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NASA NTRS1985

Composite materials for space structures

Composite materials have been extensively used for spacecraft structures because of their unique combination of high specific strength and stiffness, low weight, good dimensional stability, and high specific damping capacity. High-modulus graphite reinforced epoxies have been the principal composite material system used. For early applications composites were selected primarily to reduce weight. However, the development of high precision structures such as The Space Telescope required high modulus composites with a coefficient of thermal expansion close to zero to meet design requirements. The use of advanced composites for space structures is reviewed in this paper. Barriers likely to limit further applications of composites are discussed and highlights of current research to improve composites are presented. New developments Jn composites technology which could impact future spacecraft systems are also reviewed.

Composites↗

NASA NTRS1992

CVD of silicon carbide on structural fibers: Microstructure and composition

Structural fibers are currently being considered as reinforcements for intermetallic and ceramic materials. Some of these fibers, however, are easily degraded in a high temperature oxidative environment. Therefore, coatings are needed to protect the fibers from environmental attack. Silicon carbide (SiC) was chemically vapor deposited (CVD) on Textron's SCS6 fibers. Fiber temperatures ranging from 1350 to 1500 C were studied. Silane (SiH4) and propane (C2H8) were used for the source gases and different concentrations of these source gases were studied. Deposition rates were determined for each group of fibers at different temperatures. Less variation in deposition rates were observed for the dilute source gas experiments than the concentrated source gas experiments. A careful analysis was performed on the stoichiometry of the CVD SiC coating using electron microprobe. Microstructures for the different conditions were compared. At 1350 C, the microstructures were similar; however, at higher temperatures, the microstructure for the more concentrated source gas group were porous and columnar in comparison to the cross sections taken from the same area for the dilute source gas group.

Veitch, Lisa C.↗

NASA NTRS1992

CVD of silicon carbide on structural fibers - Microstructure and composition

Veitch, Lisa C.↗

NASA NTRS1978

CODSTRAN - Composite durability structural analysis

CODSTRAN (COmposite Durability STRucture ANalysis) a NASA Lewis Center computer program for the prediction of defect growth and fracture of composite structures when subjected to service loads is presented. Organization, capabilities and present status are discussed. Organizational aspects include executive, input, output, analysis and composite mechanics modules. Capabilities include: durability assessment of large structures and complex structural parts from composites, structural response due to static, cyclic, transient impact and thermal loads, and criteria for static, cyclic, and dynamic fracture. At the present state of development some of CODSTRAN's analysis capabilities include composite mechanics, static failures, and lamination residual stresses. An application in which CODSTRAN is used to predict the defect growth in a flat specimen, with a center through-slit under tension is studied. When completed, CODSTRAN will account for geometry and material nonlinearities, environmental effects as well as static, cyclic and dynamic fracture.

Chamis, C. C.↗

NASA NTRS2016

Buckling Design and Imperfection Sensitivity of Sandwich Composite Launch-Vehicle Shell Structures

Composite materials are increasingly being considered and used for launch-vehicle structures. For shell structures, such as interstages, skirts, and shrouds, honeycomb-core sandwich composites are often selected for their structural efficiency. Therefore, it is becoming increasingly important to understand the structural response, including buckling, of sandwich composite shell structures. Additionally, small geometric imperfections can significantly influence the buckling response, including considerably reducing the buckling load, of shell structures. Thus, both the response of the theoretically perfect structure and the buckling imperfection sensitivity must be considered during the design of such structures. To address the latter, empirically derived design factors, called buckling knockdown factors (KDFs), were developed by NASA in the 1960s to account for this buckling imperfection sensitivity during design. However, most of the test-article designs used in the development of these recommendations are not relevant to modern launch-vehicle constructions and material systems, and in particular, no composite test articles were considered. Herein, a two-part study on composite sandwich shells to (1) examine the relationship between the buckling knockdown factor and the areal mass of optimized designs, and (2) to interrogate the imperfection sensitivity of those optimized designs is presented. Four structures from recent NASA launch-vehicle development activities are considered. First, designs optimized for both strength and stability were generated for each of these structures using design optimization software and a range of buckling knockdown factors; it was found that the designed areal masses varied by between 6.1% and 19.6% over knockdown factors ranging from 0.6 to 0.9. Next, the buckling imperfection sensitivity of the optimized designs is explored using nonlinear finite-element analysis and the as-measured shape of a large-scale composite cylindrical shell. When compared with the current buckling design recommendations, the results suggest that the current recommendations are overly conservative and that the development of new recommendations could reduce the acreage areal mass of many composite sandwich shell designs by between 4% and 19%, depending on the structure.

