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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

Aeroelastic Tailoring of the NASA Common Research Model via Novel Material and Structural Configurations

This work explores the use of tow steered composite laminates, functionally graded metals (FGM), thickness distributions, and curvilinear rib/spar/stringer topologies for aeroelastic tailoring. Parameterized models of the Common Research Model (CRM) wing box have been developed for passive aeroelastic tailoring trade studies. Metrics of interest include the wing weight, the onset of dynamic flutter, and the static aeroelastic stresses. Compared to a baseline structure, the lowest aggregate static wing stresses could be obtained with tow steered skins (47% improvement), and many of these designs could reduce weight as well (up to 14%). For these structures, the trade-off between flutter speed and weight is generally strong, although one case showed both a 100% flutter improvement and a 3.5% weight reduction. Material grading showed no benefit in the skins, but moderate flutter speed improvements (with no weight or stress increase) could be obtained by grading the spars (4.8%) or ribs (3.2%), where the best flutter results were obtained by grading both thickness and material. For the topology work, large weight reductions were obtained by removing an inner spar, and performance was maintained by shifting stringers forward and/or using curvilinear ribs: 5.6% weight reduction, a 13.9% improvement in flutter speed, but a 3.0% increase in stress levels. Flutter resistance was also maintained using straightrotated ribs although the design had a 4.2% lower flutter speed than the curved ribs of similar weight and stress levels were higher. These results will guide the development of a future design optimization scheme established to exploit and combine the individual attributes of these technologies.

Jutte, Christine V.↗
NASA NTRS2017

Measurement of Sub Degree Angular Carbon Fiber Tow Misalignment

NASA is investigating the use of carbon fiber tow steering to tune aeroelastic characteristics in advanced composite structures. In support of that effort, NASA is also investigating methods of measuring the angle of carbon fiber tows as they are placed. This work presents the results of using microwave reflectometry in the approximately 2 GHz region to measure carbon fiber tow angles at 0.1deg resolution.

Wilson, William C.↗
DOE OSTI2021

Tailored Fiber Placement for Complex Preforms

Tailored Fiber Placement (TFP) offers a novel approach to optimize fiber architecture for the fabrication of complex, structural parts not traditionally suitable for advanced composites. This technology not only offers new routes for weight reduction via metal substitution, it also offers cost reduction through minimization of material scrap and reduced labor. This reduction in component weight leads to increased fuel efficiency, and reduced production energy consumption, thereby, helping to achieve the stated IACMI technical goals. This technology leverages centuries of manufacturing development in support of the textile and embroidery industry. One major drawback to this technology is the lack of commercial or non- proprietary structural performance data and robust analytical tools used to optimize fiber architecture and predict performance. This project was structured to utilize common sub-element features to validate analytical performance tools, generate performance data, and gather cost and performance data on components of interest. This project was designed to give industry sponsors the confidence and ability to take full advantage of TFP to fabricate primary, highly loaded structure and integrate features such as metallic fasteners. The project focused principally on the use of high strength carbon fiber, such as T700, and the use of aerospace epoxy resin matrix to primarily support development of new composite applications in vehicle, aerospace, and industrial markets. This project applied previously developed analytical tools to predict the performance of TFP produced parts. This work focused on developing the pipeline to characterize material in order to accurately predict component performance when modifying the TFP print paths and stitch density. This focused on experimental characterization via standardized ASTM testing, alongside experimental testing of more representative service components by testing curved beam strength, beam shear performance, a large scale TFP lug, and ultimately designing a fully TFP clip bracket that reduced weight and cost compared to a traditional metallic component. The new knowledge gained from this program included: 1) development and demonstration of novel analytical tools applied to analysis of TFP preforms; 2) development and demonstration of a building block approach using coupons and sub-elements to optimize the design of a more complex component; 3) demonstration that optimized fiber orientation using TFP can exceed performance of conventional textile composite materials and can open new applications currently limited to metallic components; 4) Demonstration of performance and cost benefits of the TFP process as compared to metallic and conventional textile composites. Recommendations for follow-on work include development of design allowables to assess the impact of high temperature/moisture exposure or saturation during loading, tracking the impact of stitching needle wear on the performance of parts and ability to stitch thicker preforms, using TFP preforms as local reinforcement at areas of bearing or complex loading, and topology optimization of components by tow steering. The expertise developed during the course of this project can be leveraged to provide commercial engineering design and fabrication services using TFP. UDRI is in the process of formalizing their partnership with Spintech, who will serve as the commercialization partner for this technology and provide molding services and deliver finished components to the end user. UDRI will continue to produce the preforms until the economics allow Spintech to procure its own TFP equipment or lease UDRI equipment, at which point UDRI will step away from manufacture and serve as the engineering and design lead on product development.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Optimization of Elastically Tailored Tow-Placed Plates with Holes

