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At least 829 records · Page 46

Revisiting Multi-Material Composite Structures with Homogenized Composite Properties

Composite structures inherently develop residual stresses during their curing process. Driven predominately by mismatched thermal strains between differing materials or ply orientations, but also affected by curing process phenomena like polymer shrinkage, these residual stresses can lead to failure within composite structures. There are several methods varying in complexity that can be used to model the development of residual stresses, all of which are capable of capturing sufficient detail to understand the residual stress state at the ply level. However, explicitly modeling all plies of a layup in a composite structure can be prohibitively expensive based on the number of plies, structure size, and required element size. The computational cost can be reduced through the homogenization of the composite layup without losing much fidelity of the overall response of the structure. The homogenization process reduces the many plies of a laminate to a single lamina that reduces complexity and increases the mesh size where a single element can span multiple plies. This report focuses on verification and validation efforts for a homogenization process using a suite of finite element simulations rather than an analytic solution derived from classical laminate theory. Initial verification using representative element volumes indicated there was minimal error in the homogenization process; however, this compounded to a small, but acceptable error in strip and split ring experimental composite structures. The error does under predict the residual stress state in the strip and split ring and should be accounted for when simulating composite structures with homogenized properties.

36 MATERIALS SCIENCE↗

An analysis of delamination in angle-ply fiber reinforced composites

An analytical investigation of the mechanics and failure modes of delamination initiated from a service-induced surface flaw in angle-ply fiber reinforced composites is presented. The analysis employs a hybrid-stress finite element method including a crack-tip singular element with its field variables expressed by Muskhelishvili's complex stress functions. Solutions are obtained for delaminated composites with various laminate parameters. The results elucidate unique and important characteristics of delamination crack-tip response and interlaminar stress transfer mechanisms. Of particular interest are the mixed-mode stress intensity factors associated with the delamination crack. The influence of ply orientation on KI and KII and their effects on subsequent crack extension are discussed.

Wang, S. S.↗

Orbital atmospheric physics and dynamics

There are two ways of modeling the upper atmosphere. One is the empirical model that makes use of experimental data on means and excursions from the mean and fits the data in a self-consistent manner. The other approach is to deal directly with the physical processes. This is difficult since what is happening is extremely complex. Data measured using an interferometer to give Doppler shifts of airglow lines showed 300 to 800 m/sec winds with a complex structure in the upper region of the thermosphere at high latitudes. Ionospheric electric fields, strongly influenced by interaction with the solar wind, drive the ionized component and large neutral winds result due to momentum transfer between the charged particles and the neutrals. Frictional heating results from movement of ions through the neutrals, which also influences the compositional structure. These are examples of the complex interactions involved. The NCAR General Circulation Model (tropospheric) was adapted for use at thermospheric altitudes: the Thermospheric General Circulation Model (TGCM). The model makes use partly of primitive equations and partly of empirical data for some quantities such as electron density, magnetic field, and ion drift.

Roble, Raymond↗

Mechanism Design and Testing of a Self-Deploying Structure Using Flexible Composite Tape Springs

The detailed mechanical design of a novel deployable support structure that positions and tensions a membrane optic for space imagining applications is presented. This is a complex three-dimensional deployment using freely deploying rollable composite tape spring booms that become load bearing structural members at full deployment. The deployment tests successfully demonstrate a new architecture based on rolled and freely deployed composite tape spring members that achieve simultaneous deployment without mechanical synchronization. Proper design of the flexible component mounting interface and constraint systems, which were critical in achieving a functioning unit, are described. These flexible composite components have much potential for advancing the state of the art in deployable structures, but have yet to be widely adopted. This paper demonstrates the feasibility and advantages of implementing flexible composite components, including the design details on how to integrate with required traditional mechanisms.

