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NASA NTRS2013

Ultrasonic Low-Friction Containment Plate for Thermal and Ultrasonic Stir Weld Processes

The thermal stir welding (TSW) process is finding applications in fabrication of space vehicles. In this process, workpieces to be joined by TSW are drawn, by heavy forces, between "containment plates," past the TSW tool that then causes joining of the separate plates. It is believed that the TSW process would be significantly improved by reducing the draw force, and that this could be achieved by reducing the friction forces between the workpieces and containment plates. Based on use of high-power ultrasonics in metal forming processes, where friction reduction in drawing dies has been achieved, it is believed that ultrasonic vibrations of the containment plates could achieve similar friction reduction in the TSW process. By applying ultrasonic vibrations to the containment plates in a longitudinal vibration mode, as well as by mounting and holding the containment plates in a specific manner such as to permit the plates to acoustically float, friction between the metal parts and the containment plates is greatly reduced, and so is the drawing force. The concept was to bring in the ultrasonics from the sides of the plates, permitting the ultrasonic hardware to be placed to the side, away from the equipment that contains the thermal stir tooling and that applies clamping forces to the plates. Tests demonstrated that one of the major objectives of applying ultrasonics to the thermal stir system, that of reducing draw force friction, should be achievable on a scaled-up system.

Graff, Karl↗
NASA NTRS2013

Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

Seshadri, Banavara R.↗
NASA NTRS2014

Low-Stroke Actuation for a Serial Robot

A serial robot includes a base, first and second segments, a proximal joint joining the base to the first segment, and a distal joint. The distal joint that joins the segments is serially arranged and distal with respect to the proximal joint. The robot includes first and second actuators. A first tendon extends from the first actuator to the proximal joint and is selectively moveable via the first actuator. A second tendon extends from the second actuator to the distal joint and is selectively moveable via the second actuator. The robot includes a transmission having at least one gear element which assists rotation of the distal joint when an input force is applied to the proximal and/or distal joints by the first and/or second actuators. A robotic hand having the above robot is also disclosed, as is a robotic system having a torso, arm, and the above-described hand.

Gao, Dalong↗
NASA NTRS2013

Integration Science and Technology of Silicon-Based Ceramics and Composites:Technical Challenges and Opportunities

Ceramic integration technologies enable hierarchical design and manufacturing of intricate ceramic and composite parts starting with geometrically simpler units that are subsequently joined to themselves and/or to metals to create components with progressively higher levels of complexity and functionality. However, for the development of robust and reliable integrated systems with optimum performance for high temperature applications, detailed understanding of various thermochemical and thermomechanical factors is critical. Different technical approaches are required for the integration of ceramic to ceramic and ceramic to metal systems. Active metal brazing, in particular, is a simple and cost-effective method to integrate ceramic to metallic components. Active braze alloys usually contain a reactive filler metal (e.g., Ti, Cr, V, Hf etc) that promotes wettability and spreading by inducing chemical reactions with the ceramics and composites. In this presentation, various examples of brazing of silicon nitride to themselves and to metallic systems are presented. Other examples of joining of ceramic composites (C/SiC and SiC/SiC) using ceramic interlayers and the resulting microstructures are also presented. Thermomechanical characterization of joints is presented for both types of systems. In addition, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be presented.

Singh, M.↗
NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗
NASA NTRS2016

Amorphous Carbon-Boron Nitride Nanotube Hybrids

A method for joining or repairing boron nitride nanotubes (BNNTs). In joining BNNTs, the nanotube structure is modified with amorphous carbon deposited by controlled electron beam irradiation to form well bonded hybrid a-C/BNNT structures. In repairing BNNTs, the damaged site of the nanotube structure is modified with amorphous carbon deposited by controlled electron beam irradiation to form well bonded hybrid a-C/BNNT structures at the damage site.

Kim, Jae Woo↗
NASA NTRS2016

Apatite-Melt Partitioning at 1 Bar: An Assessment of Apatite-Melt Exchange Equilibria Resulting from Non-Ideal Mixing of F and Cl in Apatite