Elastic stiffness tailoring of laminated composite panels by allowing the fibers to curve within the plane of the laminate is a design concept that has been demonstrated to be both beneficial and practical. The objective of the present paper is to demonstrate the effectiveness of stiffness tailoring through the use of curvilinear fibers to reduce stress concentrations around the hole and improve the load carrying capability of panels. Preliminary panel designs that are to be manufactured and tested were determined through design studies for flat plates without holes under axial compression using an optimization program. These candidate designs were then analyzed with finite element models that accurately reflect the test conditions and geometries in order to decide upon the final designs for manufacture and testing. An advanced tow-placement machine is used to manufacture the test panels with varying fiber orientation angles. A total of six large panels measuring three feet by six feet, each of which is used to produce four specimens with or without holes, are fabricated. The panels were machined into specimens with holes and tested at NASA Langley Research Center. Buckling response and failure of panels without holes and with two different hole dimensions are presented. Buckling and failure loads of tow-steered specimens are significantly greater than the buckling and failure loads of traditional straight-fiber specimens.

Jegley, Dawn C.↗
NASA NTRS2014

Aeroelastic Tailoring of Transport Aircraft Wings: State-of-the-Art and Potential Enabling Technologies

This paper provides a brief overview of the state-of-the-art for aeroelastic tailoring of subsonic transport aircraft and offers additional resources on related research efforts. Emphasis is placed on aircraft having straight or aft swept wings. The literature covers computational synthesis tools developed for aeroelastic tailoring and numerous design studies focused on discovering new methods for passive aeroelastic control. Several new structural and material technologies are presented as potential enablers of aeroelastic tailoring, including selectively reinforced materials, functionally graded materials, fiber tow steered composite laminates, and various nonconventional structural designs. In addition, smart materials and structures whose properties or configurations change in response to external stimuli are presented as potential active approaches to aeroelastic tailoring.

Jutte, Christine↗
NASA NTRS2014

Trim and Structural Optimization of Subsonic Transport Wings Using Nonconventional Aeroelastic Tailoring

Several minimum-mass aeroelastic optimization problems are solved to evaluate the effectiveness of a variety of novel tailoring schemes for subsonic transport wings. Aeroelastic strength and panel buckling constraints are imposed across a variety of trimmed maneuver loads. Tailoring with metallic thickness variations, functionally graded materials, composite laminates, tow steering, and distributed trailing edge control effectors are all found to provide reductions in structural wing mass with varying degrees of success. The question as to whether this wing mass reduction will offset the increased manufacturing cost is left unresolved for each case.

Stanford, Bret K.↗
NASA NTRS2015

Aeroelastic Tailoring of Transport Wings Including Transonic Flutter Constraints

Several minimum-mass optimization problems are solved to evaluate the effectiveness of a variety of novel tailoring schemes for subsonic transport wings. Aeroelastic stress and panel buckling constraints are imposed across several trimmed static maneuver loads, in addition to a transonic flutter margin constraint, captured with aerodynamic influence coefficient-based tools. Tailoring with metallic thickness variations, functionally graded materials, balanced or unbalanced composite laminates, curvilinear tow steering, and distributed trailing edge control effectors are all found to provide reductions in structural wing mass with varying degrees of success. The question as to whether this wing mass reduction will offset the increased manufacturing cost is left unresolved for each case.

Stanford, Bret K.↗
NASA NTRS2019

Ground Vibration Testing at NASA Armstrong, Emphasizing on Passive Aeroelastic Tailored Wing Ground Vibration Test Using Fixed Base Correction Method

How does experimental mechanics contribute to aircraft aeroelastic airworthiness? The aviation community is always improving analysis and testing techniques to realize quicker, cheaper, reliable solutions. A ground vibration test (GVT) is conducted to identify structural mode shapes, frequencies, and damping values to validate analytical models used for flutter analysis, which shows whether a structure has acceptable aeroelastic flutter margins for airworthiness. The FLL recently conducted a GVT of the Passive Aeroelastic Tailored (PAT) Wing using an experimental modal technique called Fixed Base Correction (FBC). The GVT objective was to obtain the PAT wing modal characteristics to compare test results with finite element model (FEM) results for the tow-steered wingbox.

loads testing↗
NASA NTRS2020

Passive Aeroelastic Tailoring

The Passive Aeroelastic Tailoring (PAT) project was tasked with investigating novel methods to achieve passive aeroelastic tailoring on high aspect ratio wings. The goal of the project was to identify structural designs or topologies that can improve performance and/or reduce structural weight for high-aspect ratio wings. This project considered two unique approaches, which were pursued in parallel: through-thickness topology optimization and composite tow-steering.

