporary Earth; on Mars the brittle rifting with large subsidence was characteristic of the Tharsis upland formation epoch. The ductile rifting is typical of the Venus. The differences in rheologic features of the lithospheres of different planets causes the variation in types of rifting.

Nikishin, A. M.↗
NASA NTRS1978

Method of producing complex aluminum alloy parts of high temper, and products thereof

Fully annealed aluminum sheet is first stretch formed to the complex, doubly compound shape of a previously prepared forming die, e.g., an ejection seat blowout panel of a shuttlecraft. The part is then marked with a series of grid lines for monitoring later elongation. Thereafter it is solution heat treated and refrigerated to retard hardening. While still soft, it is stretched a second time on the same die to induce a modicum of work hardening, after which it is aged to the desired stress corrosion resistant temper, preferably the T8 level, to provide the desired hardness and stress corrosion resistance.

Wilson, I. J.↗
NASA NTRS2001

Hypertonic enhancement of transmitter release from frog motor nerve terminals: Ca2+ independence and role of integrins

Hyperosmotic solutions cause markedly enhanced spontaneous quantal release of neurotransmitter from many nerve terminals. The mechanism of this enhancement is unknown. We have investigated this phenomenon at the frog neuromuscular junction with the aim of determining the degree to which it resembles the modulation of release by stretch, which has been shown to be mediated by mechanical tension on integrins.The hypertonicity enhancement, like the stretch effect, does not require Ca2+ influx or release from internal stores, although internal release may contribute to the effect. The hypertonicity effect is sharply reduced (but not eliminated) by peptides containing the RGD sequence, which compete with native ligands for integrin bonds.There is co-variance in the magnitude of the stretch and osmotic effects; that is, individual terminals exhibiting a large stretch effect also show strong enhancement by hypertonicity, and vice versa. The stretch and osmotic enhancements also can partially occlude each other.There remain some clear-cut differences between osmotic and stretch forms of modulation: the larger range of enhancement by hypertonic solutions, the relative lack of effect of osmolarity on evoked release, and the reported higher temperature sensitivity of osmotic enhancement. Nevertheless, our data strongly implicate integrins in a significant fraction of the osmotic enhancement, possibly acting via the same mechanism as stretch modulation.

Non-NASA Center↗
NASA NTRS1972

Feasibility study of applying an advanced composite structure technique to the fabrication of helicopter rotor blades

The fabrication of helicopter rotary wings from composite materials is discussed. Two composite spar specimens consisting of compressively prestressed stainless steel liner over-wrapped with pretensioned fiberglass were constructed. High liner strength and toughness together with the prescribed prestresses and final sizing of the part are achieved by means of cryogenic stretch forming of the fiber wrapped composite spar at minus 320 F, followed by release of the forming pressure and warm up to room temperature. The prestresses are chosen to provide residual compression in the metal liner under operating loads.

Gleich, D.↗
NASA NTRS1985

NASA/MSFC Large Stretch Press Study

The purpose of this study was to: A. assess and document the advantages/disadvantages of a government agency investment in a large stretch form press on the order of 5000 tons capacity (per jaw); B. develop a procurement specification for the press; and C. provide trade study data that will permit an optimum site location. Tasks were separated into four major elements: cost study, user survey, site selection, and press design/procurement specification.

Choate, M. W.↗
NASA NTRS1992

Application of advanced material systems to composite frame elements

A three phase program has been conducted to investigate DuPont's Long Discontinuous Fiber (LDF) composites. Additional tests were conducted to compare LDF composites against toughened thermosets and a baseline thermoset system. Results have shown that the LDF AS4/PEKK offers improved interlaminar (flange bending) strength with little reduction in mechanical properties due to the discontinuous nature of the fibers. In the third phase, a series of AS4/PEKK LDF C-section curved frames (representing a typical rotorcraft light frame) were designed, manufactured and tested. Specimen reconsolidation after 'stretch forming' and frame thickness were found to be key factors in this light frame's performance. A finite element model was constructed to correlate frame test results with expected strain levels determined from material property tests. Adequately reconsolidated frames performed well and failed at strain levels at or above baseline thermoset material test strains. Finally a cost study was conducted which has shown that the use of LDF for this frame would result in a significant cost savings, for moderate to large lot sizes compared with the hand lay-up of a thermoset frame.