Footdale, Joseph N.↗

Computational alchemy clarifies origins of alloy strengthening

Solid solution strengthening (SSS) is widely used to enhance mechanical properties of metals. Originally developed for dilute alloys, classical SSS theories are presently challenged by the rise of complex concentrated alloys (CCA) with nearly equiatomic compositions. Here, we propose and develop a method of “computational alchemy” in which interatomic interactions are modified to systematically vary two key physical parameters defining SSS - atomic size misfit and elastic stiffness misfit - over a maximally wide range of two misfits. The resulting alchemical alloys are subjected to massive (~10 8 atoms) molecular dynamics (MD) simulations reproducing full complexity of plastic strength response. At variance with prevailing views, stiffness misfit is observed to contribute to SSS on par if not more than size misfit. Furthermore, depending on exactly how two misfits are combined, they result in synergistic (amplification) or antagonistic (compensation) effect on alloy strengthening. Unlike real CCAs in which each component element comes with its own specific size and stiffness, our alchemical model alloys span the space of two misfits continuously revealing trends in alloy strengthening unrecognized so far. Our study demonstrates unique value of intentionally unrealistic models for gaining deep physical insights into material behaviors that are difficult to reveal otherwise.

36 MATERIALS SCIENCE↗

Deconvolution of mineral absorption bands - An improved approach

Although visible and near IR reflectance spectra contain absorption bands that are characteristic of the composition and structure of the absorbing species, deconvolving a complex spectrum is nontrivial. An improved approach to spectral deconvolution is presented that accurately represents absorption bands as discrete mathematical distributions and resolves composite absorption features into individual absorption bands. The frequently used Gaussian model of absorption bands is shown to be inappropriate for the Fe(2+) electronic transition absorptions in pyroxene spectra. A modified Gaussian model is derived using a power law relationship of energy to average bond length. The modified Gaussian model is shown to provide an objective and consistent tool for deconvolving individual absorption bands in the more complex orthopyroxene, clinopyroxene, pyroxene mixtures, and olivine spectra.

Sunshine, Jessica M.↗

Is Radioactive Tank Waste a Bingham Fluid?

Slurries and sludges across the United States Department of Energy (DOE) complex rank among the most rheologically interesting. Their composition is heterogeneous, spanning a very broad range of particle sizes, densities, and interparticle forces. All exhibit shear thinning, some have yield stresses, and many are thixotropic. Despite the variety, these complex fluids are often represented using the historic Bingham fluid model, which fits higher shear rate data to a simple straight line. The intercept provides a yield stress, which has been a key design parameter in construction of large-scale waste processing facilities. However, many radioactive wastes are simply not Bingham fluids, which extrapolate but poorly across low to intermediate shear rates that are characteristic of typical processing conditions. Indeed, processing shear rates as high as 200 1/s, which has been a typical minimum shear rate used in fitting, are seldom encountered in nuclear waste processing. Therefore, more realistic rheological models are necessary to accurately predict waste processing performance. PNNL recently re-evaluated the rheology of reconstituted Hanford REDOX sludge waste against a wide variety of rheological models including the Bingham, Cross, Cross with yield stress, Carreau, biviscous, Herschel-Bulkley (which includes a power law dependence), Casson, and Gay models. They found that all of the models provided a closer fit than the Bingham model and that the biviscous model and Cross with yield stress model were convincing. However, reconstituted Hanford REDOX sludge waste is but one type of DOE waste and a direct contrast and comparison of these three models against undiluted, unmixed tank waste (actual not simulant) has not been performed previously. Therefore, the purpose of this paper is to evaluate the rheology of actual tank waste with these more accurate rheological models. In this paper, we evaluate select rheological data for slurry samples from Hanford’s AZ-101, AZ-102, and SY-101 waste tanks. In each of these cases, we find that Cross’ model with yield stress and the biviscous model significantly outperform the Bingham fluid model. Furthermore, the AZ-101 data also shows that the shear stress peak that startup significantly exceeds the Bingham yield stress, which is commonly observed in the incipient moments of rheological measurements on simulants. In contrast, Cross’ model may empirically accommodate an initial spike in shear stress at modest shear rates. These are important observations because computational and analytical fluid dynamics simulations rely on rheological constitutive models for accurately and conservatively predict waste processing performance. These findings suggest the need for better rheological modeling of and validation against radioactive waste.

