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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Systems, Apparatuses, and Methods for Using Durable Adhesively Bonded Joints for Sandwich Structures

Systems, methods, and apparatus for increasing durability of adhesively bonded joints in a sandwich structure. Such systems, methods, and apparatus includes an first face sheet and an second face sheet as well as an insert structure, the insert structure having a first insert face sheet, a second insert face sheet, and an insert core material. In addition, sandwich core material is arranged between the first face sheet and the second face sheet. A primary bondline may be coupled to the face sheet(s) and the splice. Further, systems, methods, and apparatus of the present disclosure advantageously reduce the load, provide a redundant path, reduce structural fatigue, and/or increase fatigue life.

Smeltzer, III, Stanley S.↗
NASA NTRS2016

Methods for Using Durable Adhesively Bonded Joints for Sandwich Structures

Systems, methods, and apparatus for increasing durability of adhesively bonded joints in a sandwich structure. Such systems, methods, and apparatus includes an first face sheet and an second face sheet as well as an insert structure, the insert structure having a first insert face sheet, a second insert face sheet, and an insert core material. In addition, sandwich core material is arranged between the first face sheet and the second face sheet. A primary bondline may be coupled to the face sheet(s) and the splice. Further, systems, methods, and apparatus of the present disclosure advantageously reduce the load, provide a redundant path, reduce structural fatigue, and/or increase fatigue life.

Smeltzer, Stanley S., III↗
NASA NTRS2018

Repair of Sandwich Structure in Support of the Payload Adapter Fitting

As part of a program examining a composite payload adaptor fitting (PAF) for NASA’s Space Launch System (SLS), a repair study of impact damage and misdrilled holes was undertaken. At the beginning of this repair study, the PAF was baselined as a honeycomb sandwich structure with eight-ply quasi-isotropic, carbon-fiber-reinforced epoxy facesheets. Although the baseline configuration could change, the repair program presented herein is generic enough in nature such that it will apply to most sandwich configurations. The vast majority of loads experienced by this structure will be in-plane compression; thus, this repair study concentrates on the in-plane compression strength of representative sandwich structure specimens. The PAF is a truncated cone with a minimum diameter of about 170 inches at the top and a maximum diameter of about 335 inches at the bottom. While the launch vehicle hardware should be protected throughout its life on the ground, rogue events (or misdrilled holes) are still a possibility. This study is not meant to address large scale damage or damage to the part other than in the acreage (the uniform portion of the structure that does not consist of joints or other detailed areas), but address the most probable type of damages (small impacts and misdrilled holes) in the vast majority of the structure (the acreage).

Nettles, A. T.↗
NASA NTRS2011

High-Fidelity Modeling for Health Monitoring in Honeycomb Sandwich Structures

High-Fidelity Model of the sandwich composite structure with real geometry is reported. The model includes two composite facesheets, honeycomb core, piezoelectric actuator/sensors, adhesive layers, and the impactor. The novel feature of the model is that it includes modeling of the impact and wave propagation in the structure before and after the impact. Results of modeling of the wave propagation, impact, and damage detection in sandwich honeycomb plates using piezoelectric actuator/sensor scheme are reported. The results of the simulations are compared with the experimental results. It is shown that the model is suitable for analysis of the physics of failure due to the impact and for testing structural health monitoring schemes based on guided wave propagation.

Luchinsky, Dimitry G.↗
NASA NTRS1967

Detection of entrapped moisture in honeycomb sandwich structures

Thermal neutron moisture detection system detects entrapped moisture in intercellular areas of bonded honeycomb sandwich structures. A radium/beryllium fast neutron source bombards a specimen. The emitted thermal neutrons from the target nucleus are detected and counted by a boron trifluoride thermal neutron detector.

Hallmark, W. B.↗
NASA NTRS2018

Sandwich Structure Risk Reduction in Support of the Payload Adapter Fitting

Reducing risk for utilizing honeycomb sandwich structure for the Space Launch System payload adapter fitting includes determining what parameters need to be tested for damage tolerance to ensure a safe structure. Specimen size and boundary conditions are the most practical parameters to use in damage tolerance inspection. The effect of impact over core splices and foreign object debris between the facesheet and core is assessed. Effects of enhanced damage tolerance by applying an outer layer of carbon fiber woven cloth is examined. A simple repair technique for barely visible impact damage that restores all compression strength is presented.

Nettles, A. T.↗
NASA NTRS2013

Characterizing Facesheet/Core Disbonding in Honeycomb Core Sandwich Structure

Results are presented from an experimental investigation into facesheet core disbonding in carbon fiber reinforced plastic/Nomex honeycomb sandwich structures using a Single Cantilever Beam test. Specimens with three, six and twelve-ply facesheets were tested. Specimens with different honeycomb cores consisting of four different cell sizes were also tested, in addition to specimens with three different widths. Three different data reduction methods were employed for computing apparent fracture toughness values from the test data, namely an area method, a compliance calibration technique and a modified beam theory method. The compliance calibration and modified beam theory approaches yielded comparable apparent fracture toughness values, which were generally lower than those computed using the area method. Disbonding in the three-ply facesheet specimens took place at the facesheet/core interface and yielded the lowest apparent fracture toughness values. Disbonding in the six and twelve-ply facesheet specimens took place within the core, near to the facesheet/core interface. Specimen width was not found to have a significant effect on apparent fracture toughness. The amount of scatter in the apparent fracture toughness data was found to increase with honeycomb core cell size.

