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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Spacecraft Common Deployable Boom Hinge Deploy and Latching Mechanisms

JPL is developing deployable radio frequency (RF) reflector booms for spaceflight usage on two different earth orbiter projects scheduled to launch in the early 2020’s. The static alignment and thermal stability requirements for these RF reflector booms are challenging. A common mechanism design has been developed for the deployment and latching of boom hinges which avoids significant parasitic loads on the alignment critical structures after completion of mechanism function. The mechanism design includes a high-aspect ratio torsion spring with viscous damper for hinge closure as well as an actuator-driven flexured hook and roller latch for joint preloading. This paper describes noteworthy mechanism design details, test results, challenges, and lessons learned during the development effort.

Renson, Marcel↗
NASA NTRS2020

Static Loads Testing of a High Aspect Ratio Tow-Steered Wingbox

Static loads testing was performed on a 39-foot, high-aspect-ratio wingbox comprising carbon fiber tow-steered wing skins that were tailored for aircraft fuel efficiency under aeroelastic loads. The test article was designated the Passive Aeroelastic Tailored (PAT) wing. To date, the PAT wing, which has an aspect ratio of 13.5, is the largest wingbox designed and built to employ variably oriented carbon fibers along the span of the wing. During testing, distributed point loads were applied to the wingbox to simulate both -1g and 2.5g maneuver loads. To determine the wingbox’s flexural axis location, individual point loads were applied. The global response of the wing (displacement and rotation measurements) showed similar trends compared to the finite element model predictions, though discrepancies of up to 17% were observed when comparing actual values between model and test. It was concluded that the boundary conditions and nonstructural features of the wingbox were the likely cause of the inconsistencies. The local response of the wingbox (strain measurements), which was much less affected by factors unrelated to tow-steering, exhibited good agreement with the model predictions, validating the modelling techniques employed for tow-steered composites.

Tow-steered composites↗
NASA NTRS2021

Bioinspired Honeycomb Core Design: An Experimental Study of the Role of Corner Radius, Coping, and Interface

The honeybee’s nest has inspired the design of engineering honeycomb core that primarily abstract the hexagonal cell shape and exploit its mass minimizing properties to construct lightweight panels. This work explored three additional design features that are part of the natural honeybee comb but have not been traditionally considered as design features of interest in honeycomb design: the radius at the corner of each cell, the coping at the top of the cell walls, and the interface between cell arrays. These features were first characterized in natural honeycomb using optical and X-ray techniques, and then incorporated into honeycomb core design, and fabricated using an additive manufacturing process. The honeycomb cores were then tested in out-of-plane compression and bending, and since all three design features added mass to the overall structure, all metrics were examined per unit mass to assess performance gains. The study concluded that the addition of an interface increases specific flexural modulus but has little benefit in out-of-plane compression; coping radius positively impacts specific flexural strength; but that the corner radius has no significant effect in bending, and actually is slightly detrimental for out-of-plane compression testing.

honeycomb↗
NASA NTRS1993

Effect of Impact Damage and Open Hole on Compressive Strength of Hybrid Composite Laminates

Impact damage tolerance is a frequently listed design requirement for composites hardware. The effect of impact damage and open hole size on laminate compressive strength was studied on sandwich beam specimens which combine CFRP-GFRP hybrid skins and a syntactic foam core. Three test specimen configurations have been investigated for this study. The first two were sandwich beams which were loaded in pure bending (by four point flexure). One series had a skin damaged by impact, and the second series had a circular hole machined through one of the skins. The reduction of compressive strength with increasing damage (hole) size was compared. Additionally a third series of uniaxially loaded open hole compression coupons were tested to generate baseline data for comparison with both series of sandwich beams.

