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At least 523 records · Page 29

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NASA NTRS2014

Texture-Induced Anisotropy in an Inconel 718 Alloy Deposited Using Electron Beam Freeform Fabrication

A test block of Inconel (IN) 718 was fabricated using electron beam freeform fabrication (EBF(sup 3)) to examine how the EBF(sup 3) deposition process affects the microstructure, crystallographic texture, and mechanical properties of IN 718. Tests revealed significant anisotropy in the elastic modulus for the as-deposited IN 718. Subsequent tests were conducted on specimens subjected to a heat treatment designed to decrease the level of anisotropy. Electron backscatter diffraction (EBSD) was used to characterize crystallographic texture in the as-deposited and heat treated conditions. The anisotropy in the as-deposited condition was strongly affected by texture as evidenced by its dependence on orientation relative to the deposition direction. Heat treatment resulted in a significant improvement in modulus of the EBF(sup 3) product to a level nearly equivalent to that for wrought IN 718 with reduced anisotropy; reduction in texture through recrystallization; and production of a more homogeneous microstructure.

Tayon, W.↗

NASA NTRS2014

Launch Load Resistant Spacecraft Mechanism Bearings Made From NiTi Superelastic Intermetallic Materials

Compared to conventional bearing materials (tool steel and ceramics), emerging Superelastic Intermetallic Materials (SIMs), such as 60NiTi, have significantly lower elastic modulus and enhanced strain capability. They are also immune to atmospheric corrosion (rusting). This offers the potential for increased resilience and superior ability to withstand static indentation load without damage. In this paper, the static load capacity of hardened 60NiTi 50-mm-bore ball bearing races are measured to correlate existing flat-plate indentation load capacity data to an actual bearing geometry through the Hertz stress relations. The results confirmed the validity of using the Hertz stress relations to model 60NiTi contacts; 60NiTi exhibits a static stress capability (approximately 3.1 GPa) between that of 440C (2.4 GPa) and REX20 (3.8 GPa) tool steel. When the reduced modulus and extended strain capability are taken into account, 60NiTi is shown to withstand higher loads than other bearing materials. To quantify this effect, a notional space mechanism, a 5-kg mass reaction wheel, was modeled with respect to launch load capability when supported on standard (catalogue geometry) design 440C; 60NiTi and REX20 tool steel bearings. For this application, the use of REX20 bearings increased the static load capability of the mechanism by a factor of three while the use of 60NiTi bearings resulted in an order of magnitude improvement compared to the baseline 440C stainless steel bearings

DellaCorte, Christopher↗

NASA NTRS2016

Composite Cure Process Modeling and Simulations using COMPRO(Registered Trademark) and Validation of Residual Strains using Fiber Optics Sensors

Composite cure process induced residual strains and warping deformations in composite components present significant challenges in the manufacturing of advanced composite structure. As a part of the Manufacturing Process and Simulation initiative of the NASA Advanced Composite Project (ACP), research is being conducted on the composite cure process by developing an understanding of the fundamental mechanisms by which the process induced factors influence the residual responses. In this regard, analytical studies have been conducted on the cure process modeling of composite structural parts with varied physical, thermal, and resin flow process characteristics. The cure process simulation results were analyzed to interpret the cure response predictions based on the underlying physics incorporated into the modeling tool. In the cure-kinetic analysis, the model predictions on the degree of cure, resin viscosity and modulus were interpreted with reference to the temperature distribution in the composite panel part and tool setup during autoclave or hot-press curing cycles. In the fiber-bed compaction simulation, the pore pressure and resin flow velocity in the porous media models, and the compaction strain responses under applied pressure were studied to interpret the fiber volume fraction distribution predictions. In the structural simulation, the effect of temperature on the resin and ply modulus, and thermal coefficient changes during curing on predicted mechanical strains and chemical cure shrinkage strains were studied to understand the residual strains and stress response predictions. In addition to computational analysis, experimental studies were conducted to measure strains during the curing of laminated panels by means of optical fiber Bragg grating sensors (FBGs) embedded in the resin impregnated panels. The residual strain measurements from laboratory tests were then compared with the analytical model predictions. The paper describes the cure process procedures and residual strain predications, and discusses pertinent experimental results from the validation studies.

