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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 NTRS2011

Evaluation of Long Composite Struts

Carbon-epoxy tapered struts are structurally efficient and offer opportunities for weight savings on aircraft and spacecraft structures. Seven composite struts were designed, fabricated and experimentally evaluated through uniaxial loading. The design requirements, analytical predictions and experimental results are presented. Struts with a tapered composite body and corrugated titanium end fittings successfully supported their design ultimate loads with no evidence of failure.

Jegley, Dawn C.↗
NASA NTRS2011

Compressive Behavior of Frame-Stiffened Composite Panels

New technologies are being developed under NASA's Environmentally Responsible Aviation (ERA) Program aimed at reducing fuel burn and emissions in large commercial aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed which offers advantages over traditional metallic structure. In this concept a stitched carbon-epoxy material system is employed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners and producing a more damage tolerant design. In addition, by adding unidirectional carbon rods to the top of stiffeners and minimizing the interference between the sandwich frames and the rod-stiffened stringers, the panel becomes more structurally efficient. This document describes the results of experimentation on a PRSEUS panel in which the frames are loaded in unidirectional compression beyond the local buckling of the skin of a Hybrid Wing Body (HWB) aircraft. A comparison with analytical predictions and the relationship between these test results and the global aircraft design is presented.

Yovanof, Nicolette P.↗
NASA NTRS2011

The Influence of Restraint Systems on Panel Behavior

When a panel is tested in uniaxial compression in a test machine, the boundary conditions are not quite the same as they would be if it were part of a complete structure. A restraint system may be used to simulate conditions found in a complete vehicle. Quantifying the quality of the restraint with only point-measurement devices can leave an inadequate characterization of the out-of-plane behavior. However, today s full-field displacement monitoring techniques allow for much more accurate views of the global panel deformation and strain, and therefore allow for a better understanding of panel behavior. In the current study, the behavior of a hat-stiffened and two rod-stiffened carbon-epoxy panels is considered. Panels were approximately 2 meters tall and 0.76 to 1.06 m wide. Unloaded edges were supported by knife edges and stiffeners were attached to a support structure at selected locations to restrain out-of-plane motion. A comparison is made between test results based on full-field measurements and analyses based on assumptions of boundary conditions of a completely rigid edge restraint and the absence of any edge restraint. Results indicate that motion at the restrained edges must be considered to obtain accurate test-analysis correlation.

Jegley, Dawn C.↗
NASA NTRS2012

Development of Standards for Nondestructive Evaluation of COPVs Used in Aerospace Applications

Composite OverWrapped Pressure Vessels (COPVs) are currently accepted by NASA based on design and qualification requirements and generally not verified by NDE for the following reasons: (1) Manufactures and end users generally do not have experience and validated quantitative methods of detecting flaws and defects of concern (1-a) If detected, the flaws are not adequately quantified and it is unclear how they may contribute to degradation in mechanical response (1-b) Carbon-epoxy COPVs also extremely sensitive to impact damage and impacts may be below the visible detection threshold (2) If damage is detected, this generally results in rejection since the effect on mechanical response is generally not known (3) NDE response has not generally been fully characterized, probability of detection (POD) established, and processes validated for evaluation of vessel condition as manufactured and delivered.

Waller, Jess M.↗
NASA NTRS2012

Failure at Frame-Stringer Intersections in PRSEUS Panels

NASA, the Air Force Research Laboratory and The Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept has been developed which offers advantages over traditional metallic structures. In this concept a stitched carbon-epoxy material system has been developed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners, thereby reducing part count and labor. By adding unidirectional carbon rods to the top of stiffeners, the panel becomes more structurally efficient. This combination produces a more damage tolerant design. This study focuses on the intersection between the rod-stiffener and the foam-filled frame in a PRSEUS specimen. Compression loading is considered, which induces stress concentrations at the intersection point that can lead to failures. An experiment with accompanying analysis for a single-frame specimen is described, followed by a parametric study of simple reinforcements to reduce strains in the intersection region.

