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At least 73 records · Page 4

Improved Fabrication of Ceramic Matrix Composite/Foam Core Integrated Structures

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heatflux environments (150 W/cm2) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same pick location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cm3 in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Hurwitz, Frances I.↗

Inert Welding/Brazing Gas Filters and Dryers

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heat-flux environments (150 W/sq cm) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading-edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same "pick" location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cu cm in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Goudy, Jerry↗

STRANAL-PMC Version 2.0

Version 2.0 of the Strain Rate Dependent Analysis of Polymer Matrix Composites (STRANAL-PMC) software has been released. A prior version was reported in Analyzing Loads and Strains in Polymer- Matrix Composites (LEW-17227), NASA Tech Briefs, Vol. 26, No. 11 (November 2002), page 36. To recapitulate: Modified versions of constitutive equations of viscoplasticity of metals are used to represent deformation of a polymeric matrix. The equations are applied in a micromechanical approach, proceeding upward from slices of unit cells, through the ply level, to the laminate level. The constitutive equations are integrated in time by a Runge- Kutta technique. To predict the ultimate strength of each composite ply, failure criteria are implemented within the micromechanics. The inputs to STRANAL-PMC are the laminate geometry, properties of the fiber and matrix materials, and applied stress or strain versus time. The outputs are time-dependent stresses and strains at the slice, ply, and laminate levels. The improvements in version 2.0 include more rigorous representation of hydrostatic- stress effects in the matrix, refinement and extension of ply failure models, and capabilities to analyze transverse shear stresses. Version 2.0 can be implemented as a material-model code within transient dynamic finite-element codes.

Goldberg, Robert↗

Continuous stabilization of polyacrylonitrile (PAN) - carbon nanotube (CNT) fibers by Joule heating

We report stabilization is one of the important processes used to convert polyacrylonitrile (PAN) fibers into carbon fiber and is usually driven by energy-intensive and time-consuming convective heating. A continuous and energy-efficient alternative is desirable. Here, a continuous Joule heating process has been used for the first time to stabilize PAN fibers containing carbon nanotubes (CNT). Single-component PAN/CNT fibers and bi-component fibers with core-sheath geometry were fabricated through the gel spinning method. Joule heating was conducted continuously on a 200 filament bundle for single-component fibers and on bundles with up to 6000 filaments for the bi-component fibers. A model of heat transfer and thermodynamics occurring during Joule heating is developed and utilized to understand the reductions in stabilization time and energy consumed when compared to convective heating. The minimum energy needed for stabilization through Joule heating is estimated to be less than 1% of the energy used through convective heating.

42 ENGINEERING↗

Thermomechanical Modeling of Woven Materials With Particle-Based, Explicit-Fiber Simulations

Fiber-based materials are extensively used to protect spacecraft during entry. Insulative fibers, often in a fiber network or woven, provide rigidity, strength, and control of material anisotropy and density. Woven thermal protection materials, such as ADEPT (Adaptable, Deployable Entry and Placement Technology), 3D-MAT (3-Dimensional Multifunctional Ablative Thermal Protection), and 3MDCP (3D Woven Mid-Density Carbon Phenolic), enable missions with stronger and denser materials for entry profiles with high shear and heat flux. Vulnerabilities to woven thermal protection materials include manufacturing-induced material property variation, and impact from micrometeoroids. Simulating woven materials under these conditions require models that can resolve hierarchal structures, thermomechanical behavior, and failure. To address this, we simulate weave thermal conduction and mechanical deformation. We simulate the full weave with a coarse-grained yarn model is presented. The model combines a validated, high-resolution single 3MDCP yarn model and phenolic resin model. Instead of modeling every fiber, each yarn ply with order 10, instead of order 1000, fibers. The discrete element bonded particle model (DEM-BPM) of fibers captures the thermal and mechanical behavior within and between fibers. We study the proportion of heat transfer and stress via the contact network, fiber bonds, and overall weave geometry.

