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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Establishing the relationship between manufacturing and component performance in stretch formed thermoplastic composites

Flexible manufacturing methods are needed to reduce the cost of using advanced composites in structural applications. One method that allows for this is the stretch forming of long discontinuous fiber materials with thermoplastic matrices. In order to exploit this flexibility in an economical way, a thorough understanding of the relationship between manufacturing and component performance must be developed. This paper reviews some of the recent work geared toward establishing this understanding. Micromechanics models have been developed to predict the formability of the material during processing. The latest improvement of these models includes the viscoelastic nature of the matrix and comparison with experimental data. A finite element scheme is described which can be used to model the forming process. This model uses equivalent anisotropic viscosities from the micromechanics models and predicts the microstructure in the formed part. In addition, structural models have been built to account for the material property gradients that can result from the manufacturing procedures. Recent developments in this area include the analysis of stress concentrations and a failure model each accounting for the heterogeneous material fields.

Santare, Michael H.↗
NASA NTRS1995

Risks and reliability of manufacturing processes as related to composite materials for spacecraft structures

Fabricating primary aircraft and spacecraft structures using advanced composite materials entail both benefits and risks. The benefits come from much improved strength-to-weight ratios and stiffness-to-weight ratios, potential for less part count, ability to tailor properties, chemical and solvent resistance, and superior thermal properties. On the other hand, the risks involved include high material costs, lack of processing experience, expensive labor, poor reproducibility, high toxicity for some composites, and a variety of space induced risks. The purpose of this project is to generate a manufacturing database for a selected number of materials with potential for space applications, and to rely on this database to develop quantitative approaches to screen candidate materials and processes for space applications on the basis of their manufacturing risks including costs. So far, the following materials have been included in the database: epoxies, polycyanates, bismalemides, PMR-15, polyphenylene sulfides, polyetherimides, polyetheretherketone, and aluminum lithium. The first four materials are thermoset composites; the next three are thermoplastic composites, and the last one is is a metal. The emphasis of this database is on factors affecting manufacturing such as cost of raw material, handling aspects which include working life and shelf life of resins, process temperature, chemical/solvent resistance, moisture resistance, damage tolerance, toxicity, outgassing, thermal cycling, and void content, nature or type of process, associate tooling, and in-process quality assurance. Based on industry experience and published literature, a relative ranking was established for each of the factors affecting manufacturing as listed above. Potential applications of this database include the determination of a delta cost factor for specific structures with a given process plan and a general methodology to screen materials and processes for incorporation into the current conceptual design optimization of future spacecrafts as being coordinated by the Vehicle Analysis Branch where this research is being conducted.

Bao, Han P.↗
NASA NTRS2008

Design and Analysis of Tow-Steered Composite Shells Using Fiber Placement

In this study, a sub-scale advanced composite shell design is evaluated to determine its potential for use on a future aircraft fuselage. Two composite shells with the same nominal 8-ply [+/-45/+/-Theta](sub s) layup are evaluated, where Theta indicates a tow-steered ply. To build this shell, a fiber placement machine would be used to steer unidirectional prepreg tows as they are placed around the circumference of a 17-inch diameter right circular cylinder. The fiber orientation angle varies continuously from 10 degrees (with respect to the shell axis of revolution) at the crown, to 45 degrees on the side, and back to 10 degrees on the keel. All 24 tows are placed at each point on every fiber path in one structure designated as the shell with overlaps. The resulting pattern of tow overlaps causes the laminate thickness to vary between 8 and 16 plies. The second shell without tow overlaps uses the capability of the fiber placement machine to cut and add tows at any point along the fiber paths to fabricate a shell with a nearly uniform 8-ply laminate thickness. Issues encountered during the design and analysis of these shells are presented and discussed. Static stiffness and buckling loads of shells with tow-steered layups are compared with the performance of a baseline quasi-isotropic shell using both finite element analyses and classical strength of materials theory.

Wu, K. Chauncey↗
NASA NTRS1992

ACT/ICAPS: Thermoplastic composite activities

McDonnell Aircraft Company (MCAIR) is teamed with Douglas Aircraft Company (DAC) under NASA's Advanced Composite Technology (ACT) initiative in a program entitled Innovative Composite Aircraft Primary Structures (ICAPS). Efforts at MCAIR have focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. Based on innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldline concepts. Manufacturing techniques included autoclave consideration, single diaphragm co-consolidation (SDCC), and roll-forming.

Renieri, M. P.↗
NASA NTRS1984

Constituent Property - Composite Property Relationships in Thermoset Matrices

A procedure to effectively screen and evaluate resins for aerospace structures and advanced composites is described. The following conclusions were advanced: (1) laminate damage tolerance correlates positively with neat resin G sub IC; (2) TGDDM/DDS resins can be toughened; (3) using butadiene-nitrile rubbers, neat resin G sub IC and ultimate strain increase with increasing nitrile content, with the number of chemically reactive groups per molecule, and with increasing molecular weight; (4) better balance of properties combined with high G sub IC may be achieved by using tough glassy thermoplastics instead of rubbers to modify TGDDM/DDS resins; (5) both toughening mechanisms require good phase separation with an effective interphase; (6) the kind and the amount of thermoplastic modifier remain to be selected; and (7) presently only about a fourfold increase in G sub IC was achieved, whereas a forty fold increase is sought; modification of the matrix backbone and of crosslinking is required.

