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An overview of the NASA textile composites program

The NASA Langley Research Center is conducting and sponsoring research to explore the benefits of textile reinforced composites for civil transport aircraft primary structures. The objective of this program is to develop and demonstrate the potential of affordable textile reinforced composite materials to meet design properties and damage tolerance requirements of advanced aircraft structures. In addition to in-house research, the program includes major participation by the aircraft industry and aerospace textile companies. The major program elements include development of textile preforms, processing science, mechanics of materials, experimental characterization of materials, and development and evaluation of textile reinforced composite structural elements and subcomponents. The NASA Langley in-house research is focused on science-based understanding of resin transfer molding (RTM), development of powder-coated towpreg processes, analysis methodology, and development of a performance database on textile reinforced composites. The focus of the textile industry participation is on development of multidirectional, damage-tolerant preforms, and the aircraft industry participation is in the areas of innovative design concepts, cost-effective fabrication, and testing of textile reinforced composite structural elements and subcomponents. Textile processes such as 3-D weaving, 2-D and 3-D braiding, and knitting/stitching are being compared with conventional laminated tape processes for improved damage tolerance. Through-the-thickness reinforcements offer significant damage tolerance improvements. However, these gains must be weighed against potential loss in in-plane properties such as strength and stiffness. Analytical trade studies are underway to establish design guidelines for the application of textile material forms to meet specific loading requirements. Fabrication and testing of large structural components are required to establish the full potential of textile reinforced composite materials. The goals of the NASA Langley-sponsored research program are to demonstrate technology readiness with subscale composite components by 1995 and to verify the performance of full-scale composite primary aircraft structural components by 1997. The status of textile reinforced composite structural elements under development by Boeing, Douglas, Lockheed, and Grumman are presented. Included are braided frames and woven/stitched wing and fuselage panels.

Dexter, H. Benson↗

Compositionally-Graded Shape Memory Film for Self-Deployment of Membrane Reflectors and Optics

The next generation of space systems will require large apertures in order to image faint targets or cover large areas of Earth. These large apertures must be able to fit inside a launch vehicle fairing, be light enough for launch into orbit, and deploy on orbit with repeatability and reliability. The current state-of-the-art in flight optics is represented by the 4 meter LAMP telescope, with an areal density of 10 km sq m. Development of a Beryllium mirror demonstration article for NGST (Next Generation Space Telescope) at the University of Arizona indicate areal densities of 0.5 kg sq m with flight hardware in the 12 meter range. With progressive improvements in existing deployment, packaging, and structural technologies, the size of optics and reflectors will continue to increase, while mass is reduced. However, without a breakthrough in materials, packaging and/or deployment technologies, the goal for Gossamer structures of 0.1 kg sq m is unachievable for the near and mid-term NASA missions. Membrane technology provides the best hope of achieving such low areal densities. In combination with advances in membrane materials and structures, development of revolutionary techniques for deployment systems can provide significant improvements in large aperture technology. In this paper, the results of a six-month Phase I research effort to demonstrate the application of thin film NiTi to aerospace-qualified membrane and mesh materials are presented. Deposition of shape memory thin film was achieved Astromesh (trademark) metal mesh and CP-1, and optical-quality polymer membrane. Not only was full-coating deposition demonstrated, but also small segment deposition which holds potential for local surface control. Deployment of these materials was also demonstrated, setting the stage for the development of a larger test article.

Hill, Lisa↗

Analytical Failure Prediction Method Developed for Woven and Braided Composites

Historically, advances in aerospace engine performance and durability have been linked to improvements in materials. Recent developments in ceramic matrix composites (CMCs) have led to increased interest in CMCs to achieve revolutionary gains in engine performance. The use of CMCs promises many advantages for advanced turbomachinery engine development and may be especially beneficial for aerospace engines. The most beneficial aspects of CMC material may be its ability to maintain its strength to over 2500 F, its internal material damping, and its relatively low density. Ceramic matrix composites reinforced with two-dimensional woven and braided fabric preforms are being considered for NASA s next-generation reusable rocket turbomachinery applications (for example, see the preceding figure). However, the architecture of a textile composite is complex, and therefore, the parameters controlling its strength properties are numerous. This necessitates the development of engineering approaches that combine analytical methods with limited testing to provide effective, validated design analyses for the textile composite structures development.