Sreekantamurthy, Thammaiah↗

NASA NTRS2016

Experimental Comparison of Piezoelectric and Magnetostrictive Shunt Dampers

A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.

energy conversion↗

NASA NTRS2016

Experimental Comparison of Piezoelectric and Magnetostrictive Shunt Dampers

A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30%PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.

piezoelectric↗

NASA NTRS2017

Crack Growth Testing of an Aluminum Oxynitride (AlON) for International Space Station Kick Panes

The mechanical properties of an aluminum oxynitride supplied as ground beams and disks were measured using ASTM International (formerly American Society for Testing and Materials) standard test methods. The slow crack growth tests were complicated by a "short" finish that increased strength scatter. Refining of the finish by more material removal in the second stage of grinding or the use of uniaxial grinding as specified in ASTM C1499 might have avoided the issue. The structural design parameters are an elastic modulus of E = 319 GPa, Poisson's ratio of v = 0.26, a fracture toughness of KIvb(A) = 2.18 MPa/m, slow crack growth (SCG) parameter n = 36, and SCG parameter A = 1.96 x 10-11 m/s.(MPa/m)n. For a ground finish, the Weibull parameters are a mean modulus of m = 14.0 and characteristic strength of sigma theta = 250.2 MPa. The 2015 vintage material exhibits similar mechanical properties to a 2010 vintage billet. Indentation flaws were not sensitive to the inherent crack growth mechanisms of this material and produced misleading results.

strength↗

NASA NTRS2017

Design Study for the Asteroid Redirect Vehicle (ARV) Composite Primary Bulkhead

A design study was undertaken of a carbon fiber primary bulkhead for a large solar electric propulsion (SEP) spacecraft. The bulkhead design, supporting up to 16 t of xenon propellant, progressed from one consisting of many simple parts with many complex joints, to one consisting of a few complex parts with a few simple joints. The unique capabilities of composites led to a topology that transitioned loads from bending to in-plane tension and shear, with low part count. This significantly improved bulkhead manufacturability, cost, and mass. The stiffness-driven structure utilized high-modulus M55J fiber unidirectional prepregs. A full-scale engineering demonstration unit (EDU) of the concept was used to demonstrate manufacturability of the concept. Actual labor data was obtained, which could be extrapolated to a full bulkhead. The effort demonstrated the practicality of using high-modulus fiber (HMF) composites for unique shape topologies that minimize mass and cost. The lessons are applicable to primary and secondary aerospace structures that are stiffness driven.

Cressman, Thomas O.↗

NASA NTRS2018

Simulation of Stochastic Mud-Crack Damage Formation in an Environmental Barrier Coating

The integrated Finite Element Analysis–Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button–sized disk–shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300oC to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.

residual tensile stress↗

NASA NTRS2019

A Three-Dimensional Thermodynamically Based Function for the Progressive Failure of Unidirectional Composites

A thermodynamically-based work potential theory for modeling progressive damage for laminated, unidirectional composites assuming plane stress (2D Schaperystheory) is extended to three dimensioanl (3D). An internal state variable, S, is defined to account for the dissipated energy due to damage evolution in the form of microstructure changes in the matrix. With the stationary of the total work potential with respect to the internal state variable, a thermodynamically-consistent set of evolution equationsis derived. The internal state variable is related to the transverse and shear modulithrough microdamage functions. In the first part of this work, coupon specimensare prepared to conduct experiments to characterize the relations between the internalstate variable and the transverse modulus as well as shear modulus. The informationis subsequent used for the prediction of three point bending test. In the second partof this work, objectivity is studied. Three separate methods utilizing different definitions of a reduced internal state variable or of the order of the polynomials are used to represent the matrix micro-damage functions are employed. The three methods are implemented in a user defined subroutine within a commercial finite element method software package. Results from numerical simulations of a center-notched composites panel are compared. The agreement in the maximum stress predictions among the three methods indicates that objectivity, with respect to the functional form of themicrodamage functions, is satisfied.

carbon fiber reinforced polymer composites↗

NASA NTRS2019

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

lattice geometry↗

NASA NTRS2018

Weibull-Based Stochastic Simulation of Mud-Crack Damage Formation in an Environmental Barrier Coating

The integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC (Micromechanics Analysis Code/Generalized Method of Cells) multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button-sized disk-shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300 degrees Centigrade to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.

