High Rate Composites for Aircraft Manufacturing
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Thermoplastics↗
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Offset-Stoichiometric Reflowable Composite Bonding Method with Adhesive for Mitigating Strict Faying Surface Tolerances
Inherent susceptibility of adhesive bonds to miniscule quantities of contamination can cause undetectable weakened bonds. For this reason, the Federal Aviation Administration (FAA) places strict regulations on adhesively bonded joints in primary aircraft structures. To meet certification requirements aircraft manufactures resort to redundant load paths in the form of fasteners which inherently add weight to the structure and increase manufacturing time. In prior work, a secondary bonding technique called AERoBOND was developed, which utilized off-stoichiometric epoxymatrix resins to facilitate reflow and diffusion of the resin within the joint interface during a secondary bonding/cure process, thus achieving a bond similar to a co-cured joint. However, the AERoBOND process required tight spatial tolerances between the two parts being joined. This study examined the utilization of conventional adhesive with the AERoBOND method to act as a filler in the joint line, effectively reducing the need for tight tolerances on the joining parts and serving as a flexible alternative for existing manufacturing processes. Ultrasonic inspection, optical microscopy, and ASTM International standard tests were performed to analyze the joints for defects and to quantify the mode-I and mode-II interlaminar fracture toughness and short beam strength of the proposed methodology with varying manufacturing parameters. The comprehensive results indicate that the AERoBOND+ method with and without surface preparation performs comparably to co-cured and conventional, adhesively bonded joints when secondary cured in an autoclave with 791 kPa of pressure. As an example, the AERoBOND+ panel without surface preparation bonded with 791 kPa of pressure (referred to as AB+3 throughout paper) had a mode-I fracture toughness (G Ic ) of 0.643 kJ/m 2 and a mode-II fracture toughness (G IIc ) of 4.000 kJ/m 2 in the non-precracked condition and 4.218 kJ/m 2 in the precracked condition at the adhesive-to-prepreg interface. These results were 96%, 142%, and 217%, respectively, of a co-cured baseline panel (referred to as C1 throughout paper).
Composites↗
SRTM on-orbit structural dynamics
The primary product of the Space Radar Topography Mission was a topographic database of 80 percent of the earth's land surface. The resulting digital terrain data set provides a significant improvement over currently existing global topography data sets.
SRTM↗
Satellite remote sensing of primary production
Leaf structure and function are shown to result in distinctive variations in the absorption and reflection of solar radiation from plant canopies. The leaf properties that determine the radiation-interception characteristics of plant canopies are directly linked to photosynthesis, stomatal resistance and evapotranspiration and can be inferred from measurements of reflected solar energy. The effects of off-nadir viewing and atmospheric constituents, coupled with the need to measure changing surface conditions, emphasize the need for multitemporal measurements of reflected radiation if primary production is to be estimated.
Tucker, C. J.↗
System concept for a moderate cost Large Deployable Reflector (LDR)
A study was carried out at JPL during the first quarter of 1985 to develop a system concept for NASA's LDR. Major features of the concept are a four-mirror, two-stage optical system; a lightweight structural composite segmented primary reflector; and a deployable truss backup structure with integral thermal shield. The two-stage optics uses active figure control at the quaternary reflector located at the primary reflector exit pupil, allowing the large primary to be passive. The lightweight composite reflector panels limit the short-wavelength operation to approximately 30 microns but reduce the total primary reflector weight by a factor of 3 to 4 over competing technologies. On-orbit thermal analysis indicates a primary reflector equilibrium temperature of less than 200 K with a maximum gradient of about 5 C across the 20-m aperture. Weight and volume estimates are consistent with a single Shuttle launch, and are based on Space Station assembly and checkout.