Schultz, Marc R.↗

NASA NTRS2006

Mode I Toughness Measurements of Core/Facesheet Bonds in Honeycomb Sandwich Structures

Composite sandwich structures will be used in many future applications in aerospace, marine and offshore industries due to the fact that the strength and stiffness to mass ratios surpass any other structural type. Sandwich structure also offers advantages over traditional stiffened panels such as ease of manufacturing and repair. During the last three decades, sandwich structure has been used extensively for secondary structure in aircraft (fuselage floors, rudders and radome structure). Sandwich structure is also used as primary structure in rotorcraft, the most common example being the trailing edge of rotor blades. As with other types of composite construction, sandwich structure exhibits several types of failure mode such as facesheet wrinkling, core crushing and sandwich buckling. Facesheet/core debonding has also been observed in the marine and aerospace industry. During this failure mode, peel stresses applied to an existing facesheet/core debond or an interface low in toughness, results in the facesheet being peeled from the core material, possibly leading to a significant loss in structural integrity of the sandwich panel. In an incident during a test on a liquid hydrogen fuel tank of the X-33 prototype vehicle, the outer graphite/epoxy facesheet and honeycomb core became debonded from the inner facesheet along significant areas, leading to failure of the tank. As a consequence of the accident; significant efforts were made to characterize the toughness of the facesheet/core bond. Currently, the only standardized method available for assessing the quality of the facesheet/core interface is the climbing drum peel test (ASTM D1781). During this test a sandwich beam is removed from a panel and the lip of one of the facesheets is attached to a drum, as shown in Fig. 1. The drum is then rotated along the sandwich beam, causing the facesheet to peel from the core. This method has two major drawbacks. First, it is not possible to obtain quantitative fracture data from the test and so the results can only be used in a qualitative manner. Second, only sandwich structure with thin facesheets can be tested (to facilitate wrapping of the facesheet around the climbing drum). In recognition of the need for a more quantitative facesheet/core fracture test, several workers have devised experimental techniques for characterizing the toughness of the facesheet/core interface. In all of these cases, the tests are designed to yield a mode I-dominated fracture toughness of the facesheet/core interface in a manner similar to that used to determine mode I fracture toughness of composite laminates. In the current work, a modified double cantilever beam is used to measure the mode I-dominated fracture toughness of the interface in a sandwich consisting of glass/phenolic honeycomb core reinforced with graphite epoxy facesheets. Two specimen configurations were tested as shown in Fig 2. The first configuration consisted of reinforcing the facesheets with aluminum blocks (Fig. 2a). In the second configuration unreinforced specimens were tested (Fig. 2b). Climbing drum peel tests were also conducted to compare the fracture behavior observed between this test and the modified double cantilever beam. This paper outlines the test procedures and data reduction strategies used to compute fracture toughness values from the tests. The effect of specimen reinforcement on fracture toughness of the facesheet/core interface is discussed.

Nettles, Alan T.↗

NASA NTRS2016

Research Developments in Nondestructive Evaluation and Structural Health Monitoring for the Sustainment of Composite Aerospace Structures at NASA

The use of composite materials continues to increase in the aerospace community due to the potential benefits of reduced weight, increased strength, and manufacturability. Ongoing work at NASA involves the use of the large-scale composite structures for spacecraft (payload shrouds, cryotanks, crew modules, etc). NASA is also working to enable both the use and sustainment of composites in commercial aircraft structures. One key to the sustainment of these large composite structures is the rapid, in-situ characterization of a wide range of potential defects that may occur during the vehicle's life. Additionally, in many applications it is necessary to monitor changes in these materials over their lifetime. Quantitative characterization through Nondestructive Evaluation (NDE) of defects such as reduced bond strength, microcracking, and delamination damage due to impact, are of particular interest. This paper will present an overview of NASA's applications of NDE technologies being developed for the characterization and sustainment of advanced aerospace composites. The approaches presented include investigation of conventional, guided wave, and phase sensitive ultrasonic methods and infrared thermography techniques for NDE. Finally, the use of simulation tools for optimizing and validating these techniques will also be discussed.