Smith, Benjamin↗
NASA NTRSDate not supplied

TPSAS-NF1676L-18502-DND

1. Aeroelastic tailoring with tow-steered composites 2. Aeroelastic tailoring with functionally-graded metals 3. Wing box topology optimization - Curvilinear rib/spar/stiffener placement - Cellular-based stringer topologies - Optimal topology of lightening holes within ribs/spars - 3D level set methods

Stanley R Cole↗
NASA NTRS2014

TPSAS-NF1676L-18913-DND

Composite materials and structures are enabling technology for modern aerospace vehicles. Numerical-control manufacturing, including automated fiber placement (AFP), is widely used to fabricate these components. However, weight and performance requirements for the next generation of aerospace vehicles will push the state-of-art even further, and require development of more advanced materials, manufacturing, and structures technologies that are both affordable and efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address much of NASA?s critical research needs in advanced composites. The baseline ISAAC system, combining a commercial robot with multiple redundant degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, enables precise and accurate additive manufacturing of composite structures, as well as development of advanced tow-steered structures with tailored load paths. The highly capable baseline system can quickly change end effectors, thus enabling further research for composites manufacturing. This extended system is similar to a high-speed machining center, where interchangeable cutters are used for different operations during metal structures fabrication. This capability enables future development, integration and assessment of new advanced manufacturing technologies, such as in-situ curing and NDE, and through-thickness reinforcements to reduce delaminations. End effectors with these advanced capabilities may be purchased, developed internally or with industry or academia, and then integrated onto the existing robotic platform to perform advanced manufacturing operations and develop new techniques and processes. Technologies, techniques and processes developed using this research-oriented system could then be transitioned to the broader composites industry.

Rob Martin↗
NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Panels for Flight Applications

Reduced weight is an ever-increasing demand within the aerospace industry, and non-traditional means of achieving this demand are increasingly being considered. There is also a desire to reduce the manual labor involved in attaching thousands of parts together with rivets and other fasteners. Using advanced stiffener concepts can avoid the weight of fasteners and streamline fabrication by reducing the part count, while still providing the mandatory strength requirements for flight certification. Described herein is a set of manufacturing trials that were completed at NASA Langley Research Center to investigate the feasibility of various integrated stiffener concepts. Fully composite stiffeners that can be integrated or attached by other means, either through bonding or interleaving them within the skin, can remove the fasteners and still maintain a rapid manufacturing rate. This study contains these advanced stiffener concepts, and the lessons learned and design iterations that resulted from the series of manufacturing trials. Each set of trials was completed with an end goal of using tow-steered integral stiffeners for flight structure in composite aircraft wings.

Composite↗
NASA NTRSDate not supplied

RESIDUAL DEFORMATION ANALYSIS IN COMPOSITE SHELL STRUCTURES MANUFACTURED USING AUTOMATED FIBER PLACEMENT

The manufacturing of composites typically produces residual stresses that can significantly affect the final shape of the structure. The process of automated fiber placement (AFP) has become a prominent manufacturing technique in developing layups with tailored, variable stiffness morphology. The steered patterns of fiber tows with and without overlaps produce residual deformations that are distinctive from traditional layups. Digital image correlation was used to measure the AFP lamina coefficients of thermal expansion, which were incorporated into finite element analyses (FEA) to model the cooling phase of the cure cycle. The effects of nonlinear analysis and temperature-dependent lamina properties calculated using self-consistent field micromechanics, on the resulting residual deformation of shells, were also modeled. The predicted residual deformation was analyzed by considering out-of-roundness in cylindrical shells and compared to the experimental results. The shell FEA results were well-correlated with the overall deformed shape of the AFP cylinder with overlaps, while the shell FEA model of the AFP cylinder without overlaps did not show as good of qualitative match of the deformation pattern. Analytical correlation with measured results were insensitive to material softening at elevated temperatures, geometric nonlinearities, and variations in measured lamina thermal properties. To improve the accuracy of the residual deformation analysis, these results suggest that the thermo-chemical shrinkages preceding the cooldown should be considered, as well as possible variations in ply level microstructure due to the presence of the embedded fiber tow gaps and overlaps.

Composites↗
NASA NTRS2019

Integrated Design and Manufacturing Analysis for Automated Fiber Placement Structures

Automated fiber placement provides many advancements beyond traditional hand layups in terms of efficiency and reliability. However, there are also a variety of unique challenges that arise with automated fiber placement technology. In particular, steering of tows over doubly-curved tool surfaces can result in material overlaps and gaps due to path convergence/divergence, fiber angle deviation, as well defects in the tows themselves such as puckers and wrinkles. Minimization of these defects is traditionally considered a task for the manufacturing discipline. Manufacturing specifications are often created for these defects based on laminate testing and can be inflexible to avoid more tests. Recent efforts have been made under the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP) to develop software tools and processes that provide automated coupling between design and manufacturing disciplines. The objective of this coupling is to provide information to the design discipline on the manufacturability of a laminate while the laminate is being designed. A variety of software tools, both existing commercial tools and research tools under development, will be used to achieve this objective: HyperSizer for laminate optimization, the Computer Aided Process Planning module for selection of manufacturing process parameters, Vericut Composite Programming for tow path simulation, and COMPRO for deposition and cure defects. The newly developed “Central Optimizer” tool will be used to tie the modules together and drive the design for manufacturing process.