Diamant, J.↗
NASA NTRS1996

Advanced AE Techniques in Composite Materials Research

Advanced, waveform based acoustic emission (AE) techniques have been successfully used to evaluate damage mechanisms in laboratory testing of composite coupons. An example is presented in which the initiation of transverse matrix cracking was monitored. In these tests, broad band, high fidelity acoustic sensors were used to detect signals which were then digitized and stored for analysis. Analysis techniques were based on plate mode wave propagation characteristics. This approach, more recently referred to as Modal AE, provides an enhanced capability to discriminate and eliminate noise signals from those generated by damage mechanisms. This technique also allows much more precise source location than conventional, threshold crossing arrival time determination techniques. To apply Modal AE concepts to the interpretation of AE on larger composite specimens or structures, the effects of modal wave propagation over larger distances and through structural complexities must be well characterized and understood. To demonstrate these effects, measurements of the far field, peak amplitude attenuation of the extensional and flexural plate mode components of broad band simulated AE signals in large composite panels are discussed. These measurements demonstrated that the flexural mode attenuation is dominated by dispersion effects. Thus, it is significantly affected by the thickness of the composite plate. Furthermore, the flexural mode attenuation can be significantly larger than that of the extensional mode even though its peak amplitude consists of much lower frequency components.

Prosser, William H.↗
NASA NTRS1972

Moisture effects on the high-temperature strength of fiber-reinforced resin composites.

Under NAS 8-27435, the Convair Aerospace Division of General Dynamics and their subcontractor, Hercules Incorporated, have conducted studies on the effects of moisture on the properties of fiber-reinforced resin composites and on the epoxy resins presently used in advanced composites. Data are presented on the resins and composites subjected to varying time/temperature/humidity or time/temperature/water-boil exposures. The effects of moisture on matrix, reinforcement, and fiber/resin interface are discussed and supported by experimental test data.

Hertz, J.↗
NASA NTRS1988

Stress concentration around circular hole in a composite material specimen representative of the X-29A forward-swept wing aircraft

The theory of anisotropic elasticity was used to evaluate the anisotropic stress concentration factors of a composite laminated plate containing a small circular hole. This advanced composite material was used to manufacture the X-29A forward swept wing. Observe that the usual isotropic material stress concentration factor is three. However, for composite material, it was found that the anisotropic stress concentration factor is no longer constant, and that the locations of maximum tangential stress points could shift by changing the fiber orientation with respect to the loading axis. The analysis showed that through the lamination process, the stress concentration factor could be drastically reduced, and therefore the structural performance could be improved. Both the mixture rule approach and the constant strain approach were used to calculate the stress concentration factor. The results predicted by the mixture rule approach were about 20 percent deviate from the experimental data. However, the results predicted by the constant strain approach matched the testing data very well. This showed the importance of the inplane shear effect on the evaluation of stress concentration factor for the X-29A composite plate.

Yeh, Hsien-Yang↗
NASA NTRS1988

Temperature effect on stress concentration around circular hole in a composite material specimen representative of X-29A forward-swept wing aircraft

The theory of anisotropic elasticity was used to evaluate the anisotropic stress concentration factors of a composite laminated plate containing a small circular hole. This advanced composite was used to manufacture the X-29A forward-swept wing. It was found for composite material, that the anisotropic stress concentration is no longer a constant, and that the locations of maximum tangential stress points could shift by changing the fiber orientation with respect to the loading axis. The analysis showed that through the lamination process, the stress concentration factor could be reduced drastically, and therefore the structural performance could be improved. Both the mixture rule approach and the constant strain approach were used to calculate the stress concentration factor of room temperature. The results predicted by the mixture rule approach were about twenty percent deviate from the experimental data. However, the results predicted by the constant strain approach matched the testing data very well. This showed the importance of the inplane shear effect on the evaluation of the stress concentration factor for the X-29A composite plate.

Yeh, Hsien-Yang↗
NASA NTRS1992

Overview of mechanics of materials branch activities in the computational structures area

Base programs and system programs are discussed. The base programs include fundamental research of composites and metals for airframes leading to characterization of advanced materials, models of behavior, and methods for predicting damage tolerance. Results from the base programs support the systems programs, which change as NASA's missions change. The National Aerospace Plane (NASP), Advanced Composites Technology (ACT), Airframe Structural Integrity Program (Aging Aircraft), and High Speed Research (HSR) programs are currently being supported. Airframe durability is one of the key issues in each of these system programs. The base program has four major thrusts, which will be reviewed subsequently. Additionally, several technical highlights will be reviewed for each thrust.