Min, James B.↗

Cryogenic Fracture Toughness Evaluation of an Investment Cast Al-Be Alloy for Structural Applications

Aluminum-Beryllium metal matrix composite materials are useful due to their desirable performance characteristics for aerospace applications. Desirable characteristics of this material includes light-weight, dimensional stability, stiffness, good vibration damping characteristics, low coefficient of thermal expansion, and workability, This material is 3.5 times stiffer and 22% lighter than conventional aluminum alloys. electro-optical systems, advanced sensor and guidance components for flight and satellite systems, components for light-weight high-performance aircraft engines, and structural components for helicopters. Aluminum-beryllium materials are now available in the form of near net shape investment castings. In this materials properties characterization study, the cryogenic tensile and fracture properties of an investment casting alloy, Beralcast 363, were determined. Tensile testing was performed at 21 C (70 F), -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F), and fracture (K(sub lc) and da/dN) testing was performed at -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F). Their use is attractive for weight critical structural applications such as advanced

Gamwell, W. R.↗

Printing Outside the Box: Additive Manufacturing Processes for Fabrication of Large Aerospace Structures

To achieve NASA's mission of space exploration, innovative manufacturing processes are being applied to the fabrication of propulsion elements. Liquid rocket engines (LREs) are comprised of a thrust chamber and nozzle extension as illustrated in figure 1 for the J2X upper stage engine. Development of the J2X engine, designed for the Ares I launch vehicle, is currently being incorporated on the Space Launch System. A nozzle extension is attached to the combustion chamber to obtain the expansion ratio needed to increase specific impulse. If the nozzle extension could be printed as one piece using free-form additive manufacturing (AM) processes, rather than the current method of forming welded parts, a considerable time savings could be realized. Not only would this provide a more homogenous microstructure than a welded structure, but could also greatly shorten the overall fabrication time. The main objective of this study is to fabricate test specimens using a pulsed arc source and solid wire as shown in figure 2. The mechanical properties of these specimens will be compared with those fabricated using the powder bed, selective laser melting technology at NASA Marshall Space Flight Center. As printed components become larger, maintaining a constant temperature during the build process becomes critical. This predictive capability will require modeling of the moving heat source as illustrated in figure 3. Predictive understanding of the heat profile will allow a constant temperature to be maintained as a function of height from substrate while printing complex shapes. In addition, to avoid slumping, this will also allow better control of the microstructural development and hence the properties. Figure 4 shows a preliminary comparison of the mechanical properties obtained.

Babai, Majid↗

Ultra-High Operation Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing: Test Facility & Performance Evaluations

Solar Heat for Industrial Processes (SHIP) cavity receivers are capable of generating electricity or industrial process heat by absorbing thermal energy from solar radiation, focused on a small area. The concentration of solar radiation on the small area of the receiver enables the achievement of high temperatures (ranging from 400°C to 1,100°C) of a working fluid, thus making the SHIP technology thermodynamically comparable with conventional power plants. A volumetric receiver consists of a porous structure-generally made of silicon carbide or metal, which absorbs solar radiation and converts it into heat energy. Heat energy from the porous materials is then transferred to the fluid following through them. A volumetric receiver acts as a convective heat exchanger, transferring heat to the fluid through convection. Open-loop volumetric receivers work with air at atmospheric pressure and are suitable for single-cycle or multi-cycle energy plants. A Model Based Systems Engineering (MBSE) approach was used to develop a test bed at Sandia national Laboratories (SNL) capable of demonstrating an open-loop volumetric air receiver developed by General Electric Aerospace (GE Aerospace). This paper presents the development of the various MBSE methods, test bed, and testing operations for the GE air receiver, which was experimentally demonstrated to achieve 1,350°C for over 3 hours of operation and an approximate 70% receiver efficiency. By being able to achieve such high temperatures >1,000°C, this work provides the potential to support many SHIP industrial use cases.