Llorente, Steven↗
NASA NTRS2007

Inflatable Aerocapture Decelerators for Mars Orbiters

A multi-disciplinary research program was recently completed, sponsored by NASA Marshall Space Flight Center, on the subject of aerocapture of spacecraft weighing up to 5 metric tons at Mars. Heavier spacecraft will require deployable drag area beyond the dimensional limits of current and planned launch fairings. This research focuses on the approach of lightweight inflatable decelerators constructed with thin films, using fiber reinforcement and having a temperature limitation of 500 C. Trajectory analysis defines trajectories for a range of low ballistic coefficients for which convective heat flux is compatible with the material set. Fluid-Structure Interaction (FSI) tools are expanded to include the rarified flow regime. Several non-symmetrical configurations are evaluated for their capability to develop lift as part of the necessary trajectory control strategy. Manufacturing technology is developed for 3-D stretch forming of polyimide films and for tailored fiber reinforcement of thin films. Finally, the mass of the decelerator is estimated and compared to the mass of a traditional rigid aeroshell.

Brown, Glen J.↗
NASA NTRS1986

Investing in a Large Stretch Press

Press for forming large aluminum parts from plates provides substantial economies. Study assessed advantages and disadvantages of investing in large stretch-forming press, and also developed procurement specification for press.

Choate, M.↗
NASA NTRS2001

Markstein Numbers of Negatively-Stretched Premixed Flames: Microgravity Measurements and Computations

The effect of flame stretch, composed of strain and curvature, plays a major role in the propagation of turbulent premixed flames. Although all forms of stretch (positive and negative) are present in turbulent conditions, little research has been focused on the stretch due to curvature. The present study quantifies the Markstein number (which characterizes the sensitivity of the flame propagation speed to the imposed stretch rate) for an inwardly-propagating flame (IPF). This flame is of interest because it is negatively stretched, and is subjected to curvature effects alone, without the competing effects of strain. In an extension of our previous work, microgravity experiments were run using a vortex-flame interaction to create a pocket of reactants surrounded by an IPF. Computations using the RUN-1DL code of Rogg were also performed in order to explain the measurements. It was found that the Markstein number of an inwardly-propagating flame, for both the microgravity experiment and the computations, is significantly larger than that of an outwardly-propagating flame. Further insight was gained by running the computations for the simplified (hypothetical) cases of one step chemistry, unity Lewis number, and negligible heat release. Results provide additional evidence that the Markstein numbers associated with strain and curvature have different values.

Ibarreta, Alfonso F.↗
DOE OSTI2022

Surrogate models for plasma displacement and current in 3D perturbed magnetohydrodynamic equilibria in tokamaks

Abstract A numerical database of over one thousand perturbed three-dimensional (3D) equilibria has been generated, constructed based on the MARS-F (Liu et al 2000 Phys. Plasmas 7 3681) computed plasma response to the externally applied 3D field sources in multiple tokamak devices. Perturbed 3D equilibria with the n = 1–4 ( n is the toroidal mode number) toroidal periodicity are computed. Surrogate models are created for the computed perturbed 3D equilibrium utilizing model order reduction (MOR) techniques. In particular, retaining the first few eigenstates from the singular value decomposition (SVD) of the data is found to produce reasonably accurate MOR-representations for the key perturbed quantities, such as the perturbed parallel plasma current density and the plasma radial displacement. SVD also helps to reveal the core versus edge plasma response to the applied 3D field. For the database covering the conventional aspect ratio devices, about 95% of data can be represented by the truncated SVD-series with inclusion of only the first five eigenstates, achieving a relative error (RE) below 20%. The MOR-data is further utilized to train neural networks (NNs) to enable fast reconstruction of perturbed 3D equilibria, based on the two-dimensional equilibrium input and the 3D source field. The best NN-training is achieved for the MOR-data obtained with a global SVD approach, where the full set of samples used for NN training and testing are stretched and form a large matrix which is then subject to SVD. The fully connected multi-layer perceptron, with one or two hidden layers, can be trained to predict the MOR-data with less than 10% RE. As a key insight, a better strategy is to train separate NNs for the plasma response fields with different toroidal mode numbers. It is also better to apply MOR and to subsequently train NNs separately for conventional and low aspect ratio devices, due to enhanced toroidal coupling of Fourier spectra in the plasma response in the latter case.

3D equilibrium↗