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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 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Millimeter Wave Holographical Inspection of Honeycomb Composites

Multi-layered composite structures manufactured with honeycomb, foam or balsa wood cores are finding increasing utility in a variety of aerospace, transportation, and infrastructure applications. Due to the low conductivity and inhomogeneity associated with these composites standard nondestructive testing (NDT) methods are not always capable of inspecting their interior for various defects caused during the manufacturing process or as a result of in-service loading. On the contrary, microwave and millimeter wave NDT methods are well-suited for inspecting these structures since signals at these frequencies readily penetrate through these structures and reflect from different interior boundaries revealing the presence of a wide range of defects such as disbond, delamination, moisture and oil intrusion, impact damage, etc. Millimeter wave frequency spectrum spans 30 GHz - 300 GHz with corresponding wavelengths of 10 - 1 mm. Due to the inherent short wavelengths at these frequencies, one can produce high spatial resolution images of these composites either using real-antenna focused or synthetic-aperture focused methods. In addition, incorporation of swept-frequency in the latter method (i.e., holography) results in high-resolution three-dimensional images. This paper presents the basic steps behind producing such images at millimeter wave frequencies and the results of two honeycomb composite panels are demonstrated at Q-band (33-50 GHz). In addition, these results are compared to previous results using X-ray computed tomography.

Case, J. T.↗
NASA NTRS1992

Transverse flexural tests as a tool for assessing damage to PMR-15 composites from isothermal aging in air at elevated temperatures

To date, the effect of thermo-oxidative aging on unidirectional composite mechanical properties has been monitored by the measurement of interlaminar shear strength (ILSS) and either three or four point longitudinal flexural strength (LFS) of the composites being tested. Both results are affected by the fiber-to-matrix bonding, the former being dependent on the shear resistance of the interface and the latter on the degree of load sharing by the fibers through the fiber/matrix interface. Recently, fiber/matrix interfacial bond strengths have been monitored using a transverse flexural strength (TFS) test method. This test method was used to evaluate the effect of fiber surface treatment on the fiber/matrix bond. The interface bonding was varied in these tests using Hercules A-fibers with three-types of surfaces that produce bonds of poor, better, and good quality. The TFS was found not only to be sensitive to the bonding, but also to the aging time of unidirectional A-fiber/PMR-15 composites. This relationship reflects the mechanism by which the PMR-15 degrades during thermal aging.

Bowles, Kenneth J.↗
NASA NTRS2014

Buckling of a Longitudinally Jointed Curved Composite Panel Arc Segment for Next Generation of Composite Heavy Lift Launch Vehicles: Verification Testing Analysis

In this work, an all-bonded out-of-autoclave (OoA) curved longitudinal composite joint concept, intended for use in the next generation of composite heavy lift launch vehicles, was evaluated and verified through finite element (FE) analysis, fabrication, testing, and post-test inspection. The joint was used to connect two curved, segmented, honeycomb sandwich panels representative of a Space Launch System (SLS) fairing design. The overall size of the resultant panel was 1.37 m by 0.74 m (54 in by 29 in), of which the joint comprised a 10.2 cm (4 in) wide longitudinal strip at the center. NASTRAN and ABAQUS were used to perform linear and non-linear analyses of the buckling and strength performance of the jointed panel. Geometric non-uniformities (i.e., surface contour imperfections) were measured and incorporated into the FE model and analysis. In addition, a sensitivity study of the specimens end condition showed that bonding face-sheet doublers to the panel's end, coupled with some stress relief features at corner-edges, can significantly reduce the stress concentrations near the load application points. Ultimately, the jointed panel was subjected to a compressive load. Load application was interrupted at the onset of buckling (at 356 kN 80 kips). A post-test non-destructive evaluation (NDE) showed that, as designed, buckling occurred without introducing any damage into the panel or the joint. The jointed panel was further capable of tolerating an impact damage to the same buckling load with no evidence of damage propagation. The OoA cured all-composite joint shows promise as a low mass factory joint for segmented barrels.

mechanical/sub-structural testing↗
NASA NTRS1982

Lacquer Reveals Impact Damage in Composites

Brittle lacquer unveils effects normally visible only by ultrasonic inspection. Laquer coating measures spread of cracking and delamination in graphite/epoxy panels subjected to cyclic compression loads after impact damage. Test specimen is coated with lacquer on side opposite surface at which projectile will be fired. Spalled area shows effect of impact without removing specimen from test fixture.