14 SOLAR ENERGY↗

Micromechanics-Based Computational Simulation of Ceramic Matrix Composites

Advanced high-temperature Ceramic Matrix Composites (CMC) hold an enormous potential for use in aerospace propulsion system components and certain land-based applications. However, being relatively new materials, a reliable design properties database of sufficient fidelity does not yet exist. To characterize these materials solely by testing is cost and time prohibitive. Computational simulation then becomes very useful to limit the experimental effort and reduce the design cycle time, Authors have been involved for over a decade in developing micromechanics- based computational simulation techniques (computer codes) to simulate all aspects of CMC behavior including quantification of scatter that these materials exhibit. A brief summary/capability of these computer codes with typical examples along with their use in design/analysis of certain structural components is the subject matter of this presentation.

Murthy, Pappu L. N.↗

Effect of Composite Substrates on the Mechanical Behavior of Brazed Joints in Metal-Composite System

Advanced composite components are being considered for a wide variety of demanding applications in aerospace, space exploration, and ground based systems. A number of these applications require robust integration technologies to join dissimilar materials (metalcomposites) into complex structural components. In this study, three types of composites (C-C, C-SiC, and SiC-SiC) were vacuum brazed to commercially pure Ti using the active metal braze alloy Cusil-ABA (63Ag-35.3Cu-1.75Ti). Composite substrates with as fabricated and polished surfaces were used for brazing. The microstructure and composition of the joint, examined using scanning electron microscopy (SEM) coupled with energy dispersive spectroscopy (EDS), showed sound metallurgical bonding in all systems. The butt strap tensile (BST) test was performed on bonded specimens at room and elevated temperatures. Effect of substrate composition, interlaminar properties, and surface roughness on the mechanical properties and failure behavior of joints will be discussed.

Singh, M.↗

A Single Stage to Orbit Design for a Hybrid Mars Ascent

A Single Stage to Orbit (SSTO) hybrid propulsion system has been previously studied as an option for a conceptual Mars Ascent Vehicle (MAV). The hybrid motor uses a wax-based fuel developed specifically for this application, so it can take advantage of a single port design. The oxidizer is Mixed Oxides of Nitrogen (MON-25). Higher Nitric Oxide concentrations have been discussed in the past, however, the lower temperature capability is no longer needed. The MAV Payload Assembly (MPA), which would house the Orbiting Sample (OS) has changed substantially from previous iterations and has become more compact. Benefits of the hybrid option include its predicted low temperature behavior, high performance and ability to restart (enabling the SSTO). However, the hybrid technology remained at a relatively low Technology Readiness Level (TRL). In an attempt to increase the TRL, a technology development program has been underway for the past four years. The results of the technology development program are now being incorporated to an updated concept for a hybrid Mars Ascent Vehicle, with the eventual goal of informing a hybrid propulsion design that closes under the guidelines currently envisioned for a potential Mars Sample Return campaign. This paper focuses on the hybrid propulsion system design and the preliminary results from the first part of the FY19 technology development program (October 2018 to July 2019) and includes some results from a Preliminary Architecture Assessment (PAA) study. In the PAA, experts from all relevant subsystems (propulsion, avionics, GN&C, structures, thermal, etc.) are brought together to determine an updated vehicle design. The PAA is being run out of Marshall Space Flight Center (MSFC) in coordination with the Mars Sample Return study lead by the Jet Propulsion Laboratory (JPL). Currently, it is thought that the Mars Ascent Vehicle would be housed in a Sample Retrieval Lander (SRL), along with a fetch rover. The SRL would be responsible for several crucial functions on the MAV including heating, erection and providing the ignition signal. This paper will also outline the future testing and path forward through the rest of the fiscal year. This includes full scale testing at Whittinghill Aerospace, hypergolic additive testing at Purdue, evaluation of adding hypergolic additives to a full-scale grain. A hybrid fuel formulation has been updated with a reduced regression rate, which again was developed by Space Propulsion Group. This design will be used to determine the benefits of a hybrid versus solid propulsion system for a MAV, as they fit into the larger vision for a potential Mars Sample Return campaign.