Rheology, Radioactive Waste↗

Aerospace Ceramic Materials: Thermal, Environmental Barrier Coatings and SiC/SiC Ceramic Matrix Composites for Turbine Engine Applications

Ceramic materials play increasingly important roles in aerospace applications because ceramics have unique properties, including high temperature capability, high stiffness and strengths, excellent oxidation and corrosion resistance. Ceramic materials also generally have lower densities as compared to metallic materials, making them excellent candidates for light-weight hot-section components of aircraft turbine engines, rocket exhaust nozzles, and thermal protection systems for space vehicles when they are being used for high-temperature and ultra-high temperature ceramics applications. Ceramic matrix composites (CMCs), including non-oxide and oxide CMCs, are also recently being incorporated in gas turbine engines for high pressure and high temperature section components and exhaust nozzles. However, the complexity and variability of aerospace ceramic processing methods, compositions and microstructures, the relatively low fracture toughness of the ceramic materials, still remain the challenging factors for ceramic component design, validation, life prediction, and thus broader applications. This ceramic material section paper presents an overview of aerospace ceramic materials and their characteristics. A particular emphasis has been placed on high technology level (TRL) enabling ceramic systems, that is, turbine engine thermal and environmental barrier coating systems and non-oxide type SiC/SiC CMCs. The current status and future trend of thermal and environmental barrier coatings and SiC/SiC CMC development and applications are described.

Thermal Barrier Coatings↗

Fiber motion in highly confined flows of carbon fiber and non-Newtonian polymer [Advanced modeling of non-Newtonian polymer and carbon fibers]

Inks compounded of short carbon fibers suspended in polymer resin can be extruded to produce composite materials during additive manufacturing or 3D printing processes. The flow process induces anisotropic orientation of the fibers which is set into the matrix and significantly affects the mechanical and physical properties of the final product. Therefore, the flow of fiber suspensions needs to be understood in order to predict the orientation distribution of the fibers during such manufacturing processes. There is still a lack of knowledge for extrusion of the complex mixture of a non-Newtonian polymer containing a high-volume fraction of fibers with high fiber aspect ratio, where both inter-particle, fluid-particle and fiber-wall interactions are computationally evaluated. This paper presents predictive numerical simulations and experimental results of such confined flow in a concentrated regime. The code is based on Lagrange multiplier technique and resolves each particle and interaction between the fibers and surrounding fluid and nozzle walls. We investigate numerically how the fiber length impacts the fiber alignment during extrusion. We found that a fiber length above 67% of the nozzle's diameter induces dramatic change in the fiber flow, causing fibers to concentrate at the nozzle boundaries with very low concentration of fibers in the center of the nozzle. It was found that the best fiber alignment is reached for fiber lengths equal to 40–50% of the nozzle diameters. Numerical findings are supported by experimental results. In conclusion, this work improves understanding of fiber orientation during 3D printing and is an important milestone for the prediction of the complex mechanical properties of additively manufactured fiber composites.

36 MATERIALS SCIENCE↗

Unconventional Complex Coacervation between Neutral Polymer and Inorganic Polyoxometalate in Aqueous Solution via Direct Water Mediation