Jegley, Dawn C.↗
NASA NTRS2013

Behavior of Frame-Stiffened Composite Panels with Damage

NASA, the Air Force Research Laboratory and The Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept has been developed which offers advantages over traditional metallic structures. In this concept, a stitched carbon-epoxy material system has been developed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners, thereby reducing part count and labor. Stitching and the use of thin skins with rod-stiffeners to move loading away from the morevulnerable outer surface produces a structurally efficient, damage tolerant design. This study focuses on the behavior of PRSEUS panels loaded in the frame direction and subjected to severe damage in the form of a severed central frame in a three-frame panel. Experimental results for a pristine two-frame panel and analytical predictions for pristine two-frame and three-frame panels as well as damaged three-frame panels are described.

Jegley, Dawn C.↗
NASA NTRS2013

Applying a Stitched, Rod-Stiffened Concept to Heavily Loaded Structure

NASA and the Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft wing structure, first in the NASA Advanced Composites Technology (ACT) program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the labor associated with panel fabrication and assembly can be significantly reduced and the need for mechanical fasteners is almost eliminated. Stitching provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. Stitching also reduces part count, and therefore, cost of the structure. The stitched panel concept used in the ACT program in the 1990's used simple blade-stiffeners as stringers, caps and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. A comparison between the blade-stiffened structure and PRSEUS is presented focusing on highly loaded structure and demonstrating improved weight reduction.

Jegley, Dawn C.↗
NASA NTRS2013

Evaluation of the Behavior of Technova Corporation Rod-Stiffened Stitched Compression Specimens

Under Space Act Agreement 1347 between NASA and Technova Corporation, Technova designed and fabricated two carbon-epoxy crippling specimens and NASA loaded them to failure in axial compression. Each specimen contained a pultruded rod stiffener which was held to the specimen skin with through-the-thickness stitches. One of these specimens was designed to be nominally the same as pultruded rod stitched specimens fabricated by Boeing under previous programs. In the other specimen, the rod was prestressed in a Technova manufacturing process to increase its ability to carrying compressive loading. Experimental results demonstrated that the specimen without prestressing carried approximately the same load as the similar Boeing specimens and that the specimen with prestressing carried significantly more load than the specimen without prestressing.

Jegley, Dawn C.↗
NASA NTRS2014

Applying a Stiffened Stitched Concept to Shear-Loaded Structure

NASA and The Boeing Company have worked to develop new low-cost, lightweight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft structure, first in the NASA Advanced Composites Technology (ACT) Program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the need for mechanical fasteners is almost eliminated. Stitching also provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. The stitched panel concept used in the ACT program used simple blade-stiffeners as stringers, caps, and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. Comparisons between stitched and unstitched structure and between blade-stiffened and rod-stiffened structure are presented focusing on a panel loaded in shear. Shear loading is representative of spar loading in wing structures.

Jegley, Dawn C.↗
NASA NTRS2015

No-Oven, No-Autoclave Composite Processing

Very large composite structures, such as those used in NASA's Space Launch System, push the boundaries imposed by current autoclaves. New technology is needed to maintain composite performance and free manufacturing engineers from the restraints of curing equipment size limitations. Recent efforts on a Phase II project by Cornerstone Research Group, Inc. (CRG), have advanced the technology and manufacturing readiness levels of a unique two-part epoxy resin system. Designed for room-temperature infusion of a dry carbon preform, the system includes a no-heat-added cure that delivers 350 F composite performance in a matter of hours. This no-oven, no-autoclave (NONA) composite processing eliminates part-size constraints imposed by infrastructure and lowers costs by increasing throughput and reducing capital-specific, process-flow bottlenecks. As a result of the Phase II activity, NONA materials and processes were used to make high-temperature composite tooling suitable for further production of carbon-epoxy laminates and honeycomb/ sandwich-structure composites with an aluminum core. The technology platform involves tooling design, resin infusion processing, composite part design, and resin chemistry. The various technology elements are combined to achieve a fully cured part. The individual elements are not unusual, but they are combined in such a way that enables proper management of the heat generated by the epoxy resin during cure. The result is a self-cured carbon/ epoxy composite part that is mechanically and chemically stable at temperatures up to 350 F. As a result of the successful SBIR effort, CRG has launched NONA Composites as a spinoff subsidiary. The company sells resin to end users, fabricates finished goods for customers, and sells composite tooling made with NONA materials and processes to composite manufacturers.