Rhodes, M. D.↗
NASA NTRS2018

Scaling Methodology for Buckling of Sandwich Composite Cylindrical Structures

The study of the buckling behavior of large shell structures through full-size tests can be complex and expensive. Therefore, scaled structures are often preferred to investigate the buckling behavior efficiently. However, it can be difficult to design scaled structures that are representative of the full-scale structures. Herein, an analytical scaling methodology for compression-loaded sandwich composite cylinders based on the nondimensionalization of the buckling equations is presented. The methodology is used to develop scaled configurations that show a similar buckling response. Both the baseline and the scaled configurations are verified by finite-element analysis. Limitations of the methodology are discussed and are a result of neglecting the flexural anisotropy and the transverse shear compliance.

Balbin, Ines Uriol↗
NASA NTRS1989

Scaling effects in the impact response of graphite-epoxy composite beams

In support of crashworthiness studies on composite airframes and substructure, an experimental and analytical study was conducted to characterize size effects in the large deflection response of scale model graphite-epoxy beams subjected to impact. Scale model beams of 1/2, 2/3, 3/4, 5/6, and full scale were constructed of four different laminate stacking sequences including unidirectional, angle ply, cross ply, and quasi-isotropic. The beam specimens were subjected to eccentric axial impact loads which were scaled to provide homologous beam responses. Comparisons of the load and strain time histories between the scale model beams and the prototype should verify the scale law and demonstrate the use of scale model testing for determining impact behavior of composite structures. The nonlinear structural analysis finite element program DYCAST (DYnamic Crash Analysis of STructures) was used to model the beam response. DYCAST analysis predictions of beam strain response are compared to experimental data and the results are presented.

Jackson, Karen E.↗
NASA NTRS1994

Test Plan. GCPS Task 4, subtask 4.2 thrust structure development

The Single Stage To Orbit (SSTO) vehicle is designed to lift off from a vertical position, go into orbit, return to earth for a horizontal landing, and be reusable for the next mission. (NASA baseline only) In order to meet its performance goals, the SSTO relies on light weight structure and the use of 8 tri-propellant engines. These engines are mounted to the thrust structure. This test plan addresses selection of the material for this structure, and the integrity of the design through testing of elements and a full-scale subcomponent. This test plan supports the development of the design for an advanced composite thrust structure for a Single Stage to Orbit manned, heavy launch vehicle. The thrust structure is designed to transmit very high thrust loads from the engines to the rest of the vehicle (see Figure 1 ). The thrust structure will also be used for primary attachment of the twin vertical tails and possibly act as the aft attach point for the wing. The combination of high loading, high vibration, long service life and high acoustic environments will need to be evaluated by tests. To minimize design risk, a building block approach will be used. We will first screen materials to determine which materials show the most promise for this application. Factors in this screening will be the suitability of these materials for chosen design concepts, particularly concerning specific strength, environmental compatibility and applicability to fabrication processes. Next we will characterize two material systems that will be used in the design; the characterization will allow us to generate preliminary design data that will be used for the analysis. Element testing will be performed to evaluate critical structural locations under load. Final testing on the full scale test article will be performed to verify the design and to demonstrate predictability of the analysis. Additionally, risks associated with fabricating full scale thrust structures will be reduced through testing activities. One of the major concerns that stems from full scale fabrication is the realities of size and the associated complexities of handling, manufacturing, and assembly. The need exists to fabricate, assemble and test_representative joint specimens to achieve_confidence in the design and manufacturing technologies being proposed.