Hiel, Clement↗
DOE OSTI2021

Fabrication of Six Degrees-of-Freedom Hexflex Positioner With Integrated Strain Sensing Using Nonlithographically Based Microfabrication

In this study, a process flow is described for the low cost, flexible fabrication of metal micro-electromechanical systems (MEMS) with high performance integrated sensing. The process is capable of producing new designs in ≈1 week at an average unit cost of <$1 k/device even at batch sizes of ≈1–10, with expected sensing performance limits of about 135 dB over a 10 kHz sensor bandwidth. This is a ≈20× reduction in cost, ≈25× reduction in time, and potentially >30× increase in sensing dynamic range over comparable state-of-the-art compliant nanopositioners. The nonlithographically based microfabrication (NLBM) process is uniquely suited to create high performance nanopositioning architectures which are customizable to the positioning requirements of a range of nanoscale applications. These can significantly reduce the cost of nanomanufacturing research and development, as well as accelerate the development of new processes and the testing of fabrication process chains without excess capital investment. A six degrees-of-freedom (6DOF) flexural nanopositioner with integrated sensing for all 6DOF was fabricated using the newly developed process chain. The fabrication process was measured to have ≈30 μ m alignment. Sensor arm, flexure, and trace widths of 150 μ m, 150 μ m, and 800 μ m, respectively, were demonstrated. Process capabilities suggest lower bounds of 25 μ m, 50 μ m, and 100 μ m, respectively. Dynamic range sensing of 52 dB was demonstrated for the nanopositioner over a 10 kHz sensor bandwidth. Improvements are proposed to approach sensor performance of about 135 dB over a 10 kHz sensor bandwidth.

42 ENGINEERING↗
NASA NTRS1980

Research on graphite reinforced glass matrix composites

High levels of mechanical performance in tension, flexure, fatigue, and creep loading situations of graphite fiber reinforced glass matrix composites are discussed. At test temperatures of up to 813 K it was found that the major limiting factor was the oxidative instability of the reinforcing graphite fibers. Particular points to note include the following: (1) a wide variety of graphite fibers were found to be comparable with the glass matrix composite fabrication process; (2) choice of fiber, to a large extent, controlled resultant composite performance; (3) composite fatigue performance was found to be excellent at both 300 K and 703 K; (4) composite creep and stress rupture at temperatures of up to 813 K was limited by the oxidative stability of the fiber; (5) exceptionally low values of composite thermal expansion coefficient were attributable to the dimensional stability of both matrix and fiber; and (6) component fabricability was demonstrated through the hot pressing of hot sections and brazing using glass and metal joining phases.

Prewo, K. M.↗
NASA NTRS1991

Relationship between voids and interlaminar shear strength of polymer matrix composites

The effect of voids on the interlaminar shear strength of a polyimide matrix composite system is described. The AS4 graphite/PMR-15 composite was chosen for study because this system can be readily processed by using the standard specified cure cycle to produce void-free composites and because preliminary work in this study had shown that the processing parameters of this resin matrix system can be altered to produce cured composites of varying void contents. Thirty-eight 12-ply unidirectional composite panels were fabricated for this study. A significant range of void contents (0 to 10 percent) was produced. The panels were mapped, ultrasonically inspected, and sectioned into interlaminar shear, flexure, and fiber content specimens. The density of each specimen was measured and interlaminar shear and flexure strength measurements were then made. The fiber content was measured last. The results of these tests were evaluated by using ultrasonic results, photomicrographs, statistical methods, theoretical relationships derived by other investigators, and comparison of the test data with the Integrated Composite Analyzer (ICAN) computer program developed at the Lewis Research Center for predicting composite ply properties. The testing is described in as much detail as possible in order to help others make realistic comparisons.

Bowles, Kenneth J.↗
NASA NTRS1991

Relationship between voids and interlaminar shear strength of polymer matrix composites

The effect of voids on the interlaminar shear strength of a polyimide matrix composite system is described. The AS4 graphite/PMR-15 composite was chosen for study because this system can be readily processed by using the standard specified cure cycle to produce void-free composites and because preliminary work in this study had shown that the processing parameters of this resin matrix system can be altered to produce cured composites of varying void contents. Thirty-eight 12-ply unidirectional composite panels were fabricated for this study. A significant range of void contents (0 to 10 percent) was produced. The panels were mapped, ultrasonically inspected, and sectioned into interlaminar shear, flexure, and fiber content specimens. The density of each specimen was measured and interlaminar shear and flexure strength measurements were then made. The fiber content was measured last. The results of these tests were evaluated by using ultrasonic results, photomicrographs, statistical methods, theoretical relationships derived by other investigations, and comparison of the test data with the Integrated Composite Analyzer (ICAN) computer program developed at the Lewis Research Center for predicting composite ply properties. The testing is described in as much detail as possible in order to help others make realistic comparisons.