bonded particle↗

Fiber Sorbents – A Versatile Platform for Sorption-Based Gas Separations

Increasing demand for high-purity fine chemicals and a drive for process intensification of large-scale separations have driven significant work on the development of highly engineered porous materials with promise for sorption-based separations. While sorptive separations in porous materials offer energy-efficient alternatives to longstanding thermal-based methods, the particulate nature of many of these sorbents has sometimes limited their large-scale deployment in high-throughput applications such as gas separations, for which the necessary high feed flow rates and gas velocities accrue prohibitive operational costs. These processability limitations have been historically addressed through powder shaping methods aimed at the fabrication of structured sorbent contactors based on pellets, beads or monoliths, commonly obtained as extrudates. These structures overcome limitations such as elevated pressure drops commonly recorded across powder adsorption beds but often accrue thermal limitations arising from elevated particle density and aggregation, which ultimately cap their maximum separation performance. Furthermore, the harsh mechanical strain to which powder particles are subjected during contactor fabrication, in the form of extrusion/compression forces, can result in partial pore occlusion and framework degradation, further limiting their performance. Here, we present the development of porous fiber sorbents as an alternative sorbent contactor design capable of addressing sorbent processability limitations while enabling an array of performance-maximizing heat integration capabilities. This new sorbent form factor leverages pre-existing know-how from hollow fiber spinning to produce fiber-shaped sorbent contactors through the phase inversion of known polymers in a process known as dry-jet/wet quenching. The process of phase inversion allows microporous sorbent particles to be latched onto a macroporous polymer matrix under mild processing conditions, thus making it compatible with soft porous materials prone to amorphization under traditional pelletization conditions. Sorbent fibers can be created with different geometries through control of the spinning apparatus and process, offering the possibility to produce monolithic and hollow fibers alike, the latter of which can be integrated with thermalization fluid flows. In this Account, we summarize our progress in the field of fiber sorbents from both design and application standpoints. We further guide the reader through the evolution of this field from the early inceptive work on zeolite hollow fibers to recent developments on MOF fibers. We highlight the versatile nature of fiber sorbents, both from the composition, fabrication and structure points of view, and further demonstrate how fiber sorbents offer alternative paths in tackling new and challenging chemical separation challenges like direct air capture (DAC), with a final perspective on the future of the field.

36 MATERIALS SCIENCE↗

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Woven↗

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Discrete Element Method↗

Buckling analysis of laminated thin shells in a hot environment

Results are presented of parametric studies to assess the effects of various parameters on the buckling behavior of angle-ply, laminated thin shells in a hot environment. These results were obtained by using a three-dimensional finite element analysis. An angle-ply, laminated thin shell with fiber orientation of (theta/-theta)(sub 2) was subjected to compressive mechanical loads. The laminated thin shell had a cylindrical geometry. The laminate contained T300 graphite fibers embedded in an intermediate-modulus, high-strength (IMHS) matrix. The fiber volume fraction was 55 percent and the moisture content was 2 percent. The residual stresses induced into the laminate structure during the curing were taken into account. Parametric studies were performed to examine the effect on the critical buckling load of the following parameters: cylinder length and thickness, internal hydrostatic pressure, different ply thicknesses, different temperature profiles through the thickness of the structure, and different lay up configurations and fiber volume fractions. In conjunction with these parameters the ply orientation was varied from 0 deg to 90 deg. Seven ply angles were examined: 0 deg, 15 deg, 30 deg, 45 deg, 60 deg, 75 deg, and 90 deg. The results show that the ply angle theta and the laminate thickness had significant effects on the critical buckling load. The fiber volume fraction, the fiber orientations, and the internal hydrostatic pressure had important effects on the critical buckling load. The cylinder length had a moderate influence on the buckling load. The thin shell with (theta/-theta)(sub 2) or (theta/-theta)(sub s) angle-ply laminate had better buckling-load performance than the thin shell with (theta)(sub 4) angle-ply laminate. The temperature profiles through the laminate thickness and various laminates with the different ply thicknesses has insignificant effects on the buckling behavior of the thin shells.

Gotsis, Pascal K.↗

Field emission microscopy of carbon nanotube fibers: Evaluating and interpreting spatial emission

In this work, the authors quantify field emission properties of cathodes made from carbon nanotube (CNT) fibers. The cathodes were arranged in different configurations to determine the effect of cathode geometry on the emission properties. Various geometries were investigated including (1) flat cut fiber tip, (2) folded fiber, (3) looped fiber, and (4) fibers wound around a cylinder. The authors employ a custom field emission microscope to quantify I-V characteristics in combination with laterally resolved field-dependent electron emission area. Additionally, they look at the very early emission stages, first when a CNT fiber is turned on for the first time, which is then followed by multiple ramp-up/down runs. Upon the first turn on, all fibers demonstrated limited and discrete emission area. During ramping runs, all CNT fibers underwent multiple (minor and/or major) breakdowns, which improved emission properties in that turn-on field decreased and field enhancement factor and emission area both increased. It is proposed that breakdowns are responsible for removing initially undesirable emission sites caused by stray fibers higher than average. This initial breakdown process gives way to a larger emission area that is created when the CNT fiber subcomponents unfold and align with the electric field. Overall, the authors' results form the basis for careful evaluation of CNT fiber cathodes for dc or low frequency pulsed power systems in which large uniform area emission is required or for narrow beam high frequency applications in which high brightness is a must.