Residual Tensile Stress↗

NASA NTRS2019

Stress Intensity Factors for Layered Pressure Vessel Inner Layer Through Cracks

A difficulty encountered when performing Fitness-for- Service assessments for layered pressure vessels (LPVs) is the lack of stress intensity factor solution in literature that produce accurate results for inner layer longitudinal through cracks. Using surrogate solutions such as a through crack in a plate or cylinder produce results that can be overly conservative especially for longer cracks. This is largely due to the ability of a layered pressure vessel to redistribute hoop load to other layers, the restricted radial movement of the cracked layer, and the friction forces applied in the cracked region. To understand this problem, a parametric finite element model (FEM) generator was developed that is capable of producing layered pressure vessel models with inner layer through cracks. The results from the FEMs were used to create a dataset of inner layer through crack stress intensity factors (KI) for layered pressure vessels corresponding to variations of internal pressure, radius, layer thicknesses, friction factor, and crack length. The elastic modulus of the material also has an effect on KI but, for this dataset, the elastic modulus was fixed at the typical value for steel - 29,500 ksi (203 GPa). Finally, a non-dimensional model was developed and calibrated using the dataset. This allows KI to be calculated without the need of a FEM using a closed-form equation. The results of the closed-form solution were then compared to FEM results showing accuracy was generally within 10%.

Hobbs, Joel R.↗

NASA NTRS2020

Molecular Dynamics Investigation of the Structural and Mechanical Properties of Off-Stoichiometric Epoxy Resins

We carried out molecular dynamics (MD) simulations to measure the mechanical properties of various off-stoichiometric polymers regarding amine to epoxy ratios (r) and to understand the stiffness of the polymers in terms of their structures. The aerospace-grade API-60 epoxy resin is used as an adhesive bond for assembling large-scale composite structures via the co-curing-ply bonding method. This method will produce a reliable and certifiable composite joint without additional fasteners. Calculated Young's modulus was measured from the uniaxial tension simulation with several high strain rates, and the experimental modulus was estimated by extrapolating the simulation results. We found that the stiffness was associated with molecular packing caused by chemical cross-linking. We also found that the number of network clusters gradually decreased as the ratio approached r = 1.0, which made the tighter cluster and the system much stiffer with an increase in the molecular weight and the degree of cross-linking. Structural properties such as Rg, MSD were measured to figure out the degree of stiffness with respect to the r.

Jang, Chang Woon↗

NASA NTRS2020

Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systèmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 °C to an ambient temperature of 23 °C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC.

Nemeth, Noel N.↗

NASA NTRSDate not supplied

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytic methods for the design of the discrete elements of ultralight lattice structures. This modular building block strategy allows for relatively simple element manufacturing as well as relatively simple robotic assembly of low mass-density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small, mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

digital materials↗

NASA NTRSDate not supplied

TPSAS-NF1676L-31622-DND

Electroactive polymers, especially electromechanically active polymers, have drawn extensive attention worldwide since the piezoelectricity and ferroelectricity of poly (vinylidene fluoride) (PVDF) was discovered in 1969. In the past three decades, several new classes of electroactive polymers that demonstrate promising electromechanical properties have been developed. Electrostrictive Graft Elastomers (G-elastomer) developed at NASA Langley Research Center have been recognized as one of the promising newly developed eletroactive polymers due to their large electric field-induced strain (~4%) and high mechanical modulus (~700 MPa). The combination of large induced strain and high mechanical modulus allows the electrostrictive graft elastomer to offer very promising electromechanical properties, in terms of output mechanical energy density, and plausible as a candidate for use in high performance and low mass actuation devices in various aerospace applications. In this presentation, the molecular structures, properties, processing and mechanisms of the electromechanical performance, as well as its applications in actuation devices for advanced aerospace technologies will be comprehensively reviewed and discussed.

Ji Su↗

NASA NTRSDate not supplied

TPSAS-NF1676L-31666-DND

Ji Su↗

NASA NTRSDate not supplied

TPSAS-NF1676L-30019-DND

Electroactive polymers, especially electromechanically active polymers, have drawn extensive attention worldwide since the piezoelectricity and ferroelectricity of poly (vinylidene fluoride) (PVDF) was discovered in 1969. In the past three decades, several new classes of electroactive polymers that demonstrated promising electromechanical properties have been developed. Electrostrictive Graft Elastomers (G-elastomer) developed at NASA Langley Research Center have been recognized as one of the newly developed promising eletroactive polymers due to their large electric field-induced strain (~4%) and high mechanical modulus (~700 MPa). The combination of large induced strain and high mechanical modulus makes the electrostrictive graft elastomer offer very promising electromechanical properties, in terms of output mechanical energy density, and plausible as a candidate for use in high performance and low mass actuation devices in various aerospace applications. In this presentation, the molecular structures, properties, processing and mechanisms of the electromechanical performance, as well as its applications in actuation devices for advanced aerospace technologies will be comprehensively reviewed and discussed.

Ji Su↗