The mineral apatite [Ca5(PO4)3(F,Cl,OH)] is present in a wide range of planetary materials. Due to the presence of volatiles within its crystal structure (X-site), many recent studies have attempted to use apatite to constrain the volatile contents of planetary magmas and mantle sources. In order to use the volatile contents of apatite to precisely determine the abundances of volatiles in coexisting silicate melt or fluids, thermodynamic models for the apatite solid solution and for the apatite components in multi-component silicate melts and fluids are required. Although some thermodynamic models for apatite have been developed, they are incomplete. Furthermore, no mixing model is available for all of the apatite components in silicate melts or fluids, especially for F and Cl components. Several experimental studies have investigated the apatite-melt and apatite-fluid partitioning behavior of F, Cl, and OH in terrestrial and planetary systems, which have determined that apatite-melt partitioning of volatiles are best described as exchange equilibria similar to Fe-Mg partitioning between olivine and silicate melt. However, McCubbin et al. recently reported that the exchange coefficients may vary in portions of apatite compositional space where F, Cl, and OH do not mix ideally in apatite. In particular, solution calorimetry data of apatite compositions along the F-Cl join exhibit substantial excess enthalpies of mixing. In the present study, we conducted apatite-melt partitioning experiments in evacuated, sealed silica-glass tubes at approximately 1 bar and 950-1050 degrees Centigrade on a synthetic Martian basalt composition equivalent to the basaltic shergottite Queen Alexandria Range (QUE) 94201. These experiments were conducted dry, at low pressure, to assess the effects of temperature and apatite composition on the partitioning behavior of F and Cl between apatite and basaltic melt along the F-Cl apatite binary join, where there is non-ideal mixing of F and Cl in apatite.

McCubbin, F. M.↗
NASA NTRS2014

Origins of the Lunar and Planetary Laboratory, University of Arizona

The roots of the Lunar and Planetary Laboratory (LPL) extend deep into the rich fabric of G. P. Kuiper's view of the Earth as a planet and planetary systems as expected companions to most stars, as well as the post-war emergent technology of infrared detectors suitable for astronomy. These concepts and events began with Kuiper's theoretical work at Yerkes Observatory on the origin of the Solar System, his discovery of two planetary satellites and observational work with his near-infrared spectrometer on the then-new McDonald 82-inch telescope in the mid- to late-1940s. A grant for the production of a photographic atlas of the Moon in the mid-1950s enabled him to assemble the best existing images of the Moon and acquire new photographs. This brought E. A. Whitaker and D. W. G. Arthur to Yerkes. Others who joined in the lunar work were geologist Carl S. Huzzen and grad student E. P. Moore, as well as undergrad summer students A. B. Binder and D. P. Cruikshank (both in 1958). The Atlas was published in 1959, and work began on an orthographic lunar atlas. Kuiper's view of planetary science as an interdisciplinary enterprise encompassing astronomy, geology, and atmospheric physics inspired his vision of a research institution and an academic curriculum tuned to the combination of all the scientific disciplines embraced in a comprehensive study of the planets. Arrangements were made with the University of Arizona (UA) to establish LPL in affiliation with the widely recognized Inst. of Atmospheric Physics. Kuiper moved to the UA in late 1960, taking the lunar experts, graduate student T. C. Owen (planetary atmospheres), and associate B. M. Middlehurst along. G. van Biesbroeck also joined the migration to Tucson; Binder and Cruikshank followed along as new grad students. Astronomy grad student W. K. Hartmann came into the academic program at UA and the research group at LPL in 1961. Senior faculty affiliating with LPL in the earliest years were T. Gehrels, A. B. Meinel, H. L. Johnson, and F. J. Low, each with their own grad students and associates. Work began on IR spectroscopy and a rectified lunar atlas. Kuiper and Johnson started the search for future observatory sites in N. America and Hawaii.

Planets↗
NASA NTRS2016

Latent Hardeners for the Assembly of Epoxy Composites

Large-scale composite structures are commonly joined by secondary bonding of molded-and-cured thermoset components. This approach may result in unpredictable joint strengths. In contrast, assemblies made by co-curing, although limited in size by the mold, result in stable structures, and are certifiable for commercial aviation because of structural continuity through the joints. Multifunctional epoxy resins were prepared that should produce fully-cured subcomponents with uncured joining surfaces, enabling them to be assembled by co-curing in a subsequent out-of-autoclave process. Aromatic diamines were protected by condensation with a ketone or aldehyde to form imines. Properties of the amine-cured epoxy were compared with those of commercially available thermosetting epoxy resins and rheology and thermal analysis were used to demonstrate the efficacy of imine protection. Optimum conditions to reverse the protecting chemistry in the solid state using moisture and acid catalysis were determined. Alternative chemistries were also investigated. For example, chain reaction depolymerization and photoinitiated catalysts would be expected to minimize liberation of volatile organic content upon deprotection and avoid residual reactive species that could damage the resin. Results from the analysis of protected and deprotected resins will be presented.

