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Device is fabricated from low-cost readily-available commercial-materials by automated methods utilizing conventional paper coating processes. Flexibility of unit prevents cracking and disintegration caused by electrode warpage and dendrite growth, major causes of early battery failure with present separators.
A system for sealing vacuum baked hybrids in a dry inert atmosphere using an overlapping spot resistance weld is described. A unique electrode configuration and fixturing that permits sealing of large and irregularly shaped gold plated Kovar packages to the hermeticity requirements of MIL-STD-883 was discussed. Metallurgical considerations and comparisons to laser sealing were made. Problems encountered during the development and optimization of the process were highlighted. Solutions to plating, fixturing, warpage, weld splatter and cracked bead problems are presented.
Evidence of the presence of lamination residual stresses in angleplied laminates were transply cracks and warpage of unsymmetric laminates which occur prior to application of any mechanical load. Lamination residual strains were measured using the embedded strain gage technique. These strains result from the temperature differences between cure and room temperature and vary linearly within this temperature range. Lamination residual stresses were usually present in angleplied fiber composites laminates; they were also present in unidirectional hybrids and superhybrids. For specific applications, the magnitudes of lamination residual stresses were determined and evaluated relative to the anticipated applied stresses. Particular attention was given to cyclic thermal loadings in applications where the thermal cycling takes place over a wide temperature range.
NASA Lewis Research Center research in the field of composite laminate residual stresses is reviewed and summarized. The origin of lamination residual stresses, evidence of their presence, experimental methods for measuring them, and theoretical methods for predicting them are described. Typical results are presented which show the magnitudes of residual stresses in various laminates including hybrids and superhybrids, and in other complex composite components. Results are also presented which show the effects of lamination residual stresses on laminate warpage and on laminate mechanical properties including fracture stresses. Finally, the major findings and conclusions derived therefrom are summarized.
The development of a universal closure lid for the space shuttle food package is reported. The revised lid needs a folded configuration which, when unfolded, fully conforms to the interior surfaces of the food cup. Experimental thermoform molds were fabricated and test lids formed. The lid material not in contact with the food conformed to the cup interior without wrinkles, permitting full nesting of the cups. The final lid design was established and thermoform tooling designed and fabricated. Lids formed on these molds were tested for strength. The heating elements were replaced and repositioned to eliminate any hot spots which may cause warpage.
This report documents the results of a dimensional stability analysis of seventeen stepped specimens that were used in the evaluation of factors influencing warpage in metallic alloys being used for cryogenic wind tunnel models. Specimens used in the analysis were manufactured from 18Ni 200 Grade Maaraging steel, PH13-8Mo, and A-286 stainless steel. Quantitative data are provided on the behavior of the specimens due to the effects of both machining and cryogenic cycling effects.
A network of channels was chemically milled into one surface of a pair of matched plates having bond planes which were neither planar or profiled to match the contour of the trailing edge of a supercritical airfoil for testing in cryogenic wind tunnels. Vacuum brazing bonded the plates together to create a network of pressure passages without blockages or cross leaks. The greatest success was achieved with the smaller samples and planar bonding surfaces. In larger samples, problems were encountered due to warpage created by the relief of residual stresses. Successful bonds were formed by brazing A286, Nitronic 40 and 300 series stainless steels at 1065 C using AMS 4777B brazing alloy, but excessive grain growth occurred in samples of 200 grade 18 nickel maraging steels. Good bonds were obtained with maraging steel using a 47 percent Nickel-47 percent Palladium-6 percent Silicon alloy and brazing at 927 C. Electro-Discharge-Machining was an effective method of cutting profiled bond planes and airfoil contours. Orifices of good definition were obtained when the EDM wire cut passed through predrilled holes. Possible configurations for joints between small segments and the larger main wing were also studied.
