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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

The effect of bending on the stresses in adhesive joints

The problem of stress distribution in adhesive joints where two orthotropic plates are bonded through a flexible adhesive layer is analyzed. It is shown that the effect of bending of the adherends on the stresses in the adhesive layer is very significant. The transverse shear deformations of the adherends appear to have little influence on the adhesive layer stresses. The maximum transverse normal stress in the adhesive is shown to be larger than the maximum longitudinal shear stress. The method of solution is applied to several examples of specific joint geometries and material combinations, and is proven to be applicable to other related problems.

Yuceoglu, U.↗
NASA NTRS1985

Welding, Bonding and Fastening, 1984

A compilation of papers presented in a joint NASA, American Society for Metals, The George Washington University, American Welding Soceity, and Society of Manufacturing Engineers conference on Welding, Bonding, and Fastening at Langley Research Center, Hampton, VA, on October 23 to 25, 1984 is given. Papers were presented on technology developed in current research programs relevant to welding, bonding, and fastening of structural materials required in fabricating structures and mechanical systems used in the aerospace, hydrospace, and automotive industries. Topics covered in the conference included equipment, hardware and materials used when welding, brazing, and soldering, mechanical fastening, explosive welding, use of unique selected joining techniques, adhesives bonding, and nondestructive evaluation. A concept of the factory of the future was presented, followed by advanced welding techniques, automated equipment for welding, welding in a cryogenic atmosphere, blind fastening, stress corrosion resistant fasteners, fastening equipment, explosive welding of different configurations and materials, solid-state bonding, electron beam welding, new adhesives, effects of cryogenics on adhesives, and new techniques and equipment for adhesive bonding.

Buckley, J. D.↗
DOE OSTI2022

Significant slowdown of plasma-optimized surface energy deactivation by vacuum sealing for efficient adhesive bonding

This work proposes an approach to minimize surface energy deactivation of plasma-treated metal and carbon fiber-reinforced polymer (CFRP) surfaces by vacuum sealing. Plasma treatments enhance adhesive wettability on post-treated surfaces for adhesive joints, but the treated surfaces deactivate quickly in air. The surface energy of aluminum alloy AA6061 and carbon fiber-reinforced polymer-polyamide (CFRP-PA66) optimally treated by a blown air plasma instrument returns to the original surface energy within one hour. Vacuum sealing of AA6061 and CFRP-PA66 reduced the surface energy deactivation over 7 days by at least 230 times and 970 times compared to in air. Double Cantilever Beam (DCB) tests performed on adhesively-bonded AA6061/CFRP-PA66 joints showed that the total energy release and energy dissipation before failure of plasma-treated and vacuum-sealed materials was up to 60% more than plasma-treated materials without vacuum sealing and up to 125% more than non-plasma-treated materials.

42 ENGINEERING↗
NASA NTRS1992

Materials technology for Stirling space power converters

This program was conducted in support of the NASA LeRC development of the Stirling power converter (SPC) for space power applications. The objectives of this contract were: (1) to perform a technology review and analyses to support the evaluation of materials issues for the SPC; (2) to evaluate liquid metal compatibility issues of the SPC; (3) to evaluate and define a transient liquid phase diffusion bonding (TLPDB) process for the SPC joints to the Udimet 720 heater head; and (4) to evaluate alternative (to the TLPDB) joining techniques. In the technology review, several aspects of the current Stirling design were examined including the power converter assembly process, materials joining, gas bearings, and heat exchangers. The supporting analyses included GLIMPS power converter simulation in support of the materials studies, and system level analysis in support of the technology review. The liquid metal compatibility study evaluated process parameters for use in the Stirling power converter. The alternative joining techniques study looked at the applicability of various joining techniques to the Stirling power converter requirements.

Baggenstoss, William↗
NASA NTRS1999

Cryotank Skin/Stringer Bondline Analysis

The need for light weight structure for advanced launch systems have presented great challenges and led to the usage of composites materials in a variety of structural assemblies where joining of two or more components is imperative. Although joints can be mechanically bolted, adhesive bonding has always been a very desirable method for joining the composite components, particularly for the cryotank systems, to achieve maximum structural efficiency. This paper presents the analytical approach resulted from the conceptual development of the DC-Y composite cryotank, conducted under the NASA/Boeing NRA 8-12 Partnership, to support the continued progress of SSTO (Single-Stage-To-Orbit) concepts. One of the critical areas of design was identified as the bonded interface between the skin (tank wall) and stringer. The approach to analyze this critical area will be illustrated through the steps which were used to evaluate the structural integrity of the bondline. Detailed finite element models were developed and numerous coupon test data were also gathered as part of the approach. Future plan is to incorporate this approach as a building block in analyzing bondline for the cryotank systems of RLVs (Reusable Launch Vehicles).