Image processing↗

Integrated damping mechanics for thick composite laminates and plates

A method for predicting the damped dynamic characteristics of thick composite laminates and plates is presented. Unified damping mechanics relate the damping of composite plates to constituent properties, fiber volume ratio, fiber orientation, laminate configuration, plate geometry, temperature, and moisture. Discrete layer damping mechanics for thick laminates, entailing piecewise continuous displacement fields and including the effects of interlaminar shear damping, are described. A semi-analytical method for predicting the modal damping and natural frequencies of thick simply-supported specialty composite plates is included. Applications demonstrate the validity, merit, and ranges of applicability of the new theory. The applications further illustrate the significance of interlaminar shear damping, and investigate the effects of lamination, thickness aspect ratio, fiber content, and temperature.

Saravanos, D. A.↗

A comparative evaluation of in-plane shear test methods for laminated graphite-epoxy composites

The objectives were to evaluate popular shear test methods for various forms of graphite-epoxy composite materials and to determine the shear response of graphite-epoxy composites with various forms of fiber architecture. Numerical and full-field experimental stress analyses were performed on four shear test configurations for unidirectional and bidirectional graphite-epoxy laminates to assess the uniformity and purity of the shear stress (strain) fields produced in the specimen test section and to determine the material in-plane shear modulus and shear response. The test methods were the 10 deg off-axis, the +/- 45 deg tension, the Iosipescu V-notch, and a compact U-notch specimen. Specimens were prepared from AS4/3501-6 graphite-epoxy panels, instrumented with conventional strain gage rosettes and with a cross-line moire grating, and loaded in a convenient testing machine. The shear responses obtained for each test method and the two methods of specimen instrumentation were compared. In a second phase of the program the shear responses obtained from Iosipescu V-notch beam specimens were determined for woven fabric geometries of different weave and fiber architectures. Again the responses of specimens obtained from strain gage rosettes and moire interferometry were compared. Additional experiments were performed on a bidirectional cruciform specimen which was also instrumented with strain gages and a moire grating.

Morton, John↗

Using optical fibers to examine thermal mixing of liquid sodium in a pool-type geometry

Sodium fast reactors (SFR) are poised to be a leading candidate for the next generation of commercial nuclear reactor deployment. Companies are commissioning designs for SFR increasing the need for experimental and computational analysis to improve the economics and safety of these reactors. Analysis of SFR behavior during reactor transients directly informs the understanding of reactor safety. Particularly, investigating the thermal transients associated with the reactor loss of flow transient allows for informed design decisions to be made regarding reactor safety. During loss of flow transients the flow rate of the coolant is significantly reduced, but not necessarily stopped. The reduction in flow rate results in coolant temperatures exiting the reactor core that can be drastically different than the coolant in upper pool. When these different temperature fluids interact, thermally stratified layers can form causing cyclic thermal fatigue on the reactor vessel potentially leading to pre-material failure. Past experimental studies have lacked high resolution temperature measurements. This research focuses on demonstrating the reliability of novel techniques for acquiring high resolution temperature measurements in a scaled liquid sodium facility. Tests are conducted that simulate postulated loss of flow transients and provide unprecedented spatial temperature distribution measurements.

42 ENGINEERING↗

Composite Blade Structural Analyzer (COBSTRAN) theoretical/programmer's manual

This manual describes the organization and flow of data and analysis in the computer code, COBSTRAN (COmposite Blade STRuctural ANalyzer). This code combines composite mechanics and laminate theory with an internal data base of fiber and matrix properties and was developed for the design and analysis of composite turbofan and turboprop blades and composite wind turbine blades. Inputs to the code are constituent fiber and matrix material properties, factors reflecting the fabrication process, composite geometry and blade geometry. COBSTRAN performs the micromechanics and laminate analyses of these fiber composites and generates a NASTRAN finite element model of the blade. This manual describes the equations formulated and solved in the code and the function of each of the seventy-two subroutines. COBSTRAN is written in FORTRAN 77.

Aiello, Robert A.↗

Interfacial stress state present in a 'thin-slice' fibre push-out test

An analysis of the stress distributions along the fiber-matrix interface in a 'thin-slice' fiber push-out test is presented for selected test geometries. For the small specimen thicknesses often required to displace large-diameter fibers with high interfacial shear strengths, finite element analysis indicates that large bending stresses may be present. The magnitude of these stresses and their spatial distribution can be very sensitive to the test configuration. For certain test geometries, the specimen configuration itself may alter the interfacial failure process from one which initiates due to a maximum in shear stress near the top surface adjacent to the indentor, to one which involves mixed mode crack growth up from the bottom surface and/or yielding within the matrix near the interface.