Bowles, Kenneth J.↗
NASA NTRS2002

Generalized Reliability Methodology Applied to Brittle Anisotropic Single Crystals

A generalized reliability model was developed for use in the design of structural components made from brittle, homogeneous anisotropic materials such as single crystals. The model is based on the Weibull distribution and incorporates a variable strength distribution and any equivalent stress failure criteria. In addition to the reliability model, an energy based failure criterion for elastically anisotropic materials was formulated. The model is different from typical Weibull-based models in that it accounts for strength anisotropy arising from fracture toughness anisotropy and thereby allows for strength and reliability predictions of brittle, anisotropic single crystals subjected to multiaxial stresses. The model is also applicable to elastically isotropic materials exhibiting strength anisotropy due to an anisotropic distribution of flaws. In order to develop and experimentally verify the model, the uniaxial and biaxial strengths of a single crystal nickel aluminide were measured. The uniaxial strengths of the <100> and <110> crystal directions were measured in three and four-point flexure. The biaxial strength was measured by subjecting <100> plates to a uniform pressure in a test apparatus that was developed and experimentally verified. The biaxial strengths of the single crystal plates were estimated by extending and verifying the displacement solution for a circular, anisotropic plate to the case of a variable radius and thickness. The best correlation between the experimental strength data and the model predictions occurred when an anisotropic stress analysis was combined with the normal stress criterion and the strength parameters associated with the <110> crystal direction.

Salem, Jonathan A.↗
NASA NTRS1994

AXAF VETA-I mirror ring focus measurements

The AXAF VETA-I mirror ring focus measurements were made with an HRI (microchannel plate) X-ray detector. The ring focus is a sharply focused ring formed by X-rays before they reach the VEAT-I focal plane. It is caused by spherical aberrations due to the finite source distance and the despace in the VETA-I test. The ring focus test reveals some aspects fo the test system distortions and the mirror surface figure which are difficult or impossible to detect at the focal plane. The test results show periodic modulations of the ring radius and width which could be caused by gravity, thermal, and/or epoxy shrinkage distortions. The strongest component of the modulation had a 12-fold symmetry, because these distortions were exerted on the mirror through 12 flexures of the VETA-I mount. Ring focus models were developed to simulate the ring image. The models were compared with the data to understand the test system distortions and the mirror glass imperfection. Further studies will be done to complete this work. The ring focus measurement is a very powerful test. We expect that a similar test for the finally assembled mirror of AXAD-I will be highly valuable.

Tananbaum, H. D.↗
NASA NTRS1993

Aeroelastic airfoil smart spar

Aircraft wings and rotor-blades are subject to undesirable bending and twisting excursions that arise from unsteady aerodynamic forces during high speed flight, abrupt maneuvers, or hard landings. These bending excursions can range in amplitude from wing-tip flutter to failure. A continuous-filament construction 'smart' laminated composite box-beam spar is described which corrects itself when subject to undesirable bending excursions or flutter. The load-bearing spar is constructed so that any tendency for the wing or rotor-blade to bend from its normal position is met by opposite twisting of the spar to restore the wing to its normal position. Experimental and theoretical characterization of these spars was made to evaluate the torsion-flexure coupling associated with symmetric lay-ups. The materials used were uniweave AS-4 graphite and a matrix comprised of Shell 8132 resin and U-40 hardener. Experimental tests were conducted on five spars to determine spar twist and bend as a function of load for 0, 17, 30, 45 and 60 deg fiber angle lay-ups. Symmetric fiber lay-ups do exhibit torsion-flexure couplings. Predictions of the twist and bend versus load were made for different fiber orientations in laminated spars using a spline function structural analysis. The analytical results were compared with experimental results for validation. Excellent correlation between experimental and analytical values was found.

