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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Design/Analysis of the JWST ISIM Bonded Joints for Survivability at Cryogenic Temperatures

A major design and analysis challenge for the JWST ISIM structure is thermal survivability of metal/composite bonded joints below the cryogenic temperature of 30K (-405 F). Current bonded joint concepts include internal invar plug fittings, external saddle titanium/invar fittings and composite gusset/clip joints all bonded to M55J/954-6 and T300/954-6 hybrid composite tubes (75mm square). Analytical experience and design work done on metal/composite bonded joints at temperatures below that of liquid nitrogen are limited and important analysis tools, material properties, and failure criteria for composites at cryogenic temperatures are sparse in the literature. Increasing this challenge is the difficulty in testing for these required tools and properties at cryogenic temperatures. To gain confidence in analyzing and designing the ISIM joints, a comprehensive joint development test program has been planned and is currently running. The test program is designed to produce required analytical tools and develop a composite failure criterion for bonded joint strengths at cryogenic temperatures. Finite element analysis is used to design simple test coupons that simulate anticipated stress states in the flight joints; subsequently the test results are used to correlate the analysis technique for the final design of the bonded joints. In this work, we present an overview of the analysis and test methodology, current results, and working joint designs based on developed techniques and properties.

Bartoszyk, Andrew↗
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↗
DOE OSTI2022

Uncertainty Quantification for Dissimilar Material Joints Under Corrosion Environment

Abstract Self-Piercing Riveting (SPR) is one of the most commonly used methods for joining dissimilar materials in the automotive industry. These joints are popular due to their adaptability, high performance and short cycle time. However, since these joints involve two dissimilar materials, they are susceptible to galvanic corrosion in the presence of an electrolyte which is driven by the difference in the equilibrium potential of the metals. This can affect the safety and resilience of these joints. In this paper, we focus on galvanic corrosion in Al-Fe SPR joints. A Machine learning (ML) based surrogate model, which is based off of FE simulations, for statistical corrosion analysis is developed. This model enables the resilience and reliability analysis of SPR joints under corrosion environment. In this study, first a physics-based finite element (FE) corrosion model has been developed to simulate the galvanic corrosion between a Fe cathode and an Al anode of a SPR joint. This model takes into account the effect of the crystal microstructure of the Al anode and the precipitation of the corrosion product. Several geometric and environmental factors including crevice gap, roughness of anode, conductivity, pH and the temperature of the electrolyte that effect corrosion are investigated. A thorough Uncertainty Quantification (UQ) analysis is conducted for the overall corrosion behavior of the Fe-Al SPR joints using a novelistic Probabilistic Confidence-Based Adaptive Sampling (PCAS) technique. PCAS is used to train the surrogate model by identifying the critical sampling points and thus reducing the overall computational costs. It is found that the electrolyte temperature has the largest effects on the material loss and needs to be managed closely for better corrosion control. By understanding the corrosion performance and resultant uncertainty impact on SPR joints, the reliability and resilience of these joints can be improved.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Adhesive-bonded scarf and stepped-lap joints

Continuum mechanics solutions are derived for the static load-carrying capacity of scarf and stepped-lap adhesive-bonded joints. The analyses account for adhesive plasticity and adherend stiffness imbalance and thermal mismatch. The scarf joint solutions include a simple algebraic formula which serves as a close lower bound, within a small fraction of a per cent of the true answer for most practical geometries and materials. Digital computer programs were developed and, for the stepped-lap joints, the critical adherend and adhesive stresses are computed for each step. The scarf joint solutions exhibit grossly different behavior from that for double-lap joints for long overlaps inasmuch as that the potential bond shear strength continues to increase with indefinitely long overlaps on the scarf joints. The stepped-lap joint solutions exhibit some characteristics of both the scarf and double-lap joints. The stepped-lap computer program handles arbitrary (different) step lengths and thickness and the solutions obtained have clarified potentially weak design details and the remedies. The program has been used effectively to optimize the joint proportions.

Hart-Smith, L. J.↗
NASA NTRS1987

Modeling of joints for the dynamic analysis of truss structures

An experimentally-based method for determining the stiffness and damping of truss joints is described. The analytical models use springs and both viscous and friction dampers to simulate joint load-deflection behavior. A least-squares algorithm is developed to identify the stiffness and damping coefficients of the analytical joint models from test data. The effects of nonlinear joint stiffness such as joint dead band are also studied. Equations for predicting the sensitivity of beam deformations to changes in joint stiffness are derived and used to show the level of joint stiffness required for nearly rigid joint behavior. Finally, the global frequency sensitivity of a truss structure to random perturbations in joint stiffness is discussed.