Contour maps of change of thickness of opaque plates subjected to external loads are obtained using holographic interferometry in conjunction with the moire effect. A simple holographic-interferometry arrangement is used first to obtain contour maps of the out-of-plane displacements of the two sides of the object. Carrier patterns of equal magnitude but opposite signs are added to these contours. Superposition of the reconstructed holograms of the two sides produces a pattern of additive-moire fringes, which are contours of change of thickness. Effects of midplane warpage of the loaded specimen are cancelled. Sensitivity is lambda/2 per fringe order, contrast of the isopachic-fringe pattern is excellent, and the process is compatible with a mechanical-testing-machine environment.
The most common intrinsic defects in dislocation-free float zone (FZ) silicon crystals are the A- and B-type swirl defects. The mechanisms of their formation and annihilation have been extensively studied. Another type of defect in dislocation-free FZ crystals is referred to as a D-type defect. Concentrations of these defects can be minimized by optimizing the growth conditions, and the residual swirls can be reduced by the post-growth extrinsic gettering process. Czochralski (Cz) silicon wafers are known to exhibit higher resistance to slip and warpage due to thermal stress than do FZ wafers. The Cz crystals containing dislocations are more resistant to dislocation movement than dislocated FZ crystals because of the locking of dislocations by oxygen atoms present in the Cz crystals. Recently a transverse magnetic field was applied during the FZ growth of extrinsic silicon. Resultant flow patterns, as revealed by striation etching and spreading resistance in Ga-doped silicon crystals, indicate strong effects of the transverse magnetic field on the circulation within the melt. At fields of 5500 gauss, the fluid flow in the melt volume is so altered as to affect the morphology of the growing crystal.
Contour maps of thickness changes were obtained for three quasi-isotropic graphite-epoxy plates with central holes, loaded in compression. Thickness changes were determined for six load increments from nearly zero to within a few percent of the failure load. The largest change of thickness occurred near the hole but not at the boundary of the hole. Below 90 percent of the failure load, the thickness changes were nearly proportional to load. Irregularities of thickness changes occurred in zones of compressive stresses and they were attributed to localized fiber buckling. A new optical technique was developed to measure thickness changes with high sensitivity. It utilizes a comparatively simple means of holographic interferometry on both sides of the specimen, followed by additive moire to obtain thickness changes as the sum of the out-of-plane displacements. Sensitivity was 12.5 x 10 to the -6 power in. per fringe order. The fringe patterns represent thickness changes uniquely, even when specimen warpage and consequent out-of-plane displacements are very large.
Effective, inexpensive pressure seal between two flat surfaces formed from silicone rubber tubing. Resembling refrigerator seal, pressure seal especially useful where shape of sealed region irregular or subject to change. Unlike gaskets and O-rings, tubing seals require no machined grooves or custom-made parts and not adversely affected by warpage of sealed surfaces.
Spectral and radiometric calibrations of the Airborne Visible/Infrared Imaging Spectrometer (AVIRIS) were performed in the laboratory in June and November, 1987, at the beginning and end of the first flight season. Those calibrations are described along with changes in instrument characteristics that occurred during the flight season as a result of factors such as detachment of the optical fibers to two of the four AVIRIS spectrometers, degradation in the optical alignment of the spectrometers due to thermally-induced and mechanical warpage, and breakage of a thermal blocking filter in one of the spectrometers. These factors caused loss of signal in three spectrometers, loss of spectral resolution in two spectrometers, and added uncertainty in the radiometry of AVIRIS. Results from in-flight assessment of the laboratory calibrations are presented. A discussion is presented of improvements made to the instrument since the end of the first flight season and plans for the future. Improvements include: (1) a new thermal control system for stabilizing spectrometer temperatures, (2) kinematic mounting of the spectrometers to the instrument rack, and (3) new epoxy for attaching the optical fibers inside their mounting tubes.
Spectral and radiometric calibrations of AVIRIS are described together with changes in instrument characteristics that occurred during the flight season. These changes include detachment of the optical fibers to two of the four AVIRIS spectrometers, degradation in the optical alignment of the spectrometers due to thermally induced and mechanical warpage, and breakage of a thermal blocking filter in one of the spectrometers. Means of improving the instrument are discussed.