Cramer, K. Elliott↗

NASA NTRS1983

Research and technology, 1983

Highlights of major accomplishments and applications made during the past year illustrate the broad range of research and technology activities at the Langley Research Center. Advances are reported in the following areas: systems engineering and operation; aeronautics; electronics; space applications; aircraft and spacecraft structures; composite structures; laminar flow control; subsonic transport aircraft; and supersonic fighter concepts. Technology utilization efforts described cover a hyperthermia monitor, a lightweight composite wheelchair; and a vehicle ride quality meter.

Source record↗

NASA NTRS1992

Composite fuselage shell structures research at NASA Langley Research Center

Fuselage structures for transport aircraft represent a significant percentage of both the weight and the cost of these aircraft primary structures. Composite materials offer the potential for reducing both the weight and the cost of transport fuselage structures, but only limited studies of the response and failure of composite fuselage structures have been conducted for transport aircraft. The behavior of these important primary structures must be understood, and the structural mechanics methodology for analyzing and designing these complex stiffened shell structures must be validated in the laboratory. The effects of local gradients and discontinuities on fuselage shell behavior and the effects of local damage on pressure containment must be thoroughly understood before composite fuselage structures can be used for commercial aircraft. This paper describes the research being conducted and planned at NASA LaRC to help understand the critical behavior or composite fuselage structures and to validate the structural mechanics methodology being developed for stiffened composite fuselage shell structure subjected to combined internal pressure and mechanical loads. Stiffened shell and curved stiffened panel designs are currently being developed and analyzed, and these designs will be fabricated and then tested at Langley to study critical fuselage shell behavior and to validate structural analysis and design methodology. The research includes studies of the effects of combined internal pressure and mechanical loads on nonlinear stiffened panel and shell behavior, the effects of cutouts and other gradient-producing discontinuities on composite shell response, and the effects of local damage on pressure containment and residual strength. Scaling laws are being developed that relate full-scale and subscale behavior of composite fuselage shells. Failure mechanisms are being identified and advanced designs will be developed based on what is learned from early results from the LaRC research activities. Results from combined load tests will be used to validate analytical models of critical nonlinear response mechanisms as well as shell scaling laws.

Starnes, James H., Jr.↗

DOE OSTI2025

Fine-scale vegetation composition and structure shape spatiotemporal variation in surface albedo across a low Arctic tundra landscape

The unprecedented rate of warming in the Arctic is driving changes in the structure and composition of tundra vegetation. Increases in deciduous tall shrub cover, height, and density are of particular concern, as these changes alter local surface albedo in ways that could amplify effects on the regional surface energy budget (SEB). Despite this importance, significant uncertainties remain in understanding the interplay between fine-scale vegetation patterns and emergent albedo dynamics across space and time. Here, we address these uncertainties by (1) quantifying spatiotemporal variation in surface shortwave albedo and (2) determining the relative influence of fine-scale vegetation composition, structure, and environmental conditions on albedo across a representative low-Arctic tundra landscape on Alaska’s Seward Peninsula. To do this, we synthesized multi-scale, multi-platform remote sensing observations, including a novel Landsat-derived albedo time series, a fine-scale map of Arctic plant functional type (PFT) fractional cover, and airborne LiDAR estimates of canopy height and topography. We show that there are substantial reductions in winter albedo for pixels dominated by tall, woody PFTs (28.13%) relative to pixels dominated by non-woody vegetation, but almost no change in summer albedo (3% increase). Further, we identified a unimodal trend in the relationship between canopy height and the timing of the springtime transition from high (snowy) to low (leafy) albedo (peak at 5.5 m), possibly because of competing ‘snow-fence’ and ‘protrusion’ snow-shrub interactions. To explore the primary drivers of albedo, we constructed a random forest model and found that canopy height and the fractional cover of woody PFTs were as- or more important predictors of winter albedo than topographic features. These findings provide strong evidence for the impacts of local vegetation characteristics on regional surface albedo, highlighting the need for better quantification of snow-shrub interactions to accurately predict the Arctic’s SEB under future environmental change.

Arctic↗

NASA NTRS1988

Composite materials: Testing and design

The present conference discusses topics in the analysis of composite structures, composite materials' impact and compression behavior, composite materials characterization methods, composite failure mechanisms, NDE methods for composites, and filament-wound and woven composite materials' fabrication. Attention is given to the automated design of a composite plate for damage tolerance, the effects of adhesive layers on composite laminate impact damage, instability-related delamination growth in thermoset and thermoplastic composites, a simple shear fatigue test for unidirectional E-glass epoxy, the growth of elliptic delaminations in laminates under cyclic transverse shear, and the mechanical behavior of braided composite materials.