Story, George↗

WFIRST CGI: Prism and Polarizer Characterization Modes

As part of its technology demonstration, the WFIRST coronagraph instrument (CGI) will demonstrate point source spectroscopy and polarization measurements of disks. The specific implementation of spectroscopy is a zero-deviation Amici prism and slit to be placed on the planet after high contrast has been achieved by CGI. The polarization optics are a set of Wollaston prisms so that orthogonal polarization states can be measured simultaneously. The CGI spectral characterization mode, being designed and built and Goddard Space Flight Center (GSFC), has a spectral resolution of R50 and is designed to accommodate a 15% bandpass spanning 610-785nm. In order to recover Stokes information, there are two sets of Wollaston prisms clocked 45 degrees with respect to one another with each measurement taken in series. The Wollaston design and optical elements are a contribution by the Japanese Aerospace Exploration Agency, with final alignment and testing being done at GSFC. The spectroscopy mode is designed to target Methane absorption features around 730nm, keeping the spectral resolution as low as possible to improve the signal-to-noise ratio and hence reduce detection time. We highlight the requirements for these modes and address the challenge of on-orbit spectral calibration for a deployable slit in the presence of pointing drifts. Of unique interest is how the observatory error budget couples into good stellar spectrum calibration and subsequent speckle subtraction. We also provide further detail on the optomechanical design, its stability based on thermal and structural predictions, modeled performance, and operations concept. These performance metrics are simulated to demonstrate how a slit located at an arbitrary field point is homed onto the planet and converted to a calibrated spectrum.

Tyler D Groff↗

Aerospace Cognitive Engineering Laboratory (ACELAB) Simulator for Electric Vertical Takeoff and Landing (eVOTL) Research and Development

A new generation of aerospace innovators are looking for ways to quickly and efficiently transport people in a safe and environmentally friendly manner. In the not-too-distant future, passengers and goods are expected to routinely fly aboard a new breed of cleaner, smarter air vehicles. This represents a new and significant challenge to the Federal Aviation Agency (FAA) which is responsible for aircraft certification, pilot licensing, operating approval and airspace integration. To help streamline this process, NASA has formulated its Advanced Air Mobility (AAM) project to provide research capabilities for development and evaluation of these new concepts and an environment where industry and regulators can work together to understand the requirements and work toward consensus standards for the new market. This paper will describe the development of the Aerospace Cognitive Engineering Lab Rapid Automation Test (ACELeRATE) simulator. ACELeRATE is an adaptable fixed-base aircraft simulator focused on the investigation of the performance and interaction of pilots and increasingly automated aircraft systems. ACELeRATE can be re-configured to support various simulation environments. The simulator includes a simple reconfigurable cockpit placed within a 10-foot spherical dome with a cluster of real-time image generators, high-resolution displays and highly realistic scenery with the surrounding digital terrain and required cultural area details (e.g., hangars, runways, ramp areas, taxiways, test range apparatus, buildings with designated rooftop landing areas, and other man-made 3D structures). This paper will also describe the various hardware and software tools employed in the ACELeRATE simulator, including engineering tools used by NASA for electric Vertical Takeoff and Landing (eVTOL) vehicle equations of motion, wind-model simulation in an urban environment, as well as the various modeling techniques and tools used to quickly generate highly realistic 3D terrain models for low level flight including urban terrain and obstacle depictions.