The Automatic Radiator Inspection Device (ARID) is a system aimed at automating the tedious task of inspecting orbiter radiator panels. The ARID must have the ability to aim a camera accurately at the desired inspection points, which are in the order of 13,000. The ideal inspection points are known; however, the panel may be relocated due to inaccurate parking and warpage. A method of determining the mathematical description of a translated as well as a warped surface by accurate measurement of only a few points on this surface is developed here. The method uses a linear warp model whose effect is superimposed on the rigid body translation. Due to the angles involved, small angle approximations are possible, which greatly reduces the computational complexity. Given an accurate linear warp model, all the desired translation and warp parameters can be obtained by knowledge of the ideal locations of four fiducial points and the corresponding measurements of these points on the actual radiator surface. The method uses three of the fiducials to define a plane and the fourth to define the warp. Given this information, it is possible to determine a transformation that will enable the ARID system to translate any desired inspection point on the ideal surface to its corresponding value on the actual surface.
An experimental study of plate buckling induced by spatial temperature gradients is described. A rectangular Hastelloy-X panel is subjected to local line heating by a focused quartz heat lamp. Two parallel panel edges are maintained at constant temperature by coolant flow. Point supports provide well-defined thermal-structural boundary conditions. Test results from transient elastic and inelastic tests demonstrate that substantial panel bending occurs due to initial panel warpage and thermally induced membrane compressive stresses.
Long Duration Exposure Facility (LDEF) Experiment A0175 involved the non-instrumented exposure of seven carbon-fiber reinforced resin-matrix advanced composite panels contained in two trays - A7 and A1. These two trays were located, respectively, on the leading and trailing faces of LDEF, obliquely oriented to the RAM (Row 9) and WAKE (Row 3) directions. The identity and location of the seven panels, which consisted of six flat laminates of the following material systems are shown: carbon/epoxy (T300/934), carbon/bismaleimide (T300/F178), and carbon/polyimide (C6000/LARC-160 and C6000/PMR-15), plus one bonded honeycomb sandwich panel (T300/934 face sheets and Nomex core) patterned after the Space Shuttle payload bay door construction. These material systems were selected to represent a range of then-available matrix resins which, by virtue of their differing polymer chemistry, could conceivably exhibit differing susceptibility to the low-earth orbit (LEO) environment. The principal exposure conditions of the LDEF environment at these tray locations are shown. Noteworthy to some of the observations discussed is the four-orders-of magnitude difference in the atomic oxygen (AO) fluence, which made a shallow incidence angle (approximately 22 deg) to Tray A7, while Tray A1 on the trailing face was essentially shielded from AO exposure. This evaluation focused on determining the individual and relative suitability of a variety of resin-matrix composite systems for long-term space structural applications. This was accomplished primarily by measuring and comparing a range of engineering mechanical properties on over 300 test coupons sectioned from the flight panels and from identical control panels, and tested at ambient and elevated temperatures. This testing was supported by limited physical characterization, involving visual examination of flight panel surface features, measurements of weight loss and warpage, and examination for changes in internal integrity (micro cracking, delamination) by ultrasonic c-scan and polished cross-sections.
A blend composed of an ethynyl terminated aspartimide (brittle component) and an ethynyl terminated arylene ether oligomer (tough component) was thermally cured to yield a resin which underwent preliminary evaluation to determine the potential for use in structural applications on aerospace vehicles. The blend exhibited good compression moldability, allowing for fabrication of neat moldings, adhesive specimens and composites at temperatures of 250 C under a pressure of 1.4 MPa (200 psi). Neat resin moldings and adhesive specimens provided relatively high mechanical properties. Composite specimens provided promising results in spite of fiber misalignment, fiber washout, and a small amount of panel warpage.
A special protractor was designed and built with a view towards supplying a simple, inexpensive, practical, portable instrument for making measurements to detect propeller warpage under practically all conditions, without the use of auxiliary equipment, and without having to remove the propeller from the airplane. A detailed description is given of the protractor. Techniques for measuring are described. Directions are given on how to use the protractor to set detachable blade-type propellers on an airplane.