Rauscher, Michael D.↗
NASA NTRS2016

Modeling Fatigue Damage Onset and Progression in Composites Using an Element-Based Virtual Crack Closure Technique Combined With the Floating Node Method

A new methodology is proposed to model the onset and propagation of matrix cracks and delaminations in carbon-epoxy composites subject to fatigue loading. An extended interface element, based on the Floating Node Method, is developed to represent delaminations and matrix cracks explicitly in a mesh independent fashion. Crack propagation is determined using an element-based Virtual Crack Closure Technique approach to determine mixed-mode energy release rates, and the Paris-Law relationship to obtain crack growth rate. Crack onset is determined using a stressbased onset criterion coupled with a stress vs. cycle curve and Palmgren-Miner rule to account for fatigue damage accumulation. The approach is implemented in Abaqus/Standard® via the user subroutine functionality. Verification exercises are performed to assess the accuracy and correct implementation of the approach. Finally, it was demonstrated that this approach captured the differences in failure morphology in fatigue for two laminates of identical stiffness, but with layups containing θdeg plies that were either stacked in a single group, or distributed through the laminate thickness.

De Carvalho, Nelson V.↗
NASA NTRS2019

Impact Damage Tolerance of Composite Laminates with Through-The-Thickness Stitches

The ability of through-the-thickness stitches to contain damage during a low-velocity impact event and increase the residual strength of stitched panels was investigated in this research. The impact response, spread of interlaminar delaminations, dent depth, surface damage, and static residual strength after impact were studied for carbon-epoxy specimens fabricated from HTS40 TohoTenax standard modulus fibers, stitched together with Vectran 1200 denier thread and infused with API 1078 resin after through-the-thickness stitching. Three different stitch patterns were used to explore the ability to arrest impact damage during and after impact. Simply supported boundary conditions were maintained during the impact testing. Non-destructive evaluations were performed using ultrasonic C-scans and X-ray computed tomography (CT) imaging to determine the shape, size, and location of delaminations. Results indicate that while the dynamic response during the impact event was almost the same for the unstitched specimens and all stitch patterns considered, the extent of delamination and the compression strength after impact varied greatly. For both the 60 J and 80 J impact energies, the delamination area was significantly less for the stitched specimens than for the unstitched specimens, but the range of delamination areas among the stitch patterns was much larger for the lower impact energy than for the greater impact energy. Similarly, while the presence of stitching influenced the compression after impact strength, the strength values for all stitch patterns were very similar. These results are a step toward quantifying the influence of through-the-thickness stitching.

Ranatunga, Vipul↗
NASA NTRS2020

Testing of Composite Laminate Specimens with Mid-Length Lateral Notches

Eight fiber-reinforced, carbon-epoxy composite laminate specimens without external stiffeners (unstiffened) were loaded to failure to determine their failure load and mode under the Advanced Composites Project (ACP) Rapid Design Tools activity. Each specimen contained a lateral notch located at the mid-length location. A description of the specimens, instrumentation, test fixtures and procedures is presented, followed by the presentation of the experimental results.

Dawn C Jegley↗
NASA NTRS2020

Hybrid AFP/Hand Layup Optimized Blades to Enhance Wind Tunnel Capability Summary of PREDICT 2018 Efforts

A project spanning four-months in 2018 was conducted at the NASA Langley Research Center (LaRC) to advance the state of the art in Automated Fiber Placement (AFP) fabrication of complex carbon fiber wind tunnel blades for NASA wind tunnels. This effort was the first step in developing a methodology for fabricating these complex parts. An AFP robotic system was used to explore whether manufacturing time and cost for production of wind tunnel blades could be reduced. Computer aided design models of the blade surfaces were created, and AFP process planning and programming was employed to study the manufacturability of the shapes. A manufacturing demonstration unit was fabricated to demonstrate a methodology to fabricate a complex shape representative of a wind tunnel blade. The present study revealed that the heater configuration on the LaRC AFP robotic system was the primary constraint that limited its ability to use AFP for wind tunnel blade manufacturing.

carbon-epoxy↗
NASA NTRSDate not supplied

Design of a Manufacturing Demonstration Unit for a Composite Lunar Landing Gear Strut