Greenberg, H. S.↗
NASA NTRS1992

Dynamic testing and analysis of extension-twist-coupled composite tubular spars

The results from a study aimed at improving the dynamic and aerodynamic characteristics of composite rotor blades through the use of extension-twist elastic coupling are presented. A set of extension-twist-coupled composite tubular spars, representative of the primary load carrying structure within a helicopter rotor blade, was manufactured using four plies of woven graphite/epoxy cloth 'prepreg.' These spars were non-circular in cross section design and were therefore subject to warping deformations. Three cross-sectional geometries were developed: square, D-shape, and flattened ellipse. Results from free-free vibration tests of the spars were compared with results from normal modes and frequency analyses of companion shell-finite-element models developed in MSC/NASTRAN. Five global or 'non-shell' modes were identified within the 0-2000 Hz range for each spar. The frequencies and associated mode shapes for the D-shape spar were correlated with analytical results, showing agreement within 13.8 percent. Frequencies corresponding to the five global mode shapes for the square spar agreed within 9.5 percent of the analytical results. Five global modes were similarly identified for the elliptical spar and agreed within 4.9 percent of the respective analytical results.

Lake, Renee C.↗
NASA NTRS1985

Composite Loads Spectra for Select Space Propulsion Structural Components: Probabilistic Load Model Development

This effort is in support of the development of the expert system of computer codes to predict the loads on select structural components of a space propulsion engine. The development will be based primarily on the space shuttle main engine (SSME) test data base. Because of random variations of the many different sources of the loadings on the selected structural components and transients, a probabilistic approach to the problems was adopted. The goal of this task is to characterize all of the individual sources of loads at critical structural locations, such as the turbine blades, the transfer ducts, and liquid oxygen posts, using state-of-the-art probabilistic methods with varying levels of sophistication. The second phase of this work is the development of a composite load model based on a probabilistic synthesis of the individual load model previously developed. This model will be based on the stochastic combination of the load variables and not on the physical process for the combination of the individual loads to the composite load seen by the selected structural components.

Kurth, R.↗
NASA NTRS2003

Unitized Regenerative Fuel Cell System Gas Storage/Radiator Development

The ancillary components for Unitized Regenerative Fuel Cell (URFC) Energy Storage System are being developed at the NASA Glenn Research Center. This URFC system is unique in that it uses the surface area of the hydrogen and oxygen storage tanks as radiating heat surfaces for overall thermal control of the system. The waste heat generated by the URFC stack during charging and discharging is transferred from the cell stack to the surface of each tank by loop heat pipes. The heat pipes are coiled around each tank and covered with a thin layer of thermally conductive layer of carbon composite. The thin layer of carbon composite acts as a fin structure that spreads the heat away from the heat pipe and across the entire tank surface. Two different sized commercial grade composite tanks were constructed with integral heat pipes and tested in a thermal vacuum chamber to examine the feasibility of using the storage tanks as system radiators. The storage radiators were subjected to different steady-state heat loads and varying heat load profiles. The surface emissivity and specific heat capacity of each tank were calculated. The results were incorporated into a model that simulates the performance of similar radiators using lightweight, space rated carbon composite tanks.

Jakupca, Ian↗
DOE OSTI2020

Summary of Analytical Results from Samples Supporting Tank Closure Cesium Removal (TCCR) Batch 3 and Modeling Results for Cs Loading on CST

Savannah River Remediation (SRR) is currently operating the Tank Closure Cesium Removal (TCCR) process to remove 137 Cs from tank waste supernate using an ion exchange process. As part of that process, Savannah River National Laboratory (SRNL) receives and analyzes samples in support of the qualification of each batch to be processed. SRNL recently received supernate samples retrieved from Tank 10H as well as in-tank batch contact samples for characterization in support of qualifying Batch 3 for processing through the TCCR unit. Some results from analysis of those samples have been previously reported. This report documents the remaining analyses of the in-tank batch contact samples as well as the results of ZAM (Zheng, Anthony, Miller) isotherm modeling performed for comparison to the measured results. Results of the additional analyses include analysis of the loading of other radionuclides besides 137 Cs on the crystalline silicotitanate (CST) contained within the in-tank batch contact test samples. Results from those analyses revealed the next highest contributor to the activity on the CST was 90 Sr with an average loading of 2.76E+08 dpm/g CST compared to 3.56E+10 dpm/g CST for the 137Cs. Isotopes of plutonium were also detected on the samples. ZAM modeling was performed using the measured composition of the Tank 10H Batch 3 qualification samples. The modeling predicted a maximum Cs loading approximately 2.2x higher than the measured result. This is a slightly lower ratio (expected/measured) compared to what was observed for the prior TCCR in-tank batch contact testing performed for Batches 1A and 2 where the ZAM results were 2.7-2.8x higher than the measured values.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1979