Whitcomb, John D.↗

NASA NTRS1998

X-34 Main Propulsion System Design and Operation

The X-34 program is a joint industry/government program to develop, test, and operate a small, fully-reusable hypersonic flight vehicle, utilizing technologies and operating concepts applicable to future Reusable Launch Vehicle (RLV) systems. The vehicle will be capable of Mach 8 flight to 250,000 feet altitude and will demonstrate an all composite structure, composite RP-1 tank, the Marshall Space Flight Center (MSFC) developed Fastrac engine, and the operability of an advanced thermal protection systems. The vehicle will also be capable of carrying flight experiments. MSFC is supporting the X-34 program in three ways: Program Management, the Fastrac engine as Government Furnished Equipment (GFE), and the design of the Main Propulsion System (MPS). The MPS Product Development Team (PDT) at MSFC is responsible for supplying the MPS design, analysis, and drawings to Orbital. The MPS consists of the LOX and RP-1 Fill, Drain, Feed, Vent, & Dump systems and the Helium & Nitrogen Purge, Pressurization, and Pneumatics systems. The Reaction Control System (RCS) design was done by Orbital. Orbital is the prime contractor and has responsibility for integration, procurement, and construction of all subsystems. The paper also discusses the design, operation, management, requirements, trades studies, schedule, and lessons learning with the MPS and RCS designs.

Champion, R. J., Jr.↗

NASA NTRS2014

Increased Tensile Strength of Carbon Nanotube Yarns and Sheets through Chemical Modification and Electron Beam Irradiation

The inherent strength of individual carbon nanotubes offers considerable opportunity for the development of advanced, lightweight composite structures. Recent work in the fabrication and application of carbon nanotube (CNT) forms such as yarns and sheets has addressed early nanocomposite limitations with respect to nanotube dispersion and loading; and has pushed the technology toward structural composite applications. However, the high tensile strength of an individual CNT has not directly translated to macro-scale CNT forms where bulk material strength is limited by inter-tube electrostatic attraction and slippage. The focus of this work was to assess post processing of CNT sheet and yarn to improve the macro-scale strength of these material forms. Both small molecule functionalization and e-beam irradiation was evaluated as a means to enhance tensile strength and Youngs modulus of the bulk CNT material. Mechanical testing results revealed a tensile strength increase in CNT sheets by 57 when functionalized, while an additional 48 increase in tensile strength was observed when functionalized sheets were irradiated; compared to unfunctionalized sheets. Similarly, small molecule functionalization increased yarn tensile strength up to 25, whereas irradiation of the functionalized yarns pushed the tensile strength to 88 beyond that of the baseline yarn.

composites↗

NASA NTRS1975

Interim Report of the Astronomy Spacelab Payloads Study: Ultraviolet and Optical Astronomy - Volume 2

The Space Shuttle will comprise NASA's primary transportation system into near-earth orbit during the 1980s. The Shuttle will provide the astronomical community with a major new capability to send a wide variety of instrumentation into orbit, to utilize it there under manned or automatic control for periods from seven to thirty days, and to return it to the ground. To this end the European Space Research Organization (ESRO) is developing Spacelab, an array of interchangeable components -pressurized manned modules, unpressurized pallets and related support systems - to be mounted in the Shuttle payload bay. Spacelab will offer important opportunities to carry out astronomical research with instruments optimized for specific objectives. With a high flight frequency and with the ability to modify or interchange telescopes and instruments between flights, one will not need to make rigid long-term commitments to specific and compromised telescope/instrument/ detector combinations as is the case for automated satellites. Observational techniques demanding the physical return of data and equipment - in particular the use of photographic film, instruments requiring tight calibration controls, cryogens, high-risk detectors and degradeable optical coatings -will open research areas not readily addressed by automated satellites. Although Shuttle flight duration will be limited to periods from seven to thirty days, substantial data can be obtained with a single instrument on short missions, if targets are carefully selected and prioritized, and a large number of instruments can be accommodated on a single flight. Important astronomical data are regularly obtained on sounding rocket flights of five minutes duration. Spacelab will provide far longer observing periods for large and small telescopes, with resources greatly exceeding those of sounding rockets, while retaining much of the sounding rocket philosophy in terms of instrument flexibility, simplicity, reliability assurance and development costs. The Ultraviolet and Optical Astronomy Program on Spacelab is being planned to provide optical astronomers with relatively simple and regular access to the extended wavelength coverage, the superior image quality and the darkness of the night sky available above the earth's atmosphere. In a rapidly evolving science one cannot predict what problems will be timely in the 1980s. Extrapolating from the current epoch, however, one can envision a continuing interest in such areas as the structure, composition and phenomenology of planetary surfaces and atmospheres; the composition and physical nature of the interstellar medium; the composition, structure and life history of stars, especially those in advanced stages of evolution; the stellar population of other galaxies; such enigmatic phenomena as X-ray binary black holes, pulsars, active galactic nuclei and quasars; large scale interactions between galaxies and the nature of the intergalactic medium; precise calibration of the Hubble law for the expansion of the universe; the average density of the universe; and the existence of extraterrestrial life.