Greenhalgh, Skott↗
NASA NTRS1994

Evaluation of Wiring Constructions for Space Applications

A NASA Office of Safety and Mission Assurance (OS&MA) program to develop lightweight, reliable, and safe wiring insulations for aerospace applications is being performed by the NASA Lewis Research Center (LeRC). As part of this effort, a new wiring construction utilizing high strength PTFE (poly tetrafluoroethylene) as the insulation has been tested and compared with the existing military standard polyimide-based MIL-W-81381 wire construction. Electrical properties which were investigated included ac corona inception and extinction voltages (sea level and 60,000 feet), time/current to smoke, and wire fusing time. The two constructions were also characterized in terms of their mechanical properties of flexural strength, abrasion resistance (23 C and 150 C), and dynamic cut-through (23 C and 200 C). The results obtained in this testing effort are presented and discussed in this paper.

Hammoud, Ahmad N.↗
NASA NTRS1983

Mechanical Property Characterization of F-100/934 Graphite-Epoxy Composite Material

Procedures for quality control, fabrication techniques, specimen machining, test methodologies, and data collection and interpretation were defined using Thornel P-100 carbon fiber combined with Fiberite's 934 epoxy resin in unidirectional tape form. Tests on the prepreg material, including gel time, resin solids content, tack, volatile content, and flow are detailed. The steps of the fabrication and machining processes are described. Both destructive and nondestructive techniques were employed to assess the properties of the cured laminates. Tests to determine tensile strength and modulus, compressive strength and modulus, interlaminar and inplane shear strength, and flexural strength and modulus are discussed. The results of these experiments are compared with data generated by other researchers.

Clinton, R. G., Jr.↗
NASA NTRS1989

Electronically Variable Pressure Regulator (EVPR)

A new programmable electronically variable pressure regulator (EVPR) concept accurately controls the local outlet or remote system pressure. It uses an integral pulse width modulated rare earth permanent magnet motor operating in response to redundant pressure transducer feedback signals. The EVPR is a simple single stage device that does not use dynamic seals or pilot valving. Conversion of partial revolution motor torque to poppet lifting force is accomplished by pure flexure action to avoid using bearings. The flexure drive (called the ROTAX) has a variable lead to minimize motor weight and power consumption. Breadboard tests were completed successfully on two critical design elements of the EVPR: the ROTAX and the motor. The ROTAX cable system was tested for 250,000 cycles without failure. The breadboard motor met the basic design requirements including the design torque and power consumption. Prototype parts were fabricated, and testing of the prototype EVPR has started. It is PC computer controlled to facilitate programming, data acquisition and analysis. A lightweight dedicated microprocessor is planned for the flightweight EVPR.

Reinicke, R. H.↗
NASA NTRS1993

Weavability of dry polymer powder towpreg

Carbon fiber yarns (3k, 6k, 12k) were impregnated with LARC (tm) thermoplastic polyimide dry powder. Parameters for weaving these yarns were established. Eight-harness satin fabrics were successfully woven from each of the three classes of yarns and consolidated into test specimens to determine mechanical properties. It was observed that for optimum results warp yarns should have flexural rigidities between 10,000 and 100,000 mg-cm. Tow handling minimization, low tensioning, and tow bundle twisting were used to reduce fiber breakage, the separation of filaments, and tow-to-tow abrasion. No apparent effect of tow size or twist was observed on either tension or compression modulus. However, fiber damage and processing costs favor the use of 12k yarn bundles versus 3k or 6k yarn bundles in the weaving of powder-coated towpreg.