AAM Simulation Cockpit↗

Force Limited Vibration Testing

This slide presentation reviews the concept and applications of Force Limited Vibration Testing. The goal of vibration testing of aerospace hardware is to identify problems that would result in flight failures. The commonly used aerospace vibration tests uses artificially high shaker forces and responses at the resonance frequencies of the test item. It has become common to limit the acceleration responses in the test to those predicted for the flight. This requires an analysis of the acceleration response, and requires placing accelerometers on the test item. With the advent of piezoelectric gages it has become possible to improve vibration testing. The basic equations have are reviewed. Force limits are analogous and complementary to the acceleration specifications used in conventional vibration testing. Just as the acceleration specification is the frequency spectrum envelope of the in-flight acceleration at the interface between the test item and flight mounting structure, the force limit is the envelope of the in-flight force at the interface . In force limited vibration tests, both the acceleration and force specifications are needed, and the force specification is generally based on and proportional to the acceleration specification. Therefore, force limiting does not compensate for errors in the development of the acceleration specification, e.g., too much conservatism or the lack thereof. These errors will carry over into the force specification. Since in-flight vibratory force data are scarce, force limits are often derived from coupled system analyses and impedance information obtained from measurements or finite element models (FEM). Fortunately, data on the interface forces between systems and components are now available from system acoustic and vibration tests of development test models and from a few flight experiments. Semi-empirical methods of predicting force limits are currently being developed on the basis of the limited flight and system test data. A simple two degree of freedom system is shown and the governing equations for basic force limiting results for this system are reviewed. The design and results of the shuttle vibration forces (SVF) experiments are reviewed. The Advanced Composition Explorer (ACE) also was used to validate force limiting. Test instrumentation and supporting equipment are reviewed including piezo-electric force transducers, signal processing and conditioning systems, test fixtures, and vibration controller systems. Several examples of force limited vibration testing are presented with some results.

random vibration testing↗

Phenylethynyl Terminated Imide (PETI) Composites Made by High Temperature VARTM

Fabrication of composite structures using vacuum assisted resin transfer molding (VARTM) is generally more affordable than conventional autoclave techniques. Recent efforts have focused on adapting VARTM for the fabrication of high temperature composites. Due to their low melt viscosity and long melt stability, certain phenylethynyl terminated imides (PETI) can be processed into composites using high temperature VARTM (HT-VARTM). However, one of the disadvantages of the current HT-VARTM resin systems has been the high porosity of the resultant composites. For aerospace applications, a void fraction of <2% is desired. In the current study, two PETI resins, LARC. PETI-330 and LARC. PETI-8 have been used to fabricate test specimens using HT-VARTM. The resins were infused into carbon fiber preforms at 260 C and cured between 316 and 371 C. Photomicrographs of the panels were taken and void contents were determined by acid digestion. Modifications to the thermal cycle used in the laminate fabrication have reduced the void content significantly; typically .3% for carbon fiber biaxially woven fabric and less than 2% for carbon fiber uniaxial fabric. Mechanical properties (short beam shear and flexure) of the panels were determined at both room and elevated temperatures. The results of this work are presented herein. This paper is declared a work of the U.S. Government and is not subject to copyright protection in the United States.

Chose, Sayata↗

Processing and Characterization of PETI Composites Fabricated by High Temperature VARTM

The use of composites as primary structures on aerospace vehicles has increased dramatically over the past decade. As these advanced structures increase in size and complexity, their production costs have grown significantly. A major contributor to these manufacturing costs is the requirement of elevated processing pressures, during the thermal cure, to create fully consolidated composites. For certain composite parts, high temperature vacuum assisted resin transfer molding (HT-VARTM) can offer reduced fabrication costs compared to conventional autoclave techniques. The process has been successfully used with phenylethynyl terminated imide (PETI) resins developed by NASA LaRC. In the current study, two PETI resins, LARC(TradeMark) PETI-330 and LARC(TradeMark) PETI-8 have been used to make test specimens using HT-VARTM. Based on previous work at NASA LaRC, larger panels with a quasi-isotropic lay-up were fabricated. The resultant composite specimens exhibited void contents <3% by volume depending on the type of carbon fabric preform used. Mechanical properties of the panels were determined at both room and elevated temperatures. These included open-hole compressive (OHC) and short beam shear (SBS) properties. Limited process modeling efforts were carried out including infusion times, composite panel size limitations and fabric permeability characterization. Work has also been carried out to develop new PETI based resins specifically geared towards HT-VARTM. The results of this work are presented herein.