Nguyen, Bao↗
NASA NTRS2011

Design, Development and Test Challenges: Separation Mechanisms for the Orion Pad Abort-1 Flight Test

On May 6, 2010, NASA launched the first successful integrated flight test, Pad Abort-1, of the Orion Project from the White Sands Missile Range in Las Cruces, New Mexico. This test demonstrated the ability to perform an emergency pad abort of a full-scale 4.8 m diameter, 8200 kg crew capsule. During development of the critical separation mechanisms for this flight test, various challenges were overcome related to environments definition, installation complications, separation joint retraction speed, thruster ordnance development issues, load path validation and significant design loads increases. The Launch Abort System retention and release (LAS R&R) mechanism consisted of 6 discrete structural connections between the LAS and the crew module (CM) simulator, each of which had a preloaded tension tie, Superbolt torque-nut and frangible nut. During the flight test, the frangible nuts were pyrotechnically split, permitting the CM to separate from the LAS. The LAS separation event was the driving case in the shock environment for many co-located hardware items. During development testing, it was necessary to measure the source shock during the separation event so the predicted shock environment could be validated and used for certification testing of multiple hardware items. The Lockheed Martin test team measured the source separation shock due to the LAS R&R function, which dramatically decreased the predicted environment by 90% at 100 Hz. During development testing a hydraulic tensioner was used to preload the joint; however, the joint relaxation with the tensioner proved unsatisfactory so the design was modified to include a Superbolt torque-nut. The observed preload creep during lab testing was 4% after 30 days, with 2.5% occurring in the first 24 hours. The conversion of strain energy (preload) to kinetic energy (retraction) was measured to be 50-75%. Design features and careful monitoring of multiple strain gauges on each tension tie allowed a pure tensile load to be applied after stacking at the launch pad. Following installation, preload in each joint was monitored for 24 hours. Due to unforeseen complications and the influence of temperature on the portable data acquisition system, the team encountered difficulty in tracking the joint relaxation. In some cases, bond-line failure of the strain gauges occurred.

Dinsel, Alison↗
DOE OSTI2023

Joining of High Strength Low Ductility AA7055 by Friction Self-piercing Rivet

High strength aluminum (Al) alloy is one of higher specific strength materials for decarbonization in transportation industries. Because of low ductility at room temperature, conventional mechanical fastening such as self-piercing riveting produces cracks at the joint. In this work, we applied friction self-piercing riveting to join Al alloy (AA) 7055. No cracks were observed in the joints because of the improved local ductility of Al alloy by the generated frictional heat during joining step. Numerical modeling of joining process was applied to guide rivet geometry design and rivet material strength. Mechanical integrity of the AA7055 joints was assessed by lap shear tensile and cross-tension testing. Metallurgical characterizations revealed solid-state bonding formed not only between the rivet and surround Al materials, but also upper and lower Al sheets at the joint interface. Both solid-state bonding and mechanical interlocking between the flared rivet and bottom AA7055 sheet were the major joint mechanisms.

Lim, Yong Chae↗
NASA NTRS2009

Development of High Temperature Dissimilar Joint Technology for Fission Surface Power Systems

NASA is developing fission surface power (FSP) system technology as a potential option for use on the surface of the moon or Mars. The goal is to design a robust system that takes full advantage of existing materials data bases. One of the key components of the power conversion system is the hot-side Heat Exchanger (HX). One possible design for this heat exchanger requires a joint of the dissimilar metals 316L stainless steel and Inconel 718, which must sustain extended operation at high temperatures. This study compares two joining techniques, brazing and diffusion bonding, in the context of forming the requisite stainless steel to superalloy joint. The microstructures produced by brazing and diffusion bonding, the effect of brazing cycle on the mechanical tensile properties of the alloys, and the strength of several brazed joints will be discussed.