Rinker, Martin↗
NASA NTRS1997

Damage-Tolerance Characteristics of Composite Fuselage Sandwich Structures with Thick Facesheets

Damage tolerance characteristics and results from experimental and analytical studies of a composite fuselage keel sandwich structure subjected to low-speed impact damage and discrete-source damage are presented. The test specimens are constructed from graphite-epoxy skins borided to a honeycomb core, and they are representative of a highly loaded fuselage keel structure. Results of compression-after-impact (CAI) and notch-length sensitivity studies of 5-in.-wide by 10-in.long specimens are presented. A correlation between low-speed-impact dent depth, the associated damage area, and residual strength for different impact-energy levels is described; and a comparison of the strength for undamaged and damaged specimens with different notch-length-to-specimen-width ratios is presented. Surface strains in the facesheets of the undamaged specimens as well as surface strains that illustrate the load redistribution around the notch sites in the notched specimens are presented and compared with results from finite element analyses. Reductions in strength of as much as 53.1 percent for the impacted specimens and 64.7 percent for the notched specimens are observed.

McGowan, David M.↗
DOE OSTI2025

Sandwich-structured paper composite with water and oil resistance for food packaging and tableware applications

The growing environmental challenges posed by plastic waste from disposable tableware highlight the urgent need for sustainable alternatives. Traditional plastics decompose over centuries, generating microplastics that threaten ecosystems and human health. While lignin has emerged as a promising material for plastic replacement, its inherent dark brown color and processing challenges in paper-based products have limited its application, particularly in food-contact materials. Here, to address these limitations, we have developed biodegradable sandwich-structured paper composites comprising parchment paper as surface layers and a lignin-polymer core with polyvinyl alcohol (PVA) and polylactic acid (PLA). This innovative structure eliminates the need for binders, minimizing potential food contamination, and enables direct application as packaging or molded tableware. Lignin micro- and nano-particles (LMNP) enhances durability and provides natural water and oil resistance without harmful additives, such as per- and polyfluoroalkyl substances (PFAS), while PVA and PLA improve the composite's tenacity. The resulting material, composed of 65 wt% lignin, demonstrates excellent water and oil resistance, with no penetration exceeding 1 h, and exhibits enhanced tensile strength (45 MPa), making it a viable and eco-friendly alternative for disposable tableware.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Actively cooled plate fin sandwich structural panels for hypersonic aircraft

An unshielded actively cooled structural panel was designed for application to a hypersonic aircraft. The design was an all aluminum stringer-stiffened platefin sandwich structure which used a 60/40 mixture of ethylene glycol/water as the coolant. Eight small test specimens of the basic platefin sandwich concept and three fatigue specimens from critical areas of the panel design was fabricated and tested (at room temperature). A test panel representative of all features of the panel design was fabricated and tested to determine the combined thermal/mechanical performance and structural integrity of the system. The overall findings are that; (1) the stringer-stiffened platefin sandwich actively cooling concept results in a low mass design that is an excellent contender for application to a hypersonic vehicle, and (2) the fabrication processes are state of the art but new or modified facilities are required to support full scale panel fabrication.

Smith, L. M.↗
NASA NTRS2016

Design Considerations for Thermally Insulating Structural Sandwich Panels for Hypersonic Vehicles

Simplified thermal/structural sizing equations were derived for the in-plane loading of a thermally insulating structural sandwich panel. Equations were developed for the strain in the inner and outer face sheets of a sandwich subjected to uniaxial mechanical loads and differences in face sheet temperatures. Simple equations describing situations with no viable solution were developed. Key design parameters, material properties, and design principles are identified. A numerical example illustrates using the equations for a preliminary feasibility assessment of various material combinations and an initial sizing for minimum mass of a sandwich panel.

Blosser, Max L.↗
NASA NTRSDate not supplied

Computational Assessment of the Opening Mode Facesheet-to-Core Fracture Toughness of a Thin-Gage Facesheet Sandwich Structure

The single-cantilevered beam test (SCB) is currently being considered for standardization for measuring the opening mode fracture toughness of sandwich structures subjected to facesheet-to-core separation. At present, the Area method is considered the benchmark method for determining energy required to propagate the crack. This method is problematic since it requires periodic unloading and cannot be evaluated instantaneously. Therefore, a method is needed to accurately and instantaneously calculate opening mode fracture toughness. In previous work, SCB tests with thin-gauge facesheets were performed to compare the J-integral approach to data reduction methods including the Modified Beam Theory (MBT) and the Area method. Large deviations (over 10%) in the calculated fracture toughness were observed between the J-integral and MBT for large displacements. In this study, a simulated SCB experiment using a virtual crackclosure technique was performed to assess the previously observed discrepancies. The predicted load displacement response, the predicted angle at the load application point, and the predicted crack growth results are in good agreement (within 5%) with the corresponding experimental data. Using the predicted load and angles, the predicted J-integral is in good agreement (within 10%) with the experimentally obtained solution. Using the MBT approach, the previously observed deviations in the fracture toughness were determined to be associated with the empirical extrapolation procedure to estimate the crack-root rotation correction from nonlinear compliance curves. The nonlinear compliance is determined to be associated with large displacement effects observed within the predicted and experimental results.