Time-temperature behavior of a unidirectional graphite/epoxy composite

A testing program to determine the time-temperature response of unidirectional T300/934 graphite/epoxy materials is presented. The short-term creep test results of tension specimens with the load at various angles to the fiber direction and at various temperatures are reported, showing that the material is elastic at all temperatures when the fiber is in the load direction. However, when the load is transverse to the fibers, the viscoelastic response varies from small amounts at room temperature to large amounts at temperatures above the 180 C transition temperature. The time-temperature superposition principle or the method of reduced variables were used to determine compliance master curves for each fiber angle, and a viscoelastic analog to the elastic orthotropic transformation equation was used incrementally to predict the master curves for the tensile compliance of the off-axis specimen.

Yeow, Y. T.↗
NASA NTRS2017

Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiC-SiC Ceramic Matrix Composite (CMC) combustors particularly under the NASA Environmentally Responsible Aviation, Fundamental Aeronautics and Transformative Aeronautics Concepts Programs. The emphases have been placed on the current design challenges of the 2700-3000F capable environmental barrier coatings for low NOX emission combustors for next generation turbine engines by using advanced plasma spray based processes, and the coating processing and integration with SiC-SiC CMCs and component systems. The developments also have included candidate coating composition system designs, degradation mechanisms, performance evaluation and down-selects; the processing optimizations using TriplexPro Air Plasma Spray Low Pressure Plasma Spray (LPPS), Plasma Spray Physical Vapor Deposition and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements under the NASA development programs, as demonstrated in the simulated engine high heat flux, combustion environments, in conjunction with high heat flux, mechanical creep and fatigue loading testing conditions.

CMAS↗
NASA NTRS1996

Evaluation of the Edge Crack Torsion (ECT) Test for Mode 3 Interlaminar Fracture Toughness of Laminated Composites

An analytical and experimental investigation was carried out on G40-800/R6376 graphite epoxy laminates to evaluate the Edge Crack Torsion (ECT) test as a candidate for a standard Mode 3 interlaminar fracture toughness test for laminated composites. The ECT test consists of a (90/(+/- 45)(sub 3)/(+/- 45)(sub 3)/90))(sub s) laminate with a delamination introduced by a non-adhesive film at the mid-plane along one edge and loaded in a special fixture to create torsion along the length of the laminate. Dye penetrate enhanced X-radiograph of failed specimens revealed that the delamination initiated at the middle of the specimen length and propagated in a self similar manner along the laminate mid-plane. A three-dimensional finite element analysis was performed that indicated that a pure Mode 3 delamination exists at the middle of specimen length away from both ends. At the ends near the loading point a small Mode 2 component exists. However, the magnitude of this Mode 2 strain energy release rate at the loading point is small compared to the magnitude of Mode 3 component in the mid-section of the specimen. Hence, the ECT test yielded the desired Mode 3 delamination. The Mode 3 fracture toughness was obtained from a compliance calibration method and was in good agreement with the finite element results. Mode 2 End-Notched Flexure (ENF) tests and Mode 1 Double Cantilever Beam (DCB) tests were also performed for the same composite material. The Mode 1 fracture toughness was much smaller than both the Mode 2 and Mode 3 fracture toughness. The Mode 2 fracture toughness was found to be 75% of the Mode 3 fracture toughness.

