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Constructed specimens for tranverse tensile testing of unidirectional graphite/epoxy tape is tested more accurately than earlier samples. Specimens are made using unsupported adhesive and commercially-available (e.g., Nomex, or equivalent) honeycomb core. Flexible adhesive and dimensionally stable core eliminate uneven thermal expansion. Tensile strength of tape at various temperatures becomes direct function of applied mechanical stress.
Activities described include: (1) determining the applicability of an ultrahigh-strength graphite fiber to composite pressure vessels; (2) defining the fatigue performance of thin-titanium-lined, high-strength graphite/epoxy pressure vessel; (3) selecting epoxy resin systems suitable for filament winding; (4) studying the fatigue life potential of Kevlar 49/epoxy pressure vessels; and (5) developing polymer liners for composite pressure vessels. Kevlar 49/epoxy and graphite fiber/epoxy pressure vessels, 10.2 cm in diameter, some with aluminum liners and some with alternation layers of rubber and polymer were fabricated. To determine liner performance, vessels were subjected to gas permeation tests, fatigue cycling, and burst tests, measuring composite performance, fatigue life, and leak rates. Both the metal and the rubber/polymer liner performed well. Proportionately larger pressure vessels (20.3 and 38 cm in diameter) were made and subjected to the same tests. In these larger vessels, line leakage problems with both liners developed the causes of the leaks were identified and some solutions to such liner problems are recommended.
The moisture absorption characteristics of two graphite/epoxy composites and their corresponding cured neat resins were studied in high humidity and water immersion environments at elevated temperatures. Moisture absorption parameters, such as equilibrium moisture content and diffusion coefficient derived from data taken on samples exposed to high humidity and water soak environments, were compared. Composite swelling in a water immersion environment was measured. Tensile strengths of cured neat resin were measured as a function of their equilibrium moisture content after exposure to different moisture environments. The effects of intermittent moderate tensile loads on the moisture absorption parameters of composite and cured neat resin samples were determined.
The validation of a proposed fatigue life prediction methodology was sought through the use of aluminum butt and scarf joint and graphite/epoxy butt joint specimens in a constant amplitude fatigue environment. The structural properties of the HYSOL 9313 adhesive system were obtained by mechanical test of molded heat adhesive specimens. Aluminum contoured double cantilever beam specimens were used to generate crack velocity versus stress intensity factor data. The specific objectives were: (1) to ascertain the feasibility of predicting fatigue failure of an adhesive in a primary bonded composite structure by incorporating linear elastic crack growth behavior; and (2) to ascertain if acoustic emission and/or compliance measurement techniques can be used to detect flaws.
Potential applications of composite materials in kilometer-size space systems are reviewed noting the advent of the NASA Space Transportation System. Antenna configurations are considered with reference to the 10-m-diam wrapped-rib antenna used on the ATS-6 satellite, a 15-m-diam graphite/epoxy wrapped-rib antenna, and a folding planar array synthetic aperture radar antenna. The heliogyro solar sail concept is presented along with solar power station designs based on either photovoltaic arrays or parabolic arrays of flat facets. The development of beam fabricators is described.
An experimental investigation was conducted to determine strain rate effects in fiber composites. Unidirectional composite specimens of boron/epoxy, graphite/epoxy, S-glass/epoxy and Kevlar/epoxy were tested at tensile strain rates of up to 27 m/m/sec. Longitudinal, transverse and in-plane shear properties, including modulus, Poisson's ratio, strength and ultimate strain, were determined by testing 0-, 90and 10-degree unidirectional coupons. Strains were measured by means of strain gages bonded on the coupons and loads were measured by means of a strain gage load cell. All specimens were loaded in an electrohydraulic loading system. The 0-degree properties which are governed by the fibers do not vary much with strain rate except for the Kevlar/epoxy material which shows an increase in both modulus and strength. The strain rate effects on 90-degree properties were small with a general trend toward higher strength with increasing strain rate. The most noticeable effect was on in-plane shear properties with shear strength values at high strain rates approximately fifteen percent higher than static values.
Specific details concerning the structural design, analysis, fabrication and testing of the Nimbus-G/Seasat-A Scanning Multichannel Microwave Radiometer (SMMR) are presented. Design requirements are illustrated and trade-off considerations discussed in terms of flight project requirements. It is shown that the application of graphite/epoxy material results in a lightweight, stiff, thermally stable antenna structure fully qualified for mission application.
An experimental study was conducted to determine the wave-propagation characteristics, transient strains and residual properties of unidirectional and angle-ply boron/epoxy and graphite/epoxy laminates impacted with silicon-rubber projectiles at velocities up to 250 m/sec. Results include the following: (1) the predominant wave is the flexural wave propagating at different velocities in different directions; (2) peak strains and strain rates in the transverse to the (outer) fiber direction are much higher than those in the direction of the fibers; (3) strain rates up to 640/sec were measured; and (4) unidirectional laminates under impact showed appreciable modulus and strength degradation in the direction transverse to fibers.
A theoretical model to predict the effect of loading sequence on the statistical distributions of the fatigue life and the residual strength under n-stress levels of cyclic loading is derived on the basis of a three-parameter model. In particular, the dual stress fatigue cumulative damage is studied, showing that the Miner's sum (the cumulative damage sum at fatigue failure) is a statistical variable. It is proved theoretically that the Miner's sum is always greater than or equal to unity for the high-low load sequence, while it is always smaller than or equal to unity for the low-high load sequence, with the deviation from unity increasing as the difference between the high and the low stress levels increases. An experimental test program using graphite/epoxy angle-ply laminates, carried out to generate statistically meaningful data for verifying the proposed model, is discussed.