Locci, Ivan E.↗
NASA NTRS2006

Diffusion Bonding of Silicon Carbide Ceramics using Titanium Interlayers

Robust joining approaches for silicon carbide ceramics are critically needed to fabricate leak free joints with high temperature mechanical capability. In this study, titanium foils and physical vapor deposited (PVD) titanium coatings were used to form diffusion bonds between SiC ceramics using hot pressing. Silicon carbide substrate materials used for bonding include sintered SiC and two types of CVD SiC. Microscopy results show the formation of well adhered diffusion bonds. The bond strengths as determined from pull tests are on the order of several ksi, which is much higher than required for a proposed application. Microprobe results show the distribution of silicon, carbon, titanium, and other minor elements across the diffusion bond. Compositions of several phases formed in the joint region were identified. Potential issues of material compatibility and optimal bond formation will also be discussed.

Halbig, Michael C.↗
NASA NTRS2012

Joining and Assembly of Bulk Metallic Glass Composites Through Capacitive Discharge

Bulk metallic glasses (BMGs), a class of amorphous metals defined as having a thickness greater than 1 mm, are being broadly investigated by NASA for use in spacecraft hardware. Their unique properties, attained from their non-crystalline structure, motivate several game-changing aerospace applications. BMGs have low melting temperatures so they can be cheaply and repeatedly cast into complex net shapes, such as mirrors or electronic casings. They are extremely strong and wear-resistant, which motivates their use in gears and bearings. Amorphous metal coatings are hard, corrosion-resistant, and have high reflectivity. BMG composites, reinforced with soft second phases, can be fabricated into energy-absorbing cellular panels for orbital debris shielding. One limitation of BMG materials is their inability to be welded, bonded, brazed, or fastened in a convenient method to form larger structures. Cellular structures (which can be classified as trusses, foams, honeycombs, egg boxes, etc.) are useful for many NASA, commercial, and military aerospace applications, including low-density paneling and shields. Although conventional cellular structures exhibit high specific strength, their porous structures make them challenging to fabricate. In particular, metal cellular structures are extremely difficult to fabricate due to their high processing temperatures. Aluminum honeycomb sandwich panels, for example, are used widely as spacecraft shields due to their low density and ease of fabrication, but suffer from low strength. A desirable metal cellular structure is one with high strength, combined with low density and simple fabrication. The thermoplastic joining process described here allows for the fabrication of monolithic BMG truss-like structures that are 90% porous and have no heat-affected zone, weld, bond, or braze. This is accomplished by welding the nodes of stacked BMG composite panels using a localized capacitor discharge, forming a single monolithic structure. This removes many complicated and costly fabrication steps. Moreover, the cellular structures detailed in this work are among the highest- strength and most energy-absorbent materials known. This implies that a fabricated structure made from these materials would have unequaled mechanical properties compared to other metal foams or trusses. The process works by taking advantage of the electrical properties of the matrix material in the metal-matrix composite, which in this case is a metallic glass. Due to the random nanoscale arrangement of atoms (without any grain boundaries), the matrix glass exhibits a near-constant electrical resistivity as a function of temperature. By placing the composite panels between two copper electrode plates and discharging a capacitor, the entire matrix of the panel can be heated to approximately 700 C in 10 milliseconds, which is above the alloy s solidus but below the liquidus. By designing the geometry of the panels into the shape of an egg box, the electrical discharge localizes only in the tips of each pyramidal cell. By applying a forging load during discharge, the nodes of the panels can be fused together into a single piece, which then dissipates heat through radiation back into a glassy state. This means that two panels can be metallurgically fused into one panel with no heat-affected zone, creating a seamless connection between panels. During the process, the soft metal particles (dendrites) that are uniformly distributed in the glassy matrix to increase the toughness are completely unaffected by the thermoplastic joining. The novelty is that a truss (or foam-like) structure can be formed with excellent energy- absorbing capabilities without the need for machining. The technique allows for large-scale fabrication of panels, well-suited for spacecraft shields or military vehicle door panels. Crystalline metal cellular structures cannot be fabricated using the thermoplastic joining technique described here. If metal panels were te assembled into a cellular structure, they would either have to be welded, brazed, bonded, or fastened together, creating a weak spot in the structure at each connection. Welded parts require a welding material to be added to the joint and exhibit a soft and weak heat-affected zone. Brazing and bonding do not form a metallurgical joint and thus exhibit low strengths, especially when the panels are pulled apart and fasteners require high-stress-concentration holes to be drilled. No equivalent rapid heating method exists for assembling metal panels together into cellular structures, and thus, those parts must be foamed, machined, or investment cast if they are to form a monolithic structure. If the crystalline panels were to be joined using capacitive discharge, as with a spot welder, their bond would be very weak, and the panels would have to be extremely thin. In contrast, the strength of joined BMG parts has been demonstrated to have strength comparable to the parent material. This technique opens up the possibility of using large-scale BMG hardware in spacecraft, military, or commercial applications.