Li, Jian↗
NASA NTRSDate not supplied

Testing and Analysis Correlation of a Large-Scale Composite Sandwich Longitudinal Bonded Joint for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composite technologies with a focus on composite bonded joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA’s expertise and capabilities. The project has goals of advancing composite technologies and providing lightweight structures to support future NASA exploration missions. In particular, the CTE project will demonstrate weight-saving, performance-enhancing composite bonded joint technology for Space Launch System (SLS)-scale composite hardware. Advancements from the CTE project may be incorporated as future block upgrades for SLS structural components. This paper discusses the details of the development of a composite sandwich bonded longitudinal joint for a generic space launch vehicle structure called the CTE Point Design. This paper reports on the large-scale longitudinal bonded joint test articles that were fabricated and tested under axial compressive loading conditions to test the capability of the bonded joint design for buckling and joint failure. Test and analysis correlation of an as-manufactured undamaged longitudinal bonded joint panel are presented in the paper for tests to the onset of buckling and panel failure. Analysis predictions for buckling initiation and panel failure were both within 10% of the longitudinal bonded joint panel test results. This testing and analysis provide confidence in the potential use of composite bonded joints for future launch vehicle structures.

David W Sleight↗
DOE OSTI2022

Mechanical Properties of High-Temperature Fiber-Reinforced Thermoset Composites with Plain Weave and Unidirectional Carbon Fiber Fillers

Fiber-reinforced thermoset composites are a class of materials that address the arising needs from the aerospace and hypersonic industries for high specific strength, temperature-resistant structural materials. Among the high-temperature resistant thermoset categories, phenolic triazine (PT) cyanate esters stand out thanks to their inherent high degradation temperature, glass transition temperature, and mechanical strength. Despite the outstanding properties of these thermosets, the performance of carbon fiber composites using PT cyanate esters as matrices has not been thoroughly characterized. This work evaluated PT and carbon fiber composites’ compressive properties and failure mechanisms with different fiber arrangements. A PT resin with both plain weave (PW) and non-crimped unidirectional (UD) carbon fiber mats was analyzed in this research. Highly loaded thermoset composites were obtained using process temperatures not exceeding 260 °C, and the composites proved to retain compressive strength at temperatures beyond 300 °C. Compressive testing revealed that PT composites retained compressive strength values of 50.4% of room temperature for UD composites and 61.4% for PW composites. Post-compressive failure observations of the gage section revealed that the mechanisms for failure evolved with temperature from brittle, delamination-dominant failure to shear-like failure promoted by the plastic failure of the matrix. This study demonstrated that PT composites are a good candidate for structural applications in harsh environments.

Hall, Samuel Ernesto↗
NASA NTRS1977

Biaxial fatigue loading of notched composites

Thin-walled, 2.54-cm diameter tubular specimens of graphite/epoxy were fatigue cycled in combinations of axial, torsional, and internal pressure loading. Two different four-ply layup configurations were tested: (0-90)s and (+ or- 45)s; each tube contained a 0.48-cm diameter circular hole penetrating one wall midway along the tube length. S-N curves were developed to characterize fatigue behavior under pure axial, torsional, or internal pressure loading, as well as combined loading fatigue. A theory was developed based on a plane stress model which enabled the S-N curve for combined stress states to be predicted from the S-N data for the uniaxial loading modes. Correlation of the theory with the experimental data proved to be remarkably good.

Francis, P. H.↗
NASA NTRS1981

Development of CdO-graphite-Ag coatings for gas bearings to 427 C

Graphite is one of the most commonly known lubricants. Its effectiveness in a range between room temperature (RT) and 540 C is reportedly improved by adding cadmium oxide. CdO-graphite powder in a gas carrier has been used in numerous applications that rely on dry lubrication. A coating of this composition was developed and successfully tested in foil air bearings for long periods up to a temperature of 427 C and at a normal contacting load (during starting and stopping) of 14 kPa based on bearing projected area. The addition of ultra-fine silver to the CdO-graphite has improved the coating endurance. At 427 C, the CdO-graphite-Ag coating performed better than CdO-graphite without silver, both for extended periods at 14 kPa loading and for limited periods at 35 kPa. At 288 C, the coating was tested for an extended period up to 28 kPa and has also successfully completed high-speed shock tests to an acceleration level of 100g.

Bhushan, B.↗