Water, specifically in a hydration shell, is critical for many biological supramolecular aggregations in nature, where water can directly mediate intermolecular association via hydrogen bonding and is regarded as “structured water”. Conversely, little has been reported on the biomimetic water-mediated supramolecular assembly with adequately high water content to date, because of the competing thermodynamic processes of water hydration and water as a building block to participate in self-assembly. In this work, we explore water-mediated complexation based on entropy-driven biphasic coacervate formation using highly hydrophilic neutral polymer and inorganic mineral-analogous nanoclusters. For the first time (to the best of our knowledge), nonelectrostatic liquid–liquid separating coacervate formation is demonstrated between polyethylene glycol (PEG) and polyoxometalate (POM) nanoclusters in aqueous solutions of varied PEG and POM concentrations, POM types, and aqueous medium conditions. Comprehensive characterization using fluorescence microscopy, small-angle X-ray scattering, calorimetry, and other techniques has confirmed that the compositions, microstructure, and thermodynamics of PEG–POM complex coacervation are highly similar to entropy-driven complex coacervation between oppositely charged polyelectrolytes in aqueous solution. However, the effect of heavy water on critical POM concentration for the onset of coacervate formation suggests that water, instead of the counter ions as commonly debated for polyelectrolyte complex coacervation, is responsible for PEG–POM coacervate formation. Specifically, structured water works as a hydrogen bond donor for both highly hydrated PEG and POM to directly mediate the PEG–water–POM association, resulting in the release of excess hydrated water for entropy-driven PEG–POM complex coacervation. Furthermore, water-mediated complex coacervation could be developed as a general and simple strategy to build biomimetic hybrid nanomaterials with high water content for various applications from energy-related functional nanomaterials to biomedical ramification.

36 MATERIALS SCIENCE↗

Statistical detection of differentially abundant ions in mass spectrometry-based imaging experiments with complex designs

Mass Spectrometry Imaging (MSI) characterizes changes in chemical composition between regions of biological samples such as tissues. This translates into a statistical goal of class comparison, i.e. determining analytes that change in abundance between conditions more systematically than as expected by random variation. To reach accurate and reproducible conclusions, statistical analysis must appropriately reflect the initial research question, the design of the MSI experiment, and all the associated sources of variation. This manuscript highlights the importance of following these general statistical principles. Using the example of two case studies with complex experimental designs, and with dierent strategies of data acquisition, we demonstrate the extent to which choices made at key points of this workflow impact the results, and provide suggestions for appropriate design and analysis of MSI experiments that aim at detecting dierentially abundant analytes.

NanoDESI, mass spectrometry, MSIQuickView↗

ER-associated VAP27-1 and VAP27-3 proteins functionally link the lipid-binding ORP2A at the ER-chloroplast contact sites

Abstract The plant endoplasmic reticulum (ER) contacts heterotypic membranes at membrane contact sites (MCSs) through largely undefined mechanisms. For instance, despite the well-established and essential role of the plant ER-chloroplast interactions for lipid biosynthesis, and the reported existence of physical contacts between these organelles, almost nothing is known about the ER-chloroplast MCS identity. Here we show that the Arabidopsis ER membrane-associated VAP27 proteins and the lipid-binding protein ORP2A define a functional complex at the ER-chloroplast MCSs. Specifically, through in vivo and in vitro association assays, we found that VAP27 proteins interact with the outer envelope membrane (OEM) of chloroplasts, where they bind to ORP2A. Through lipidomic analyses, we established that VAP27 proteins and ORP2A directly interact with the chloroplast OEM monogalactosyldiacylglycerol (MGDG), and we demonstrated that the loss of the VAP27-ORP2A complex is accompanied by subtle changes in the acyl composition of MGDG and PG. We also found that ORP2A interacts with phytosterols and established that the loss of the VAP27-ORP2A complex alters sterol levels in chloroplasts. We propose that, by interacting directly with OEM lipids, the VAP27-ORP2A complex defines plant-unique MCSs that bridge ER and chloroplasts and are involved in chloroplast lipid homeostasis.

59 BASIC BIOLOGICAL SCIENCES↗

Momentum source signatures in thermospheric neutral composition

Perturbations in the structure of the neutral atmosphere were measured in narrow latitude bands near the dayside polar cusp by mass spectrometers aboard the S3-1 and Esro 4 satellites. The disturbances are characterized by an in-phase variation of both the lighter and the heavier species. They are observed to occur in latitude bands of about 5-10 deg extent in the altitude region of 200 km during periods of increased geomagnetic activity. It is suggested that thermospheric winds driven by momentum sources associated with ion convection are the predominant cause for these disturbances. The narrow structure features associated with the momentum source are superimposed on the thermospheric changes caused by Joule heating. Both effects may be present simultaneously, resulting in a complex response pattern of the neutral gas composition in the thermosphere.