The goal of the current work was to develop an analytical framework for design of composite struts using various levels of model fidelity. An additional goal of this work was to perform an initial assessment of using automated fiber placement (AFP) and other advanced manufacturing methods to explore their feasibility for the fabrication of struts for lunar landers, strut-braced wings, and other aerospace components. In particular, designs were considered for fabrication at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility at Langley Research Center (LaRC). The designs presented in this paper do not represent the exact geometry and material systems currently in use by the Artemis landing system, but they are considered to be representative. The designs produced during this study will be used to develop manufacturing demonstration units (MDU) that can be fabricated at ISAAC and tested in lab facilities at LaRC

carbon-epoxy↗
NASA NTRSDate not supplied

STITCHED COMPOSITES WITH THREE-DIMENSIONAL STITCH PATHS

Stitched composites have been shown to exhibit damage tolerance and to reduce weight compared to traditional layered composites through unitization of the structure by elimination of fasteners. Stitching capabilities have been incorporated into the Integrated Structural Assembly of Advanced Composites (ISAAC) system at NASA Langley Research Center with the introduction of two stitching heads. Stitching path control was initially implemented as straight lines in space, as was done for previous stitching development. However, more complex stitched structures such as a wind tunnel blade or around cutouts within a fuselage or wing skin, require that the stitching paths be implemented as three-dimensional (3D) stitching paths in space. Unfortunately, control programming output by an existing preprocessor program cannot stitch these curved paths due to problems that arise in stitch formation and the introduction of side forces on the needles using the conventional programming approach whereby the head is simultaneously controlled through translations and rotations. This lack of capability is most significant for the single-sided stitching head, where two needles are in the preform at the same time for the majority of the stitching process. A means to program 3D stitching paths in space was developed whereby the translation and rotation of each stitch were decoupled, thereby eliminating the problems associated with current control programming approach. Using this newly developed stitching path definition and control programming, complex stitching paths have successfully been stitched at the ISAAC facility. The ability to stitch general 3D stitching paths in space enables the use of stitching on more complex parts.

carbon-epoxy↗
NASA NTRSDate not supplied

Stitched Composites with Three-Dimensional Stitch Paths

Stitched composites have been shown to exhibit damage tolerance and to reduce weight compared to traditional layered composites through unitization of the structure by elimination of fasteners. Stitching capabilities have been incorporated into the Integrated Structural Assembly of Advanced Composites (ISAAC) system at NASA Langley Research Center with the introduction of two stitching heads. Stitching path control was initially implemented as straight lines in space, as was done for previous stitching development. However, more complex stitched structures such as a wind tunnel blade or around cutouts within a fuselage or wing skin, require that the stitching paths be implemented as three-dimensional (3D) stitching paths in space. Unfortunately, control programming output by an existing preprocessor program cannot stitch these curved paths due to problems that arise in stitch formation and the introduction of side forces on the needles using the conventional programming approach whereby the head is simultaneously controlled through translations and rotations. This lack of capability is most significant for the single-sided stitching head, where two needles are in the preform at the same time for the majority of the stitching process. A means to program 3D stitching paths in space was developed whereby the translation and rotation of each stitch were decoupled, thereby eliminating the problems associated with current control programming approach. Using this newly developed stitching path definition and control programming, complex stitching paths have successfully been stitched at the ISAAC facility. The ability to stitch general 3D stitching paths in space enables the use of stitching on more complex parts.

carbon-epoxy↗
NASA NTRSDate not supplied

Design of a Manufacturing Demonstration Unit for a Composite Lunar Landing Gear Strut

The goal of the current work was to develop an analytical framework for design of composite struts using various levels of model fidelity. Rapid optimization trade studies were performed using low fidelity two-dimensional (2D) axisymmetric models with smeared composite properties. The optimum 2D model was compared with three-dimensional (3D) models with higher levels of fidelity in material property representation. Good agreement was found with all models. The buckling performance of the highest fidelity 3D model was found to be satisfactory for the intended loading conditions. An additional goal of this work was to perform an initial assessment of using automated fiber placement (AFP) and other advanced manufacturing methods to explore their feasibility for the fabrication of struts for lunar landers, strut-braced wings, and other aerospace components. The designs produced during this study are intended to be used to develop manufacturing demonstration units (MDU) that can be fabricated at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility at Langley Research Center (LaRC) and tested in lab facilities at LaRC.

carbon-epoxy↗