Noevere, August↗
NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement

Commercial aircraft structures are frequently manufactured from carbon-epoxy materials because of their weight and stiffness advantages compared to metallic materials. Wing cover panels are regularly manufactured using an automated fiber placement (AFP) process, but current design and manufacturing methodologies do not fully take advantage of the opportunities afforded by AFP. Design and manufacturing studies were undertaken at the NASA Langley Research Center at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to quantify manufacturing benefits and limitations associated with AFP to create structurally efficient integral stiffeners as an alternative to bonded or mechanically fastened stiffeners. This methodology could save weight and remove failure mechanisms by reducing the need for rivets and bonding materials since the stiffener plies are interleaved within the skin plies. The use of AFP with integral stiffeners can open the design space, but a fundamental, systematic evaluation of manufacturing limitations is necessary. Manufacturing trials are described herein, where considered manufacturing variables included stiffener location, stiffener course staggering, stiffener widths, stiffener intersections, and material thicknesses for both the skin and stiffener plies. The manufacturing process and lessons learned from each trial are described, including the most successful current design which contains staggered stiffeners, non-traditional laminate angles, and a combination of multiple material thicknesses within the same laminate.

Automated Fiber Placement↗
NASA NTRSDate not supplied

Design for Manufacturing of Structures with Automated Fiber Placement via Integration of Analysis and Process Planning

Under the Design for Manufacturing (DFM) task in the NASA HiCAM program, significant process has been made towards establishing a fully automated optimization process that spans the structural analysis, design, and manufacturing process planning for Automated Fiber Placement (AFP) structures. Previous efforts in this area established the data formats and mapping processes needed to exchange data between disciplines. The software tools used in the framework are HyperX (structural optimization), CAPP (process planning), and VCP (AFP path generation). The work has culminated with automation of data exchanges and an optimization process that drives the three software toward convergence. Within this framework, HyperX is used to generate mass-optimum composite designs which are iterated with VCP and CAPP to improve manufacturability of the designs. As the ply manufacturing process is adjusted by CAPP and VCP, HyperX continually re-assesses the structural integrity of the part and makes adjustments to the laminate as needed. For example, the position of fiber steering and tow overlaps/gaps can necessitate changes to the laminate design. Once the design converges, the end result is a stack of plies that meets both structural and manufacturing requirements. This paper presents the details of the framework and demonstrations the automated process on several parts with significant double-curvature.

HiCAM↗
NASA NTRS2007

Evaluation of a Highly Anticlastic Panel with Tow Overlaps

A rectangular, variable-stiffness panel with tow overlaps was manufactured using an advanced tow placement machine. The cured panel had large anticlastic imperfections, with measured amplitudes of over two times the average panel thickness. These imperfections were not due to the overall steered-fiber layup or the tow overlaps, but instead resulted from local asymmetries in the laminate that were caused by a manufacturing oversight. In the nominal panel layup, fiber angles vary linearly from 60 degrees on the panel axial centerline to 30 degrees on the parallel edges. A geometrically nonlinear analysis was performed with a -280 degree Fahrenheit thermal load to simulate the postcure cooldown to room temperature. The predicted geometric imperfections correlated well with the measured panel shape. Unique structural test fixtures were then developed which greatly reduced these imperfections, but they also caused prestresses in the panel. Surface imperfections measured after the panel was installed in the test fixtures were used with nonlinear finite element analyses to predict these fixturing-induced prestresses. These prestresses were also included in structural analyses of panel end compression to failure, and the analytical results compared well with test data when both geometric and material nonlinearities were included.

Wu, K. Chauncey↗
NASA NTRS1973

Handling properties of diverse automobiles and correlation with full scale response data

Driver/vehicle response and performance of a variety of vehicles in the presence of aerodynamic disturbances are discussed. Steering control is emphasized. The vehicles include full size station wagon, sedan, compact sedan, van, pickup truck/camper, and wagon towing trailer. Driver/vehicle analyses are used to estimate response and performance. These estimates are correlated with full scale data with test drivers and the results are used to refine the driver/vehicle models, control structure, and loop closure criteria. The analyses and data indicate that the driver adjusts his steering control properties (when he can) to achieve roughly the same level of performance despite vehicle variations. For the more disturbance susceptible vehicles, such as the van, the driver tightens up his control. Other vehicles have handling dynamics which cause him to loosen his control response, even though performance degrades.

Hoh, R. H.↗