The paper describes the design and test procedure for the QCSEE (quiet, clean, short-haul experimental engine). The engines designed for the YC-14 and YC-15 STOL aircraft, both use a very low fan pressure ratio to keep jet-flap noise about 3 dB below total system noise. Other noise reducing features discussed are the low tip speed fans and a carefully selected number of fan blades and vanes with adequate spacing between them. Attention is also given to the development of a low emissions combustor, and reduction of fan frame weight, through the use of graphite/epoxy material. The YC-15 engine also employs variable pitch fans to provide thrust reversal, thus saving weight. Finally, it is noted that the tests have proven that the engines could be configurated to meet the needs of a powered lift system without excessively compromising performance or weight.
Minimum-mass designs were obtained for insulated structural panels loaded by a general set of inplane forces and a time dependent temperature. Temperature and stress histories in the structure are given by closed-form solutions, and optimization of the insulation and structural thicknesses is performed by nonlinear mathematical programming techniques. Design calculations are described to evaluate the structural efficiency of eight materials under combined heating and mechanical loads: graphite/polyimide, graphite/epoxy, boron/aluminum, titanium, aluminum, Rene 41, carbon/carbon, and Lockalloy. The effect on design mass of intensity and duration of heating were assessed. Results indicate that an optimum structure may have a temperature response well below the recommended allowable temperature for the material.
A model is developed relating composite constituents properties with ultrasonic energy loss factors for longitudinal waves propagating in the principal directions of a unidirectional graphite/epoxy fiber composite. All the constituents are assumed to behave as linear viscoelastic materials with energy dissipation properties defined by loss factors. It is found that by introducing a new constituent called the interface material, the composite and constituent properties can be brought into consistency with simple series and parallel models. An expression relating the composite loss factors to the loss factors of the constituents is derived and its coefficients are evaluated.
A program was conducted by NASA with the JT9D engine manufacturer to develop a lightweight, cost effective, composite material fan exit guide vane design having satisfactory structural durability for commerical engine use. Based on the results of a previous company supported program, eight graphite/epoxy and graphite-glass/epoxy guide vane designs were evaluated and four were selected for fabrication and testing. Two commercial fabricators each fabricated 13 vanes. Fatigue tests were used to qualify the selected design configurations under nominally dry, 38 C (100 F) and fully wet and 60 C (140 F) environmental conditions. Cost estimates for a production rate of 1000 vanes per month ranged from 1.7 to 2.6 times the cost of an all aluminum vane. This cost is 50 to 80 percent less than the initial program target cost ratio which was 3 times the cost of an aluminum vane. Application to the JT9D commercial engine is projected to provide a weight savings of 236 N (53 lb) per engine.
A quasi-three dimensional, nonlinear elastic finite element stress analysis of finite width composite laminates including curing stresses is presented. Cross-ply, angle-ply, and two quasi-isotropic graphite/epoxy laminates are studied. Curing stresses are calculated using temperature dependent elastic properties that are input as percent retention curves, and stresses due to mechanical loading in the form of an axial strain are calculated using tangent modulii obtained by Ramberg-Osgood parameters. It is shown that curing stresses and stresses due to tensile loading are significant as edge effects in all types of laminate studies. The tensor polynomial failure criterion is used to predict the initiation of failure. The mode of failure is predicted by examining individual stress contributions to the tensor polynomial.
Nonmetallic composites such as the graphite/epoxy system were investigated as possible substrates for the primary mirror of the large space telescope. The possible use of fiber reinforced metal matrix composites was reviewed in the literature. Problems arising out of the use of composites as substrate materials such as grinding, polishing, adherence of reflective coatings, rigidity of substrate, hygrospcopici tendency of the composites, thermal and temporal stability and other related problems were examined.
The influence of hole quality on the structural behavior of composite materials was investigated. From an industry survey it was determined that the most frequent imperfections encountered during hole fabrication are chipout, delamination, and oversize conditions. These hole flaw types were generated in critical areas of static, compression, and fatigue specimens fabricated from T300/5208 graphite/epoxy system. The specimens were tested in static and cyclic pin bearing modes in addition to compression loading. Results of these tests are presented and discussed. The hole chipout defect reduced the static and cyclic endurance characteristics. Oversize holes also lowered the cyclic pin bearing endurance, but had no influence of the static pin bearing characteristics. Delamination had no insignificant influence on the static tension and cyclic pin bearing characteristics. Compression tests demonstrated a deleterious effect for chipout of delamination defects. Hole quality requirements proposed are discussed.
The design and analysis of stiffened composite panel that is representative of the fuselage structure of existing wide bodied aircraft is discussed. The panel is a minimum weight design, based on the current level of technology and realistic loads and criteria. Several different stiffener configurations were investigated in the optimization process. The final configuration is an all graphite/epoxy J-stiffened design in which the skin between adjacent stiffeners is permitted to buckle under design loads. Fail safe concepts typically employed in metallic fuselage structure have been incorporated in the design. A conservative approach has been used with regard to structural details such as skin/frame and stringer/frame attachments and other areas where sufficient design data was not available.
A NASTRAN model of a UH-1B tail boom that had been designed for another project was used to investigate the effect on structural integrity of simulated projectile damage. Elements representing skin, and sections of stringers, longerons and bulkheads were systematically deleted to represent projectile damage. The structure was loaded in a manner to represent the flight loads that would be imposed on the tail boom at a 130 knot cruise. The deflection of four points on the rear of the tail boom relative to the position of these points for the unloaded, undamaged condition of the tail boom was used as a measure of the loss of structural rigidity. The same procedure was then used with the material properties of the aluminum alloys replaced with the material properties of T300/5208 high strength graphite/epoxy fibrous composite material, (0, + or - 45, 90)s for the skin and (0, + or - 45)s for the longerons, stringers, and bulk heads.