Hofmann, Douglas C.↗
DOE OSTI2025

Current activated reactive ultrafast joining (CARUJ) of silicon carbide

In this work we propose and demonstrate a novel approach for rapid fabrication of ceramic-ceramic joint assemblies, using sintered Silicon Carbide (SiC) as an initial example. Current Activated Reactive Ultrafast Joining (CARUJ) utilizes resistive heating of carbon-based materials to apply localized heat at or around the joint zone at heating rates of 101– 103 °C/min. CARUJ is used to fabricate SiC-SiC joints with a Si-SiC interface using minimal pressure (1–2 MPa) at time scales considerably shorter (several minutes opposed to hours) than conventional approaches for similar systems. The reaction of an interfacial precursor based on elemental silicon and carbon leads to in-situ SiC formation to produce a continuous and dense bond in a single step. Measured average joint strengths of roughly 15 MPa are achieved when tested in single lap offset (SLO) compressive shear. Optional additions of refractory metals such as molybdenum can be utilized to introduce secondary inclusions such as MoSi 2 within the joint interface. We further demonstrate SiC-SiC joining using Active Brazing Alloys (ABA) and proof of concept joining of tubular geometries. The localized and rapid heat application realizes a versatile material joining technique that could be extended for joining components at the plant site.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Plasma treatment on both adhesive tape and adherends for significantly enhanced CFRTP-related adhesive joints

Unlike existing literature that primarily concentrates on either the plasma treatment of adherends alone or solely on adhesive surfaces, this work leverages plasma modification of both adhesive in tape form and adherend surfaces to largely enhance the interfacial bonding between a thermoset-based adhesive tape and carbon-fiber-reinforced thermoplastic polymer (CFRTP) for structural bonding applications. Here, by conducting single lap shear tests on adhesively-bonded AA6061-CFRPPA (carbon-fiber-reinforced polyphthalamide) dissimilar joints, it is shown that the plasma treatment of adherends alone can increase the lap shear strength (LSS) of the joints by approximately 200% compared to non-treated counterparts. An additional plasma treatment of adhesive tape surfaces leads to even higher LSS improvement, reaching up to 315%, due to the formation of a denser crosslinked network of covalent bonds and a reduced area fraction of interfacial voids at the CFRPPA/adhesive interface. The highest plasma-enhanced LSS of the metal-CFRTP dissimilar joints rivals that of metal-metal joints, which is typically stronger than the joints associated with fiber-reinforced polymers. This study is important for achieving strong CFRTP-related structural components bonded using adhesive tape, providing better compatibility with plasma treatment and other joining methods like riveting compared to adhesive paste or liquid.

36 MATERIALS SCIENCE↗
NASA NTRS1987

NDE of Space Shuttle Solid Rocket Motor field joint

One of the most critical areas for inspection in the Space Shuttle Solid Rocket Motors is the bond between the steel case and rubber insulation in the region of the field joints. The tang-and-clevis geometry of the field joints is sufficiently complex to prohibit the use of resonance-based techniques. One approach we are investigating is to interrogate the steel-insulation bondline in the tang and clevis regions using surface-travelling waves. A low-frequency contact surface wave transmitting array transducer is under development at our laboratory for this purpose. The array is placed in acoustic contact with the steel and surface waves are launched on the inside surface or the clevis leg which propagate along the steel-insulation interface. As these surface waves propagate along the bonded surface, the magnitude of the ultrasonic energy leaking into the steel is monitored on the outer surface of the case. Our working hypothesis is that the magnitude of energy received at the outer surface of the case is dependent upon the integrity of the case-insulation bond, with less attenuation for propagation along a disbond due to imperfect acoustic coupling between the steel and rubber. Measurements on test specimens indicate a linear relationship between received signal amplitude and the length of good bend between the transmitter and receiver, suggesting the validity of this working hypothesis.