Belvin, W. Keith↗
NASA NTRS1989

Conjugate (solid/fluid) computational fluid dynamics analysis of the space shuttle solid rocket motor nozzle/case and case field joints

Three-dimensional, conjugate (solid/fluid) heat transfer analyses of new designs of the Solid Rocket Motor (SRM) nozzle/case and case field joints are described. The main focus was to predict the consequences of multiple rips (or debonds) in the ambient cure adhesive packed between the nozzle/case joint surfaces and the bond line between the mating field joint surfaces. The models calculate the transient temperature responses of the various materials neighboring postulated flow/leakpaths into, past, and out from the nozzle/case primary O-ring cavity and case field capture O-ring cavity. These results were used to assess if the design was failsafe (i.e., no potential O-ring erosion) and reusable (i.e., no excessive steel temperatures). The models are adaptions and extensions of the general purpose PHOENICS fluid dynamics code. A non-orthogonal coordinate system was employed and 11,592 control cells for the nozzle/case and 20,088 for the case field joints are used with non-uniform distribution. Physical properties of both fluid and solids are temperature dependent. A number of parametric studies were run for both joints with results showing temperature limits for reuse for the steel case on the nozzle joint being exceeded while the steel case temperatures for the field joint were not. O-ring temperatures for the nozzle joint predicted erosion while for the field joint they did not.

Doran, D.↗
NASA NTRS1992

Correlation and prediction of dynamic human isolated joint strength from lean body mass

A relationship between a person's lean body mass and the amount of maximum torque that can be produced with each isolated joint of the upper extremity was investigated. The maximum dynamic isolated joint torque (upper extremity) on 14 subjects was collected using a dynamometer multi-joint testing unit. These data were reduced to a table of coefficients of second degree polynomials, computed using a least squares regression method. All the coefficients were then organized into look-up tables, a compact and convenient storage/retrieval mechanism for the data set. Data from each joint, direction and velocity, were normalized with respect to that joint's average and merged into files (one for each curve for a particular joint). Regression was performed on each one of these files to derive a table of normalized population curve coefficients for each joint axis, direction, and velocity. In addition, a regression table which included all upper extremity joints was built which related average torque to lean body mass for an individual. These two tables are the basis of the regression model which allows the prediction of dynamic isolated joint torques from an individual's lean body mass.

Pandya, Abhilash K.↗
NASA NTRS1994

Joint for a variable geometry truss and method of constructing same

A joint and a method of constructing a joint for a variable geometry truss having a variable number of planes of variable length battens connected together in a triangular configuration, each plane being connected by six fixed length longerons in a Stewart platform configuration, are presented. The variable length battens allow the orientation of one end plane of the variable geometry truss to be changed to the other end plane in a controlled manner by selectively adjusting the lengths of the variable length battens. A main pivot joint pivotally connects two battens about a pivotal axis. A universal joint is pivotally connected to the main joint such that the pivotal axis of the universal joint is coextensive with the pivotal axis at the main joint. Two longerons are pivotally connected to the universal joint. Each longeron is thereby provided with three intersecting axes of rotation. Each longeron may include a revolute joint, allowing rotation about the longitudinal axis of the longeron.

Horner, Garnett C.↗
NASA NTRS1999

Development of Thermal Barriers for Solid Rocket Motor Nozzle Joints

The Space Shuttle solid rocket motor case assembly joints are sealed using conventional 0-ring seals. The 5500+F combustion gases are kept a safe distance away from the seals by thick layers of insulation. Special joint-fill compounds are used to fill the joints in the insulation to prevent a direct flowpath to the seals. On a number of occasions. NASA has observed in several of the rocket nozzle assembly joints hot gas penetration through defects in the joint- fill compound. The current nozzle-to-case joint design incorporates primary, secondary and wiper (inner-most) 0-rings and polysulfide joint-fill compound. In the current design, 1 out of 7 motors experience hot gas to the wiper 0-ring. Though the condition does not threaten motor safety, evidence of hot gas to the wiper 0-ring results in extensive reviews before resuming flight. NASA and solid rocket motor manufacturer Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and a thermal barrier, This paper presents burn-resistance, temperature drop, flow and resiliency test results for several types of NASA braided carbon-fiber thermal barriers. Burn tests were performed to determine the time to burn through each of the thermal barriers when exposed to the flame of an oxy-acetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Thermal barriers braided out of carbon fibers endured the flame for over 6 minutes, three times longer than solid rocket motor burn time. Tests were performed on two thermal barrier braid architectures, denoted Carbon-3 and Carbon-6, to measure the temperature drop across and along the barrier in a compressed state when subjected to the flame of an oxyacetylene torch. Carbon-3 and Carbon-6 thermal barriers were excellent insulators causing temperature drops through their diameter of up to a 2800 and 2560 F. respectively. Gas temperature 1/4" downstream of the thermal barrier were within the downstream Viton 0-ring temperature limit of 600 F. Carbon-6 performed extremely well in subscale rocket "char" motor tests when subjected to hot gas at 3200 F for an 11 second rocket firing, simulating the maximum downstream joint cavity fill time. The thermal barrier reduced the incoming hot gas temperature by 2200 F in an intentionally oversized gap defect, spread the incoming jet flow, and blocked hot slag, thereby offering protection to the downstream 0-rings.