Poe, C. C., Jr.↗
NASA NTRS2001

Thermal Testing of Tow-Placed, Variable Stiffness Panels

Commercial systems for precise placement of pre-preg composite tows are enabling technology that allows fabrication of advanced composite structures in which the tows may be precisely laid down along curvilinear paths within a given ply. For laminates with curvilinear tow paths, the fiber orientation angle varies continuously throughout the laminate, and is not required to be straight and parallel in each ply as in conventional composite laminates. Hence, the stiffness properties vary as a function of location in the laminate, and the associated composite structure is called a "variable stiffness" composite structure.

Wu, K. Chauncey↗
NASA NTRS1997

A Review of the NASA Textile Composites Research

During the past 15 years NASA has taken the lead role in exploiting the benefits of textile reinforced composite materials for application to aircraft structures. The NASA Advanced Composites Technology (ACT) program was started in 1989 to develop composite primary structures for commercial transport airplanes with costs that are competitive with metal structures. As part of this program, several contractors investigated the cost, weight, and performance attributes of textile reinforced composites. Textile composites made using resin transfer molding type processes were evaluated for numerous applications. Methods were also developed to predict resin infiltration and flow in textile preforms and to predict and measure mechanical properties of the textile composites. This paper describes the salient results of that program.

Poe, C. C., Jr.↗
NASA NTRS1980

Buckling and postbuckling research on flat and curved composite panels

Progress in the development of verified design technology for generic advanced-composite structural components loaded in compression is reported. Generic structural configurations material systems and load ranges of interest for a given application were investigated using structural procedures, structural analysis procedures, and laboratory testing of structural specimens. Both flat and curved composite compression panels that are designed either to be buckling resistant or to have postbuckling strength depending on the expected application of the panels were considered.

Starnes, J. H., Jr.↗
NASA NTRS1980

NASA service experience with composite components

NASA Langley has been active in sponsoring flight service programs with advanced composites during the past decade. A broad data base and confidence in the durability of composite structures are being developed. Flight service experience is reported for more than 140 composite aircraft components with up to 8 years service and almost two million successful component flight hours. Composite components are being evaluated on Boeing, Douglas, and Lockheed transport aircraft. Components are currently under development for service evaluation on Bell and Sikorsky helicopters. Design concepts and inspection and maintenance results are reported for components currently in service. Components under development in the NASA Aircraft Energy Efficiency (ACEE) program are discussed. Results of flight, outdoor ground, and controlled laboratory environmental tests on composite materials used in the flight service programs are also presented.

Dexter, H. B.↗
NASA NTRS1986

Performance and loads data from a hover test of a full-scale advanced technology XV-15 rotor

A hover test of a full-scale, composite, advanced technology XV-15 rotor was conducted at the Outdoor Aerodynamic Research Facility at Ames Research Center. The primary objective of the test was to obtain accurate measurements of the hover performance of this rotor system. Data were acquired for rotor tip Mach numbers ranging from 0.35 to 0.73. The rotor was tested with several alternate blade root and blade-tip configurations. Data are presented on rotor performance, rotor-wake downwash velocities, and rotor system loads.

Felker, Fort F.↗
NASA NTRS1988

High performance composites research at NASA-Langley

Barriers to the more extensive use of advanced composites in heavily loaded structures on commercial transports are discussed from a materials viewpoint. NASA-Langley matrix development activities designed to overcome these barriers are presented. These include the synthesis of processible, tough, durable matrices, the development of resin property/composite property relationships which help guide the synthesis program, and the exploitation of new processing technology to effectively combine reinforcement filament with polymer matrices. Examples of five classes of polymers being investigated as matrix resins at NASA Langley are presented, including amorphous and semicrystalline thermoplastics, lightly crosslinked thermoplastics, semi-interpenetrating networks and toughened thermosets. Relationships between neat resin modulus, resin fracture energy, interlaminar fracture energy, composite compression strength, and post-impact compression strength are shown. Powder and slurry processing techniques are discussed.

Stclair, Terry L.↗
NASA NTRS1988

High performance composites research at NASA-Langley

Barriers to the more extensive use of advanced composites in heavily loaded structures on commercial transports are discussed from a materials viewpoint. NASA Langley matrix development activities designed to overcome these barriers are presented. These include the synthesis of processable, tough, durable matrices, the development of resin-property/composite-property relationships which help guide the synthesis program, and the exploitation of new processing technology to effectively combine reinforcement filaments with polymer matrices. Examples of five classes of polymers being investigated as matrix resins at NASA Langley are presented, including amorphous and semicrystalline thermoplastics, lightly crosslinked thermoplastics, semiinterpenetrating networks, and toughened thermosets. Relationships between neat resin modulus, resin fracture energy, interlaminar fracture energy, composite compression strength, and postimpact compression strength are shown. Powder and slurry processing techniques are discussed.

Saint Clair, Terry L.↗
NASA NTRS1992

Composite materials for structures on planetary surfaces

The physical and mechanical properties of advanced composite materials as related to their use in structures on planetary surfaces are reviewed. Polymer matrix composites are recommended as the best materials in the first exploration stages. Achievement of mechanical properties, physical properties, improved processability, and ease of assembly required on planetary surfaces depends on the tailorability of composites.

Radford, Donald W.↗