Sandwich Composite↗
NASA NTRS1978

Effect of temperature on composite sandwich structures subjected to low velocity projectile impact

An experimental investigation was conducted to study the effect of low velocity projectile impact on graphite/epoxy and Kevlar 49- graphite/epoxy sandwich structural components. Testing was performed at moderately low- and high-temperatures to assess the strength degradation of composites as compared to room temperature values. Low energy projectile impact is considered to simulate the damage caused by runway debris such as small rocks, dropping of hand tools during servicing, etc., on secondary aircraft structures fabricated out of composites. The preload and impact energy necessary to cause catastrophic failure were determined. The residual strength of impact-damaged specimens was also measured.

Sharma, A. V.↗
NASA NTRS2011

Measuring Moisture Levels in Graphite Epoxy Composite Sandwich Structures

Graphite epoxy composite (GEC) materials are used in the construction of rocket fairings, nose cones, interstage adapters, and heat shields due to their high strength and light weight. However, they absorb moisture depending on the environmental conditions they are exposed to prior to launch. Too much moisture absorption can become a problem when temperature and pressure changes experienced during launch cause the water to vaporize. The rapid state change of the water can result in structural failure of the material. In addition, heat and moisture combine to weaken GEC structures. Diffusion models that predict the total accumulated moisture content based on the environmental conditions are one accepted method of determining if the material strength has been reduced to an unacceptable level. However, there currently doesn t exist any field measurement technique to estimate the actual moisture content of a composite structure. A multi-layer diffusion model was constructed with Mathematica to predict moisture absorption and desorption from the GEC sandwich structure. This model is used in conjunction with relative humidity/temperature sensors both on the inside and outside of the material to determine the moisture levels in the structure. Because the core materials have much higher diffusivity than the face sheets, a single relative humidity measurement will accurately reflect the moisture levels in the core. When combined with an external relative humidity measurement, the model can be used to determine the moisture levels in the face sheets. Since diffusion is temperaturedependent, the temperature measurements are used to determine the diffusivity of the face sheets for the model computations.

Nurge, Mark↗
NASA NTRS1999

Facesheet Wrinkling in Sandwich Structures

The purpose of this paper is to provide a concise summary of the state-of-the-art for the analysis of the facesheet wrinkling mode of failure in sandwich structures. This document is not an exhaustive review of the published research related to facesheet wrinkling. Instead, a smaller number of key papers are reviewed in order to provide designers and analysts with a working understanding of the state-of-the-art. Designers and analysts should use this survey to guide their judgement when deciding which one of a wide variety of available facesheet wrinkling design formulas is applicable to a specific design problem.

Ley, Robert P.↗
NASA NTRS2010

Sizing Single Cantilever Beam Specimens for Characterizing Facesheet/Core Peel Debonding in Sandwich Structure

This technical publication details part of an effort focused on the development of a standardized facesheet/core peel debonding test procedure. The purpose of the test is to characterize facesheet/core peel in sandwich structure, accomplished through the measurement of the critical strain energy release rate associated with the debonding process. Following an examination of previously developed tests and a recent evaluation of a selection of these methods, a single cantilever beam (SCB) specimen was identified as being a promising candidate for establishing such a standardized test procedure. The objective of the work described here was to begin development of a protocol for conducting a SCB test that will render the procedure suitable for standardization. To this end, a sizing methodology was developed to ensure appropriate SCB specimen dimensions are selected for a given sandwich system. Application of this method to actual sandwich systems yielded SCB specimen dimensions that would be practical for use. This study resulted in the development of a practical SCB specimen sizing method, which should be well-suited for incorporation into a standardized testing protocol.

Ratcliffe, James G.↗
NASA NTRS2010

Sizing Single Cantilever Beam Specimens for Characterizing Facesheet/Core Peel Debonding in Sandwich Structure

This paper details part of an effort focused on the development of a standardized facesheet/core peel debonding test procedure. The purpose of the test is to characterize facesheet/core peel in sandwich structure, accomplished through the measurement of the critical strain energy release rate associated with the debonding process. The specific test method selected for the standardized test procedure utilizes a single cantilever beam (SCB) specimen configuration. The objective of the current work is to develop a method for establishing SCB specimen dimensions. This is achieved by imposing specific limitations on specimen dimensions, with the objectives of promoting a linear elastic specimen response, and simplifying the data reduction method required for computing the critical strain energy release rate associated with debonding. The sizing method is also designed to be suitable for incorporation into a standardized test protocol. Preliminary application of the resulting sizing method yields practical specimen dimensions.

Ratcliffe, James G.↗