Swanson, P. N.↗
The matrix exponential in transient structural analysis
The primary usefulness of the presented theory is in the ability to represent the effects of high frequency linear response with accuracy, without requiring very small time steps in the analysis of dynamic response. The matrix exponential contains a series approximation to the dynamic model. However, unlike the usual analysis procedure which truncates the high frequency response, the approximation in the exponential matrix solution is in the time domain. By truncating the series solution to the matrix exponential short, the solution is made inaccurate after a certain time. Yet, up to that time the solution is extremely accurate, including all high frequency effects. By taking finite time increments, the exponential matrix solution can compute the response very accurately. Use of the exponential matrix in structural dynamics is demonstrated by simulating the free vibration response of multi degree of freedom models of cantilever beams.
Minnetyan, Levon↗
Ceramic Matrix Composite (CMC) Thermal Protection Systems (TPS) and Hot Structures for Hypersonic Vehicles
Thermal protection systems (TPS) and hot structures are required for a range of hypersonic vehicles ranging from ballistic reentry to hypersonic cruise vehicles, both within Earth’s atmosphere and non-Earth atmospheres. This includes single-stage to orbit (SSTO), two-stage to orbit (TSTO) accelerators, access to space vehicles, and hypersonic cruise vehicles. This presentation will start out with a brief discussion of aerodynamic heating and thermal management techniques to address the high heating. The argument is presented that as we move from rocket-based vehicles to air-breathing vehicles, we need to move away from the “insulated airplane” approach used on the Space Shuttle Orbiter to a wide range of TPS and hot structure approaches. The primary portion of the paper will discuss issues and design options for CMC TPS and hot structure components. The two primary technical challenges impacting the use of CMC TPS and hot structures for hypersonic vehicles are environmental durability and fabrication, and will be discussed briefly.
ceramic matrix composites↗
Coronagraph for astronomical imaging and spectrophotometry
A coronagraph designed to minimize scattered light in astronomical observations caused by the structure of the primary mirror, secondary mirror, and secondary support structure of a Cassegrainian telescope is described. Direct (1:1) and reducing (2.7:1) imaging of astronomical fields are possible. High-quality images are produced. The coronagraph can be used with either a two-dimensional charge-coupled device or photographic film camera. The addition of transmission dispersing optics converts the coronagraph into a low-resolution spectrograph. The instrument is modular and portable for transport to different observatories.
Vilas, Faith↗
Damage Simulation in Composite Materials: Why It Matters and What Is Happening Currently at NASA in This Area
Use of lightweight composite materials in space and aircraft structure designs is often challenging due to high costs associated with structural certification. Of primary concern in the use of composite structures is durability and damage tolerance. This concern is due to the inherent susceptibility of composite materials to both fabrication and service induced flaws. Due to a lack of general industry accepted analysis tools applicable to composites damage simulation, a certification procedure relies almost entirely on testing. It is this reliance on testing, especially compared to structures comprised of legacy metallic materials where damage simulation tools are available, that can drive costs for using composite materials in aerospace structures. The observation that use of composites can be expensive due to testing requirements is not new and as such, research on analysis tools for simulating damage in composite structures has been occurring for several decades. A convenient approach many researchers/model-developers in this area have taken is to select a specific problem relevant to aerospace structural certification and develop a model that is accurate within that scope. Some examples are open hole tension tests, compression after impact tests, low-velocity impact, damage tolerance of an embedded flaw, and fatigue crack growth to name a few. Based on the premise that running analyses is cheaper than running tests, one motivation that many researchers in this area have is that if generally applicable and reliable damage simulation tools were available the dependence on certification testing could be lessened thereby reducing overall design cost. It is generally accepted that simulation tools if applied in this manner would still need to be thoroughly validated and that composite testing will never be completely replaced by analysis. Research and development is currently occurring at NASA to create numerical damage simulation tools applicable to damage in composites. The Advanced Composites Project (ACP) at NASA Langley has supported the development of composites damage simulation tools in a consortium of aerospace companies with a goal of reducing the certification time of a commercial aircraft by 30%. And while the scope of ACP does not include spacecraft, much of the methodology and simulation capabilities can apply to spacecraft certification in the Space Launch System and Orion programs as well. Some specific applications of composite damage simulation models in a certification program are (1) evaluation of damage during service when maintenance may be difficult or impossible, (2) a tool for early design iterations, (3) gaining insight into a particular damage process and applying this insight towards a test coupon or structural design, and (4) analysis of damage scenarios that are difficult or impossible to recreate in a test. As analysis capabilities improve, these applications and more will become realized resulting in a reduction in cost for use of composites in aerospace vehicles. NASA is engaged in this process from both research and application perspectives. In addition to the background information discussed previously, this presentation covers a look at recent research at NASA in this area and some current/potential applications in the Orion program.