Palmieri, Frank↗
NASA NTRS2017

Partitioning of F and Cl Between Apatite and a Synthetic Shergottite Liquid (QUE 94201) at 4 Gpa from 1300 TO 1500 C

Apatite [Ca5(PO4)3(F,Cl,OH)] is present in a wide range of planetary materials. Due to the presence of volatiles within its crystal structure (Xsite), many recent studies have attempted to use apatite to constrain the volatile contents of planetary magmas and mantle sources. In order to use the volatile contents of apatite to accurately determine the abundances of volatiles in coexisting silicate melt or fluids, thermodynamic models for the apatite solid solution and for the apatite components in multicomponent silicate melts and fluids are required. Although some thermodynamic models for apatite have been developed, they are incomplete. Furthermore, no mixing model is available for all of the apatite components in silicate melts or fluids, especially for F and Cl components. Several experimental studies have investigated the apatite-melt and apatite-fluid partitioning behavior of F, Cl, and OH in terrestrial and planetary systems, which have determined that apatite-melt partitioning of volatiles are best described as exchange equilibria similar to Fe-Mg partitioning between olivine and silicate melt. However, McCubbin et al., recently reported that the exchange coefficients vary in portions of apatite compositional space where F, Cl, and OH do not mix ideally in apatite. In particular, solution calorimetry data of apatite compositions along the F-Cl join exhibit substantial excess enthalpies of mixing, and McCubbin et al. reported substantial deviations in the Cl-F exchange Kd along the F-Cl apatite join that could be explained by the preferential incorporation of F into apatite. In the present study, we assess the effect of apatite crystal chemistry on F-Cl exchange equilibria between apatite and melt at 4 GPa over the temperature range of 1300-1500 C. The goal of these experiments is to assess the variation in the Ap-melt Cl-F exchange Kd over a broad range of F:Cl ratios in apatite. The results of these experiments could be used to understand at what composition apatite shifts from a hexagonal unit cell with space group P63/m to a unit cell with monoclinic symmetry within space group P21/b. We anticipate that this transition occurs at >70% chlorapatite based on solution calorimetry data.

McCubbin, F. M.↗
NASA NTRS2017

Analysis of High-order Social Interaction of Female Mice on the International Space Station

Social interactions are adaptive responses to environmental pressures that have evolved to facilitate the success of individual animals and their progeny. Quantifying social behavior in social animals is therefore one method of evaluating an animal's health, wellbeing and their adjustment to changes in their environment. The interaction between environment and animal can influence numerous other physiological and psychological responses that may enhance, deter or shift an animals social paradigm. For this study, we utilized flight video from the Rodent Research Hardware and Operations Validation mission (Rodent Research-1; RR1) on the International Space Station (ISS). Female mice spent 37 days in microgravity on the ISS and video was captured during the final 33 days. In a previous analysis of individual behavior, we also reported an observed spontaneous ambulatory behavior which we termed circling or 'race tracking,' and we anecdotally observed an increase in group organization around this behavior. In this analysis we further examined this behavior, and other social interactions, to determine if (1) animals joining in on this behavior were induced by other cohort members already participating in this circling behavior, (2) rates of joining varied by number already participating.

spacefligh↗
NASA NTRS2018

Inertial Weldment of Rhenium and Inconel 718

Inertia welding has been found to be a successful method for joining pure rhenium to Inconel 718, and with additional experimentation, this process may have great potential for rocket nozzle applications. Refractory metals are ideally suited to this application, where high temperatures and oxidizing environment survivability is required, but not all of the thruster must be made of these materials, only the areas that require them. A bolted joint between the two metals is not ideal, especially for small thrusters where the mess of a bolted join will come at a steep price. A welded joint would be preferred for flight thrusters.

Cavender, D. P.↗
NASA NTRS2017

Kelt-16b: A Highly Irradiated, Ultra-Short Period Hot Jupiter Nearing Tidal Disruption