Kallas, M. N.↗

Photo-Curing 3D Printing of Thermosetting Sacrificial Tooling for Fabricating Fiber-Reinforced Hollow Composites

Carbon fiber-reinforced hollow composites play a vital role in lightweighting modern cars and aircrafts. Fabrication of such hollow composites with seamless internal finish requires sacrificial tooling that can be used under pressure and high temperature. For the very first time, high performance sacrificial tooling that can be used to fabricate fiber-reinforced hollow composites is produced using photocuring 3D printing technology. This is achieved by developing UV-curable resins containing highly soluble yet hydrolysable acetal acrylate cross-linker and hydrophilic 4-acryloylmorpholine monomer. It is found that the cross-linker content greatly affects the printing speed. Further, the widely adopted UV post-curing method is found to have negligible impact on improving the thermal-mechanical properties of printed structures. Additionally, after thermal post-treatment, printed sacrificial tooling exhibits a heat deflection temperature of 112 °C at 0.455 MPa and an average coefficient of linear thermal expansion of 59 ppm °C -1 between 30 and 100 °C. As a result, printed tooling enables fabrication of carbon fiber-reinforced hollow composites with complex geometry, which shows a tensile strength of 802 MPa and an elastic modulus of 50.2 GPa.

36 MATERIALS SCIENCE↗

Composite blade structural analyzer (COBSTRAN) user's manual

The installation and use of a computer code, COBSTRAN (COmposite Blade STRuctrual ANalyzer), developed for the design and analysis of composite turbofan and turboprop blades and also for composite wind turbine blades was described. This code combines composite mechanics and laminate theory with an internal data base of fiber and matrix properties. Inputs to the code are constituent fiber and matrix material properties, factors reflecting the fabrication process, composite geometry and blade geometry. COBSTRAN performs the micromechanics, macromechanics and laminate analyses of these fiber composites. COBSTRAN generates a NASTRAN model with equivalent anisotropic homogeneous material properties. Stress output from NASTRAN is used to calculate individual ply stresses, strains, interply stresses, thru-the-thickness stresses and failure margins. Curved panel structures may be modeled providing the curvature of a cross-section is defined by a single value function. COBSTRAN is written in FORTRAN 77.

Aiello, Robert A.↗

New Fracture Diagnostic Tool for Unconventionals: High-Resolution Distributed Strain Sensing via Rayleigh Frequency Shift during Production in Hydraulic Fracture Test 2

Fiber Optic monitoring in unconventional reservoirs has proven to be an invaluable diagnostic tool for assessing both near-wellbore stimulation effectiveness and to help describe the far-field frac geometries created by hydraulic fracture stimulation. Unfortunately, gaining any detailed qualitative and quantitative understanding of the near-wellbore frac geometry or cluster/stage productivity during production via Fiber Optic (FO) has proven to be more difficult, particularly in wells producing liquids. A new FO diagnostic method, Distributed Strain Sensing based on Rayleigh Frequency Shift (DSS-RFS), first demonstrated for oil and gas applications in the Hydraulic Test Site 2 (HFTS2) provides new insights about the characteristics of near-wellbore-region (NWR) during production. DSS-RFS is different from other FO strain measurements because it relies on accurate measurement of frequency shifts of Rayleigh backscattered spectrum obtained by scanning the fiber with a coherent optical time-domain reflectometer with a range of laser frequencies using a tunable-wavelength laser system. Changes in strain are measured with an extremely high spatial resolution of 20 cm and with high signal-to-noise ratios over long distances. In HFTS2, strain changes for the entire wellbore have been measured twice during scheduled shut-in and reopening operations (February 2020 and September 2020). After removing temperature effects, consistent strain changes have been observed at the location of most perforation clusters. These are caused by near wellbore fracture aperture changes due to pressure increases during shut-in within the near-wellbore fracture network. The strain-change patterns from the DSS-RFS during shut-in correlate very well with the location of clusters and allow for the definition of extending intervals with positive strain signals at each cluster and slightly compressing intervals with negative strain signals between the clusters and in the non stimulated intervals. The locations of the measured positive strain peaks also show good correspondence to DAS acoustic intensity measurements acquired during the stimulation. The geometry and magnitude of the strain changes differ significantly between the two tested completion designs in the same well. During shut in and reopening each cluster exhibit its own strain-change / pressure path. In addition, the September 2020 dataset also revealed the existence of small but measurable strain changes as consequence of pressure decline during production. These strain changes also correlate well with the presence of producing clusters, but the strain-rate signals are opposite to that obtained during shut-in and reopening operations. Although Downloaded from http://onepetro.org/URTECONF/proceedings-pdf/21URTC/2-21URTC/D021S031R002/2477551/urtec-2021-5408-ms.pdf/1 by Carol Worster on 28 February 2022 URTeC 5408 2 we are still in the early stages of exploring the potential of this novel FO technique, we believe that the highly detailed information contained in the measurement of strain changes using DSS-RFS during production can significantly improve our understanding of near-wellbore hydraulic fracture characteristics and the relationships between stimulation and production from unconventional oil and gas wells.

04 OIL SHALES AND TAR SANDS↗