McElroy, Mack↗
Evaluation of coated columbium alloy heat shields for space shuttle thermal protection system application. Volume 3, phase 3: Full size TPS evaluation
The thermal protection system (TPS), designed for incorporation with space shuttle orbiter systems, consists of one primary heat shield thermally and structurally isolated from the test fixture by eight peripheral guard panels, all encompassing an area of approximately 12 sq ft. TPS components include tee-stiffened Cb 752/R-512E heat shields, bi-metallic support posts, panel retainers, and high temperature insulation blankets. The vehicle primary structure was simulated by a titanium skin, frames, and stiffeners. Test procedures, manufacturing processes, and methods of analysis are fully documented. For Vol. 1, see N72-30948; for Vol. 2, see N74-15660.
Baer, J. W.↗
Design Study of 8 Meter Monolithic Mirror UV/Optical Space Telescope
The planned Ares V launch vehicle with its 10 meter fairing shroud and 55,000 kg capacity to the Sun Earth L2 point enables entirely new classes of space telescopes. NASA MSFC has conducted a preliminary study that demonstrates the feasibility of launching a 6 to 8 meter class monolithic primary mirror telescope to Sun-Earth L2 using an Ares V. Specific technical areas studied included optical design; structural design/analysis including primary mirror support structure, sun shade and secondary mirror support structure; thermal analysis; launch vehicle performance and trajectory; spacecraft including structure, propulsion, GN&C, avionics, power systems and reaction wheels; operations and servicing; mass and power budgets; and system cost.
Stahl, H. Philip↗
Structures IVHM for 3rd Generation RLVs
The primary goal of a Structures Integrated Vehicle Health Management (IVHM) system for 3rd generation Reusable Launch Vehicles (RLV) is to provide near 100% structural sensing coverage and thus eliminate both routine, and especially unplanned, inspections which are costly and time consuming. To meet this goal, significant advances in sensing and measurement system technology, data systems architectures, and structures based analysis methodology will be required to enable the needed large numbers of sensors with little weight penalty. This program will leverage X-33, 2nd Gen RLV, Shuttle, and Aviation Safety SIVHM system development experience to address this goal.
Rogowski, Robert S.↗
Design study of structural concepts for an arrow-wing supersonic-cruise aircraft
An analytical study was performed to determine the best structural approach for design of primary wing and fuselage structure of a Mach number 2.7 arrow-wing supersonic cruise aircraft. Concepts were evaluated considering near-term start-of-design. Emphasis was placed on the complex interactions between thermal stress, static aeroelasticity, flutter, fatigue and fail-safe design, static and dynamic loads, and the effects of variations in structural arrangements, concepts and materials on these interactions. Results indicate that a hybrid wing structure incorporating low-profile convex-beaded and honeycomb sandwich surface panels of titanium alloy 6Al-4V were the most efficient. The substructure includes titanium alloy spar caps reinforced with Boron-polyimide composites. The fuselage shell is a closed-hat stiffened skin and frame construction of titanium alloy 6Al-4V. This paper presents an executive summary of the study effort, and includes a discussion of the overall study logic, design philosophy and interaction between the analytical methods for supersonic cruise aircraft design.