Trinks, H.↗

Structures of the TMC-1 complex illuminate mechanosensory transduction

The initial step in the sensory transduction pathway underpinning hearing and balance in mammals involves the conversion of force into the gating of a mechanosensory transduction channel1. Despite the profound socioeconomic impacts of hearing disorders and the fundamental biological significance of understanding mechanosensory transduction, the composition, structure and mechanism of the mechanosensory transduction complex have remained poorly characterized. Here we report the single-particle cryo-electron microscopy structure of the native transmembrane channel-like protein 1 (TMC-1) mechanosensory transduction complex isolated from Caenorhabditis elegans. The two-fold symmetric complex is composed of two copies each of the pore-forming TMC-1 subunit, the calcium-binding protein CALM-1 and the transmembrane inner ear protein TMIE. CALM-1 makes extensive contacts with the cytoplasmic face of the TMC-1 subunits, whereas the single-pass TMIE subunits reside on the periphery of the complex, poised like the handles of an accordion. A subset of complexes additionally includes a single arrestin-like protein, arrestin domain protein (ARRD-6), bound to a CALM-1 subunit. Single-particle reconstructions and molecular dynamics simulations show how the mechanosensory transduction complex deforms the membrane bilayer and suggest crucial roles for lipid–protein interactions in the mechanism by which mechanical force is transduced to ion channel gating.

59 BASIC BIOLOGICAL SCIENCES↗

Investigation of Magmatic Activities on Early Mars Using Igneous Mineral Chemistry in Gale Crater, Mars