Steinetz, Bruce M.↗
NASA NTRS2003

Flaw Tolerance In Lap Shear Brazed Joints

This paper presents results of the second part of an on-going effort to gain better understanding of defect tolerance in braze joints. In the first part of this three-part series, we mechanically tested and modeled the strength of the lap joints as a function of the overlap distance. A failure criterion was established based on the zone damage theory, which predicts the dependence of the lap joint shear strength on the overlap distance, based on the critical size of a finite damage zone or an overloaded region in the joint. In this second part of the study, we experimentally verified the applicability of the damage zone criterion on prediction of the shear strength of the lap joint and introduced controlled flaws into the lap joints. The purpose of the study was to evaluate the lap joint strength as a function of flaw size and its location through mechanical testing and nonlinear finite element analysis (FEA) employing damage zone criterion for definition of failure. The results obtained from the second part of the investigation confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width. The same failure criterion was applicable to the lap joints containing flaws.

Wang, Len↗
NASA NTRS2013

Integrated High-Speed Torque Control System for a Robotic Joint

A control system for achieving high-speed torque for a joint of a robot includes a printed circuit board assembly (PCBA) having a collocated joint processor and high-speed communication bus. The PCBA may also include a power inverter module (PIM) and local sensor conditioning electronics (SCE) for processing sensor data from one or more motor position sensors. Torque control of a motor of the joint is provided via the PCBA as a high-speed torque loop. Each joint processor may be embedded within or collocated with the robotic joint being controlled. Collocation of the joint processor, PIM, and high-speed bus may increase noise immunity of the control system, and the localized processing of sensor data from the joint motor at the joint level may minimize bus cabling to and from each control node. The joint processor may include a field programmable gate array (FPGA).

Davis, Donald R.↗
NASA NTRS2017

Development of Stable, Low Resistance Solder Joints for a Space-Flight HTS Lead Assemblies

The solder joints in spaceflight high temperature superconductor (HTS) lead assemblies for certain astrophysics missions have strict constraints on size and power dissipation. In addition, the joints must tolerate years of storage at room temperature, many thermal cycles, and several vibration tests between their manufacture and their final operation on orbit. As reported previously, solder joints between REBCO coated conductors and normal metal traces for the Astro-H mission showed low temperature joint resistance that grew approximately as log time over the course of months. Although the assemblies worked without issue in orbit, for the upcoming X-ray Astrophysics Recovery Mission we are attempting to improve our solder process to give lower, more stable, and more consistent joint resistance. We produce numerous sample joints and measure time- and thermal cycle-dependent resistance, and characterize the joints using x-ray and other analysis tools. For a subset of the joints, we use SEMEDS to try to understand the physical and chemical processes that effect joint behavior.

high temperature superconductivity↗
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↗
NASA NTRSDate not supplied

Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) Hinge Joint Structural Performance

The Tendon Actuated Lightweight In-Space MANipulator (TALISMAN), invented and initially developed under the Space Technology Mission Directorate Human Robotics Systems program, is a tendon-actuated robot that established a new structural architecture for long-reach space manipulators. The TALISMAN is designed to have significant stiffness and strength in the plane of the tendons or cables, and operations are designed such that all primary loads are applied in that same plane. However, during normal operations it is possible for out-of-plane forces to be applied on the TALISMAN when secondary loads are imparted by a tool or action at the wrist. These secondary loading conditions will induce out-of-plane bending loads in the TALISMAN hinge joints. The TALISMAN hinge joints must be designed for these out-of-plane loads, to ensure no failure of the joint occurs during operations. A series hinge joint out-of-plane stiffness tests were conducted at five different joint angles; at three cable pre-loads from 25-lbf to 100-lbf; up to an equivalent out-of-plane tip load of 27.28-lbf at the end of a 51-in. long distal link. The objective of the tests was to provide an initial set of deflection, cable load, and strain data to inform accurate modeling of the hinge joint out-of-plane stiffness. The test objective was achieved by developing an FEM of the hinge joint able to predict tip displacement to within 10% of values measured in tests. The hinge joint FEM may now be implemented into a full-scale analysis model of the TALISMAN V2.0 to provide predictions of out-of-plane displacement under different load and joint angle conditions.