Sakata, I. F.↗
Evaluation of structural design concepts for an arrow-wing supersonic cruise aircraft
An analytical study was performed to determine the best structural approach for design of primary wing and fuselage structure of a Mach 2.7 arrow wing supersonic cruise aircraft. Concepts were evaluated considering near term start of design. Emphasis was placed on the complex interactions between thermal stress, static aeroelasticity, flutter, fatigue and fail safe design, static and dynamic loads, and the effects of variations in structural arrangements, concepts and materials on these interactions. Results indicate that a hybrid wing structure incorporating low profile convex beaded and honeycomb sandwich surface panels of titanium alloy 6Al-4V were the most efficient. The substructure includes titanium alloy spar caps reinforced with boron polyimide composites. The fuselage shell consists of hat stiffened skin and frame construction of titanium alloy 6Al-4V. A summary of the study effort is presented, and a discussion of the overall logic, design philosophy and interaction between the analytical methods for supersonic cruise aircraft design are included.
Sakata, I. F.↗
Space Station truss structures and construction considerations
Although a specific configuration has not been selected for the Space Station, a gravity gradient stabilized station as a basis upon which to compare various structural and construction concepts is considered. The Space Station primary truss support structure is described in detail. Three approaches (see sketch A) which are believed to be representative of the major techniques for constructing large structures in space are also described in detail so that salient differences can be highlighted.
Mikulas, M. M., Jr.↗
Evaluation of Composite Structures Technologies for Application to NASA's Vision for Space Exploration (CoSTS)
A trade study was conducted to determine the suitability of composite structures for weight and life cycle cost savings in primary and secondary structural systems for crew exploration vehicles, crew and cargo launch vehicles, landers, rovers, and habitats. The results of the trade study were used to identify and rank order composite material technologies that can have a near-term impact on a broad range of exploration mission applications. This report recommends technologies that should be developed to enable usage of composites on Vision for Space Exploration vehicles towards mass and life-cycle cost savings.
Deo, Ravi↗
Atmospheric Disturbance Environment Definition
Traditionally, the application of atmospheric disturbance data to airplane design problems has been the domain of the structures engineer. The primary concern in this case is the design of structural components sufficient to handle transient loads induced by the most severe atmospheric "gusts" that might be encountered. The concern has resulted in a considerable body of high altitude gust acceleration data obtained with VGH recorders (airplane velocity, V, vertical acceleration, G, altitude, H) on high-flying airplanes like the U-2 (Ehernberger and Love, 1975). However, the propulsion system designer is less concerned with the accelerations of the airplane than he is with the airflow entering the system's inlet. When the airplane encounters atmospheric turbulence it responds with transient fluctuations in pitch, yaw, and roll angles. These transients, together with fluctuations in the free-stream temperature and pressure will disrupt the total pressure, temperature, Mach number and angularity of the inlet flow. For the mixed compression inlet, the result is a disturbed throat Mach number and/or shock position, and in extreme cases an inlet unstart can occur (cf. Section 2.1). Interest in the effects of inlet unstart on the vehicle dynamics of large, supersonic airplanes is not new. Results published by NASA in 1962 of wind tunnel studies of the problem were used in support of the United States Supersonic Transport program (SST) (White, at aI, 1963). Such studies continued into the late 1970's. However, in spite of such interest, there never was developed an atmospheric disturbance database for inlet unstart analysis to compare with that available for the structures load analysis. Missing were data for the free-stream temperature and pressure disturbances that also contribute to the unStart problem.
Tank, William G.↗
An 8 Meter Monolithic UV/Optical Space Telescope
The planned Ares V launch vehicle with its 10 meter fairing and at least 55,600 kg capacity to Earth Sun L2 enables entirely new classes of space telescopes. A consortium from NASA, Space Telescope Science Institute, and aerospace industry are studying an 8-meter monolithic primary mirror UV/optical/NIR space telescope to enable new astrophysical research that is not feasible with existing or near-term missions, either space or ground. This paper briefly reviews the science case for such a mission and presents the results of an on-going technical feasibility study, including: optical design; structural design/analysis including primary mirror support structure, sun shade and secondary mirror support structure; thermal analysis; launch vehicle performance and trajectory; spacecraft including structure, propulsion, GN&C, avionics, power systems and reaction wheels; operations & servicing; mass budget and cost.
Stahl, H. Philip↗