Source record↗

NASA NTRS1992

Composite fuselage shell structures research at NASA Langley Research Center

Fuselage structures for transport aircraft represent a large portion of both the weight and cost of these aircraft primary structures. Composite materials offer the potential for reducing both the weight and cost of these structures, but only limited studies of the response and failure of composite fuselage structures have been conducted. The research is described which is being conducted and planned at NASA Langley to understand the critical behavior of composite fuselage structures and to validate the structural mechanics methodology being developed for stiffened composite fuselage shell structure subjected to combined internal pressure and mechanical loads. Stiffened shell and curved stiffened panel designs are currently being developed and analyzed, and these designs will be fabricated and then tested to study critical fuselage behavior and to validate structural analysis and design methodology. The research includes studies of the effects of combined internal pressure and mechanical loads on nonlinear stiffened panel and shell behavior, the effects of cutouts and other gradient producing discontinuities on composite shell response, and the effects of local damage on pressure containment and residual strength. Scaling laws are being developed that relate full scale and subscale behavior of composite fuselage shells.

Starnes, James H., Jr.↗

NASA NTRS1978

CODSTRAN: Composite durability structural analysis

CODSTRAN (COmposite Durability STRuctural ANalysis) is an integrated computer program being developed for the prediction of defect growth and fracture of composite structures subjected to service loads and environments. CODSTRAN is briefly described with respect to organization, capabilities and present status. Application of CODSTRAN current capability to a flat composite laminate with a center slit which was subjected to axial tension loading predicted defect growth which is in good agreement with C-scan ultrasonic test records.

Chamis, C. C.↗

NASA NTRS1979

Development of a beam builder for automatic fabrication of large composite space structures

The composite material beam builder which will produce triangular beams from pre-consolidated graphite/glass/thermoplastic composite material through automated mechanical processes is presented, side member storage, feed and positioning, ultrasonic welding, and beam cutoff are formed. Each process lends itself to modular subsystem development. Initial development is concentrated on the key processes for roll forming and ultrasonic welding composite thermoplastic materials. The construction and test of an experimental roll forming machine and ultrasonic welding process control techniques are described.

Bodle, J. G.↗

NASA NTRS1998

Factors Affecting Fiber Design and Selection for Advanced Ceramic Composites

Structural Ceramic Matrix Composites (CMC) have the potential for application in the hot sections of a variety of advanced propulsion and power systems. It is therefore necessary to have a general understanding of the key properties of CMC and Reinforcing Fibers. This need is complicated by the wide variety of application conditions and structural requirements for which CMC's will be used, and the proprietary concerns of the design engineers. CMC's, to be successful, must display properties which are competitive with the currently used high temperature structural materials: (i.e., Iron and Nickel based superalloys, tough monolithic ceramics, and carbon/carbon composites.) Structural CMC offers several areas of competition: (1) performance, (i.e., strength and strength retention, creep resistance, and thermal conductivity), (2) reliability (i.e., environmental durability, and damage tolerance) and (3) processing (i.e., capability for varying sizes and shapes, and cost effective fabrication). The presentation further discusses, and illustrates with fiber and CMC data the key fiber properties and processes which strongly affect each CMC area of competition. The presentation further discusses the current knowledge of the important factors which control the key fiber properties. A design guidelines for the optimum fiber characteristics is developed, and the currently available fibers are compared against those guidelines.

DiCarlo, James A.↗