Matthew K Mahlin↗
NASA NTRSDate not supplied

Material Variability Effects on Damage Development Within Composite Adhesively Bonded Joints

Use of composite adhesively bonded joints (ABJ) is of critical importance to the adoption of composite materials in the automotive industry, as ABJ enable lower stress concentrations as compared to conventional mechanically fastened joints. ABJ are better suited for joining composite materials as compared to fastened joints because fastened joints require drilling of holes which locally affect composite material structure. Composite materials and adhesives are subject to unavoidable stochastic local material variations which make different failure scenarios possible. An experimentally tested ABJ configuration is simulated using finite element analysis (FEA). Experimentally, under tension, the joints failed by three major failure modes, with peak loads ranging from 13.0-16.1 kips. Progressive failure analysis tools are used to simulate damage development within each material within the joint. The simulation agreed well with the average experimental peak load. Stochastically occurring adhesive porosity and matrix-fiber micro-disbonding were numerically simulated. The simulations revealed a similar trend as observed experimentally: joints which failed at higher peak loads had lower levels of damage within the face-sheets of the composite panels which were adhesively bonded; these joints which failed at higher peak loads also had greater damage in the doubler of the experimentally tested double lap joint configuration.

Richard Larson↗
DOE OSTI2026

Demonstration of high-rate manufacturing of π-joint using additive manufacturing

Bonded composite π-joints are critical to support wing geometries in aerospace/aircraft structures. Its lightweight and robust load-bearing capabilities/design guarantee high structural integrity and reliability. Current manufacturing techniques of π-joints are complex and laborious, and do not always offer high-quality joining. This study presents a high-rate manufacturing approach to fabricate π-joints using an integrated Additive Manufacturing and Compression Molding (AMCM) process. The joints were manufactured using unidirectional aerospace-grade LMPAEK/CF at 60% fiber loading for the stiffeners/skin and LM-PAEK/GF as the adhesive and characterized to evaluate their microstructure and strength. While the results indicate void formation at the joint caused by inadequate pressure, the peak tensile load of 600N recorded is akin to injection-autoclave molded π-joints, which validates the potential of this high-rate integrated approach to eliminate time-consuming and labour-intensive processes of making π-joints to reduce cost and produce high-quality joints.

Marathe, Umesh [ORNL]↗
NASA NTRS1976

Bolted joints in graphite-epoxy composites

All-graphite/epoxy laminates and hybrid graphite-glass/epoxy laminates were tested. The tests encompassed a range of geometries for each laminate pattern to cover the three basic failure modes - net section tension failure through the bolt hole, bearing and shearout. Static tensile and compressive loads were applied. A constant bolt diameter of 6.35 mm (0.25 in.) was used in the tests. The interaction of stress concentrations associated with multi-row bolted joints was investigated by testing single- and double-row bolted joints and open-hole specimens in tension. For tension loading, linear interaction was found to exist between the bearing stress reacted at a given bolt hole and the remaining tension stress running by that hole to be reacted elsewhere. The interaction under compressive loading was found to be non-linear. Comparative tests were run using single-lap bolted joints and double-lap joints with pin connection. Both of these joint types exhibited lower strengths than were demonstrated by the corresponding double-lap joints. The analysis methods developed here for single bolt joints are shown to be capable of predicting the behavior of multi-row joints.

Hart-Smith, L. J.↗
NASA NTRS1978

Spacesuit mobility joints

Joints for use in interconnecting adjacent segments of an hermetically sealed spacesuit which have low torques, low leakage and a high degree of reliability are described. Each of the joints is a special purpose joint characterized by substantially constant volume and low torque characteristics. Linkages which restrain the joint from longitudinal distension and a flexible, substantially impermeable diaphragm of tubular configuration spanning the distance between pivotally supported annuli are featured. The diaphragms of selected joints include rolling convolutions for balancing the joints, while various joints include wedge-shaped sections which enhance the range of motion for the joints.

Vykukal, H. C.↗