Patrick H. Johnston↗
NASA NTRS2018

Modeling Principles Using the Relation Between Lagrange Multipliers and Bond Graphs

Final document is attached. Modeling dynamic systems by bond graphs has become state of the art technology since hundreds of researchers around the world have incorporated the technology in many fields of engineering and science. The legacy of its invertor Prof. Henry Paynter at MIT in 1959 is now a fundamental and practical technique to understand reality by building computer models. This paper addresses a particular aspect of this technology when modeling of mechanical systems require relaxation of constraints by means of Lagrange principles. Lagrange's equations are a useful means of describing and solving systems with kinematic constraints. Lagrange multipliers are variables used in equations to find the extremes of multivariate functions. Here we explore the relation of Lagrange multipliers to solve modeling difficulties of a space vehicle with equations with dependent derivatives. Lagrange multipliers were used in conjunction with bond graphs to simulate a system where joints of kinematic linkages produce dependent derivatives. NASA's Morpheus Project lunar lander was used as a case study. The Morpheus Project is a terrestrial test vehicle designed to fly the terminal descent trajectory of a lunar lander to advance the Autonomous Landing Hazard Avoidance Technology (ALHAT). An objective of this study is to apply the modeling approach herein to capture the dynamic movement of the lander as the propellant is sloshed and consumed. This paper expands further the analysis presented by (Granda, J J. Nguyen, L, Carlson, T, Sahragard-Monfared, G., Fornalski, E., Brocker 2016). Using an automated approach bond graph models of state space equations were generated using the Computer Aided Modeling Program (CAMPG). Integral causality models and derivative causality models were considered in order to find the simpler solution for the mathematical dependencies produced in modeling this vehicle.

Granda, Jose J.↗
NASA NTRS2015

Non-destructive Evaluation of Bonds Between Fiberglass Composite and Metal

To assess the integrity and reliability of an adhesive joint in an automotive composite component, several non-destructive evaluation (NDE) methodologies are correlated to lap shear bond strengths. A glass-fabric-reinforced composite structure was bonded to a metallic structure with a two-part epoxy adhesive. Samples were subsequently cut and tested in shear, and flaws were found in some areas. This study aims to develop a reliable and portable NDE system for service-level adhesive inspection in the automotive industry. The results of the experimental investigation using several NDE methods are presented and discussed. Fiberglass-to-metal bonding is the ideal configuration for NDE via thermography using excitation with induction heating, due to the conductive metal and non-conductive glass-fiber-reinforced composites. Excitation can be either by a research-grade induction heater of highly defined frequency and intensity, or by a service-level heater, such as would be used for sealing windshields in a body shop. The thermographs thus produced can be captured via a high-resolution infrared camera, with principal component analysis and 2D spatial Laplacian processing. Alternatively, the thermographs can be captured by low resolution thermochromic microencapsulated liquid crystal film imaging, which needs no post-processing and can be very inexpensive. These samples were also examined with phased-array ultrasound. The NDE methods are compared to the lap shear values and to each other for approximate cost, accuracy, and time and level of expertise needed.

Zhao, Selina↗
NASA NTRS2000

Piezoelectric Shunt Vibration Damping of F-15 Panel under High Acoustic Excitation

At last year's SPIE symposium, we reported results of an experiment on structural vibration damping of an F-15 underbelly panel using piezoelectric shunting with five bonded PZT transducers. The panel vibration was induced with an acoustic speaker at an overall sound pressure level (OASPL) of about 90 dB. Amplitude reductions of 13.45 and 10.72 dB were achieved for the first and second modes, respectively, using single- and multiple-mode shunting. It is the purpose of this investigation to extend the passive piezoelectric shunt-damping technique to control structural vibration induced at higher acoustic excitation levels, and to examine the controllability and survivability of the bonded PZT transducers at these high levels. The shunting experiment was performed with the Thermal Acoustic Fatigue Apparatus (TAFA) at the NASA Langley Research Center using the same F-15 underbelly panel. The TAFA is a progressive wave tube facility. The panel was mounted in one wall of the TAFA test section using a specially designed mounting fixture such that the panel was subjected to grazing-incidence acoustic excitation. Five PZT transducers were used with two shunt circuits designed to control the first and second modes of the structure between 200 and 400 Hz. We first determined the values of the shunt inductance and resistance at an OASPL of 130 dB. These values were maintained while we gradually increased the OASPL from 130 to 154 dB in 6-dB steps. During each increment, the frequency response function between accelerometers on the panel and the acoustic excitation measured by microphones, before and after shunting, were recorded. Good response reduction was observed up to the 148dB level. The experiment was stopped at 154 dB due to wire breakage from vibration at a transducer wire joint. The PZT transducers, however, were still bonded well on the panel and survived at this high dB level. We also observed shifting of the frequency peaks toward lower frequency when the OASPL was increased. Detailed experimental results will be presented.

Wu, Shu-Yau↗