We announce the discovery of KELT-16b, a highly irradiated, ultra-short period hot Jupiter transiting the relatively bright (visual magnitude equals 11.7) star TYC 2688-1839-1/KELT-16. A global analysis of the system shows KELT-16 to be an F7V star with effective temperature equal to 6236 plus or minus 54 degrees Kelvin, log g (sub asterisk) equal to 4.253 from plus 0.031 to minus 0.036, [Fe/H] equal to minus 0.002 from plus 0.086 to minus 0.085, mass (sub asterisk) equal to 1.211 from plus 0.043 to minus 0.046 times the solar mass, and radius (sub asterisk) equal to 1.360 from plus 0.064 o minus 0.053 times the solar radius. The planet is a relatively high-mass inflated gas giant with planetary mass equal to 2.75 from plus 0.016 to minus 0.15 times Jupiter's mass, planetary radius equal to 1.415 from plus 0.084 to minus 0.067 times Jupiter's radius, density planetary rho equal to 1.20 plus or minus 0.18 grams per cubic centimeter, surface gravity, log planetary gravity equal to 3.530 from plus 0.042 to minus 0.049, and equatorial temperature equal to 2453 from plus 55 to minus 47 degrees Kelvin. The best-fitting linear ephemeris is T(sub C) equal to 22457247.24791 plus or minus 0.00019 BJD (sub TDB) and P equal to 0.9689951 plus or minus 0.0000024 day. KELT-16b joins WASP-18b, -19b, -43b, -103b, and HATS-18b as the only giant transiting planets with periodicity P less than 1 day. Its ultra-short period and high irradiation make it a benchmark target for atmospheric studies by the Hubble Space Telescope, Spitzer, and eventually the James Webb Space Telescope. For example, as a hotter, higher-mass analog of WASP-43b, KELT-16b may feature an atmospheric temperature-pressure inversion and day-to-night temperature swing extreme enough for TiO to rain out at the terminator. KELT-16b could also join WASP-43b in extending tests of the observed mass-metallicity relation of the solar system gas giants to higher masses. KELT-16b currently orbits at a mere approximately 1.7 Roche radii from its host star, and could be tidally disrupted in as little as a few times 10 (sup 5) years (for a stellar tidal quality factor of Q (sup prime) (sub asterisk) equal to 10 (sup 5). Finally, the likely existence of a widely separated bound stellar companion in the KELT-16 system makes it possible that Kozai-Lidov (KL) oscillations played a role in driving KELT-16b inward to its current precarious orbit.

Oberst, Thomas E.↗
NASA NTRS2019

Assembling and Testing NASA’s Space Launch System for First Flight

NASA is planning its next step toward human expansion into the solar system. The Space Launch System (SLS) (Figure 1) is a critical enabling component of that expansion. SLS payloads for its early missions include the Orion crew vehicle and components for Gateway, a lunar outpost orbiting the Moon that will facilitate research, technology and partnerships for eventual Mars missions. All major core stage hardware for test and flight completed structural manufacturing in 2018. The major components for the first flight vehicle are complete or approaching completion of internal equipment installation. The core stage forward join operation is also complete. The 10 booster segments needed for first flight have been cast and are ready to ship to NASA’s Kennedy Space Center (KSC) for mating and stacking. The four RS-25 core stage engines completed processing at NASA’s Stennis Space Center (SSC) and are ready for core stage integration. The Orion Stage Adapter (OSA) joined the Interim Cryogenic Propulsion Stage (ICPS) at KSC to await the rest of SLS flight hardware. Production and preparation of hardware for the second mission is also underway. Looking ahead to a busy 2019, liquid oxygen (LOX) tank, liquid hydrogen (LH2) tank and intertank structural testing will take place. This paper will discuss the current and planned status of SLS development in context of NASA’s overall exploration plans.

Askin, Bruce R.↗
NASA NTRS2019

NASA’s Space Launch System: Exploration Mission-1 Hardware Nears Completion

The Space Launch System (SLS) Program completed several significant production milestones in 2018 for the launch vehicle’s first mission (Fig. 1) and is poised for greater accomplishments in 2019. With manufacturing and hardware installation finished, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The upper stage, the Interim Cryogenic Propulsion Stage (ICPS), and the Orion Stage Adapter (OSA), where 13 6U CubeSats will ride to deep space on EM-1, were completed and delivered to Exploration Ground Systems at KSC in 2017 and 2018, respectively. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗
NASA NTRS2019

NASA’s Space Launch System: First Mission Hardware Nears Completion

The Space Launch System (SLS) Program (Fig. 1) completed several significant production milestones in 2018 for its first mission and is poised for greater accomplishments in 2019. With manufacturing and hardware installation complete, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success and scientific discovery. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗
NASA NTRS2020

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗
NASA NTRSDate not supplied

Novel insights enabled by combining mouse muscle datasets from the Rodent Research-1 mission

Biological space experiments are often expensive and difficult to conduct. As such, it is critical to maximize the value of the data that is collected during these experiments. One way to do this is to combine multiple–previously separate–datasets. This can increase the number of replicates for the conditions of interest (and hence statistical power), allow new multi-factor questions to be asked, and potentially highlight new patterns that otherwise would not have been identified from single-dataset studies. However, the process of combining datasets introduces noise due to inherent technical variations between experiments. To better understand the insights that can be gained from multi-dataset analyses and the problems that may arise from joining multiple datasets, several mouse muscle RNA-Seq datasets from the Rodent Research-1 mission were first selected. Then, using the R package DESeq2, principal component analysis (PCA) plots and differentially expressed gene (DEG) lists between ground and flight muscle samples were generated for individual datasets and for different pairwise combinations of datasets. Several new DEGs were identified in the combined datasets, and patterns in the PCA plots were affected depending on which datasets were joined. Understanding the results of this work will be critical for future studies that seek to perform multi-dataset analyses.

spaceflight↗