Hugh, Maylene K.↗
NASA NTRS2006

Testing of Flexible Ballutes in Hypersonic Wind Tunnels for Planetary Aerocapture

Studies were conducted for the In-Space Propulsion (ISP) Ultralightweight Ballute Technology Development Program to increase the technical readiness level of inflatable decelerator systems for planetary aerocapture. The present experimental study was conducted to develop the capability for testing lightweight, flexible materials in hypersonic facilities. The primary objectives were to evaluate advanced polymer film materials in a high-temperature, high-speed flow environment and provide experimental data for comparisons with fluid-structure interaction modeling tools. Experimental testing was conducted in the Langley Aerothermodynamics Laboratory 20-Inch Hypersonic CF4 and 31-Inch Mach 10 Air blowdown wind tunnels. Quantitative flexure measurements were made for 60 degree half angle afterbody-attached ballutes, in which polyimide films (1-mil and 3-mil thick) were clamped between a 1/2-inch diameter disk and a base ring (4-inch and 6-inch diameters). Deflection measurements were made using a parallel light silhouette of the film surface through an existing schlieren optical system. The purpose of this paper is to discuss these results as well as free-flying testing techniques being developed for both an afterbody-attached and trailing toroidal ballute configuration to determine dynamic fluid-structural stability. Methods for measuring polymer film temperature were also explored using both temperature sensitive paints (for up to 370 C) and laser-etched thin-film gages.

Buck, Gregory M.↗
NASA NTRS2007

Testing of Flexible Ballutes in Hypersonic Wind Tunnels for Planetary Aerocapture

Studies were conducted for the In-Space Propulsion (ISP) Ultralightweight Ballute Technology Development Program to increase the technical readiness level of inflatable decelerator systems for planetary aerocapture. The present experimental study was conducted to develop the capability for testing lightweight, flexible materials in hypersonic facilities. The primary objectives were to evaluate advanced polymer film materials in a high-temperature, high-speed flow environment and provide experimental data for comparisons with fluid-structure interaction modeling tools. Experimental testing was conducted in the Langley Aerothermodynamics Laboratory 20-Inch Hypersonic CF4 and 31-Inch Mach 10 Air blowdown wind tunnels. Quantitative flexure measurements were made for 60 degree half angle afterbody-attached ballutes, in which polyimide films (1-mil and 3- mil thick) were clamped between a 1/2-inch diameter disk and a base ring (4-inch and 6-inch diameters). Deflection measurements were made using a parallel light silhouette of the film surface through an existing schlieren optical system. The purpose of this paper is to discuss these results as well as free-flying testing techniques being developed for both an afterbody-attached and trailing toroidal ballute configuration to determine dynamic fluid-structural stability. Methods for measuring polymer film temperature were also explored using both temperature sensitive paints (for up to 370 C) and laser-etched thin-film gages.

Buck, Gregory M.↗
NASA NTRS1992

Static and dynamic strain energy release rates in toughened thermosetting composite laminates

In this work, the static and dynamic fracture properties of several thermosetting resin based composite laminates are presented. Two classes of materials are explored. These are homogeneous, thermosetting resins and toughened, multi-phase, thermosetting resin systems. Multi-phase resin materials have shown enhancement over homogenous materials with respect to damage resistance. The development of new dynamic tests are presented for composite laminates based on Width Tapered Double Cantilevered Beam (WTDCB) for Mode 1 fracture and the End Notched Flexure (ENF) specimen. The WTDCB sample was loaded via a low inertia, pneumatic cylinder to produce rapid cross-head displacements. A high rate, piezo-electric load cell and an accelerometer were mounted on the specimen. A digital oscilloscope was used for data acquisition. Typical static and dynamic load versus displacement plots are presented. The ENF specimen was impacted in three point bending with an instrumented impact tower. Fracture initiation and propagation energies under static and dynamic conditions were determined analytically and experimentally. The test results for Mode 1 fracture are relatively insensitive to strain rate effects for the laminates tested in this study. The test results from Mode 2 fracture indicate that the toughened systems provide superior fracture initiation and higher resistance to propagation under dynamic conditions. While the static fracture properties of the homogeneous systems may be relatively high, the apparent Mode 2 dynamic critical strain energy release rate drops significantly. The results indicate that static Mode 2 fracture testing is inadequate for determining the fracture performance of composite structures subjected to conditions such as low velocity impact. A good correlation between the basic Mode 2 dynamic fracture properties and the performance is a combined material/structural Compression After Impact (CAI) test is found. These results underscore the importance of examining rate-dependent behavior for determining the longevity of structures manufactured from composite materials.

Cairns, Douglas S.↗