Ghose, Sayata↗

Sintered Cathodes for All-Solid-State Structural Lithium-Ion Batteries

All-solid-state structural lithium ion batteries serve as both structural load-bearing components and as electrical energy storage devices to achieve system level weight savings in aerospace and other transportation applications. This multifunctional design goal is critical for the realization of next generation hybrid or all-electric propulsion systems. Additionally, transitioning to solid state technology improves upon battery safety from previous volatile architectures. This research established baseline solid state processing conditions and performance benchmarks for intercalation-type layered oxide materials for multifunctional application. Under consideration were lithium cobalt oxide and lithium nickel manganese cobalt oxide. Pertinent characteristics such as electrical conductivity, strength, chemical stability, and microstructure were characterized for future application in all-solid-state structural battery cathodes. The study includes characterization by XRD, ICP, SEM, ring-on-ring mechanical testing, and electrical impedance spectroscopy to elucidate optimal processing parameters, material characteristics, and multifunctional performance benchmarks. These findings provide initial conditions for implementing existing cathode materials in load bearing applications.

Ceramics↗

Characterizing Early Damage Evolution in CMCs

Silicon carbide / silicon carbide ceramic matrix composites (SiC/SiC CMCs) are structural ceramics that are well-suited for the extreme environment conditions of space and aerospace applications largely due to their low weight, creep resistance, damage tolerance, and high specific strength. In CMCs, the initiation and accumulation of damage depends on characteristics of the constituent landscape including porosity, interfacial properties, and geometric distribution of CMC constituents. In order to accurately predict the lifetimes of these advanced composites, it is critical to understand the evolution of damage and to characterize which early damage mechanisms subsequently lead to crack coalescence and macroscopic failure. In this study, SiC/SiC minicomposites are characterized through an experimental approach combining acoustic emission (AE) with tensile testing in-SEM (scanning electron microscope), in order to examine early damage initiation (below the proportional limit) and its evolution at room temperature. The approach provides insight into the relative activity of early damage mechanisms in CMCs at both the surface and subsurface levels and sheds light on the impact of fabrication choices on the evolution of damage to final failure. The potential application of this combined approach towards the characterization of damage in SiC/SiC CMCs under more complex testing conditions will also be discussed.

damage evolution↗

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗

High Temperature VARTM of Phenylethynyl Terminated Imides (PETI) Resins

Fabrication of composite structures using vacuum assisted resin transfer molding (VARTM) is generally more affordable than conventional autoclave techniques. Recent efforts have focused on adapting VARTM for the fabrication of high temperature composites. Due to their low melt viscosity and long melt stability, certain phenylethynyl terminated imides (PETI) can be processed into composites using high temperature VARTM (HT-VARTM). However, one of the disadvantages of the current HT-VARTM resin systems has been the high porosity of the resultant composites. For aerospace applications a void fraction of less than 2% is desired. In the current study, two PETI resins, LARCTM PETI-330 and LARCTM PETI-8 have been used to fabricate test specimens using HT-VARTM. The resins were infused into carbon fiber preforms at 260 C and cured between 316 C and 371 C. Modifications to the thermal cycle used in the laminate fabrication have reduced the void content significantly (typically < 3%) for carbon fiber biaxially woven fabric. Photomicrographs of the panels were taken and void contents were determined by acid digestion. For carbon fiber uniaxial fabric, void contents of less than 2% have been obtained using both PETI-8 and PETI-330. Mechanical properties of the panels were determined at both room and elevated temperatures. These include short beam shear and flexure tests. The results of this work are presented herein.

Ghose, Sayata↗