One objective of rover missions is exploring the geological context of the surroundings. Over the years, igneous petrology and sedimentology have been disconnected, the first investigating magmatic processes and volcanic activities, and the second seeking environmental conditions in the past and assessing the habitability of the planet. Although different, one is related to the other: igneous rocks are altered and broken down, leading to the formation of sedimentary rocks, which can in turn be used to back out the nature of their magmatic source. The Curiosity rover that landed in the 3.7 Gyr old impact crater Gale is traveling through sedimentary rocks. About fifty float rocks have been observed, and several of them with ambiguous texture and composition have been classified as igneous or sedimentary depending on studies such as Jake_M. The composition of several unambiguous igneous rocks has been analyzed [4- 6] but their heterogeneity at a larger instrumental (measurement size < 2 cm) scale prevents the measurement of a bulk composition as performed on Earth. An original approach avoiding these two last issues is to consider igneous mineral chemistry analyzed within igneous and sedimentary rocks to assess magmatic processes that could have formed them. Most Curiosity data are used to explore ancient environmental conditions, and a significant number of compositional analyses are under-explored for constraining magmatic activities. We will present how we can make use of sedimentary data for investigating igneous processes in the vicinity of Gale crater. Geological Context: We focus on the first 750 martian days, corresponding to measurements in a coherent lacustrine sedimentary unit called Bradbury, because all sedimentary rocks were sourced from the same watershed and appear to have a consistent source with minimal alteration [2-3]. Igneous detrital minerals including feldspar and pyroxene, are observed in sedimentary rocks. Monte Carlo models showed that minimal cation loss is observed based on the composition of all Bradbury rocks, implying negligible weathering [3]. Although clay minerals are detected in few rocks [7], chemical compositions of rocks can be explained by a mixture of primary igneous minerals [3]. Variation of composition within Bradbury rocks can be explained by mineral sorting and one distinct source component. While a common magmatic source is suggested, Bradbury sediments likely come from several volcanic eruptions from a single magmatic chamber [9- 10]. The occurrence of alkali minerals like sanidine and K-rich rocks throughout Bradbury supports the presence of a potassic component, likely trachytic, while plagioclase and a mafic composition suggest a basaltic component [8-9]. Instruments: Mineral chemistry can be estimated by three instruments onboard Curiosity. The CheMin instrument enables detection of mineral assemblages using X-ray diffraction (XRD). Using Rietveld refinement, each mineral is identified according to their 1D XRD pattern [11]. Note that distinction between pyroxene minerals is challenging with the CheMin instrument due to overlapping peaks on XRD patterns and low angular resolution of the instrument [12]. Then, using least square regression and optimization algorithms based on unit-cell parameters, mineral chemistry has been estimated by [11]. Plagioclase composition has been estimated using the NaAlSi3O8- CaAl2Si2O8 system and alkali feldspar is based on the NaAlSi3O8-KAlSi3O8 system (stars in Fig.1). Two mudstone samples (John Klein and Cumberland) and one sandstone sample (Windjana) were analyzed by CheMin at Yellowknife Bay and Kimberley, respectively. Figure 1. Ternary diagrams of feldspars (top) and pyroxene (bottom) quadrilateral. Stars correspond to CheMin composition and the gray patches to ChemCam composition. The colored dots are the composition of feldspar and pyroxene that crystallized during fractional crystallization at FMQ+1 of a melt extracted at distinct melting degree during the adiabatic ascent of a primitive mantle composition, without any water (left panels) and with 0.5 wt.% of water (right panels) at distinct pressure. The ChemCam instrument enables the analysis of the chemical compositions of rocks at hundreds of micrometer scale (350-550 μm) using laser induced breakdown spectroscopy (LIBS), which may provide the composition of minerals when they are larger than the beam spot (>550 μm) [13]. Within >5000 LIBS points, we performed a typical stoichiometric filtering allowing us to distinguish 56 feldspar and 10 pyroxene mineral compositions (grey patches in Fig. 1). Finally, the Alpha Particle X-ray Spectrometer (APXS) analyzes the composition of rocks with a 1.6 cm diameter spot size. Monte Carlo mass balance modeling allowed [3] to decipher a feldspar range varying between An30 and An40 (Fig. 1). Discussion: Although there could be a more complex history and other ways to form the whole compositional range of igneous minerals analyzed within the Bradbury formation, we are presenting here simple magmatic pathways commonly occurring on Earth using the thermodynamical softwares pMELTS and rhyoliteMELTS [14]. The objective is to find reasonable igneous processes that produce minerals that parallel the compositions of feldspar and pyroxene analyzed by the Curiosity rover. As commonly observed for mid-ocean ridge basalts, the adiabatic ascent of a primitive mantle composition [15] partially melting at 2 GPa has been modeled, followed by the extraction of a liquid at distinct degrees of partial melting, which undergoes fractional crystallization at an oxygen fugacity +1 log unit above the fayalite-magnetite-quartz (FMQ) buffer within the crust (0.02-0.4 GPa) with H2O = 0- 0.5 wt. %. These latter conditions correspond to those recorded within igneous clasts from the Noachian martian breccia NWA 7034 and paired and within Gale igneous rocks (colored dots in Fig. 1) [16-17]. To check the reliability of these 2-step models, we also tested fractional crystallization at similar conditions (FMQ+1; P=0.02-0.4 GPa; H2O = 0-0.5 wt. %) of starting compositions corresponding to that of magmas with distinct melting degrees obtained from isobaric experiments at 2 GPa [18]. Mineral compositions obtained from both models are similar. As shown on Fig. 1, the whole range of observed feldspar compositions cannot be reproduced by fractionation of one magma only. Indeed, while alkali feldspar and Na-plagioclase likely crystallized from fractional crystallization of a low-degree melt (here <15%), plagioclase and pyroxene can only be formed by fractional crystallization of a higher degree melt (here >19%). The corresponding liquid descent lines are broadly in agreement with compositions estimated by ChemCam corresponding to float igneous rocks (Fig. 2) [4-6]. Figure 2. Silica versus alkali content. Lines show the liquid lines of descent from magmas with distinct degrees of melting. Gray patches represents the composition of Gale igneous rocks [4-6]. Trachytic to rhyolitic magmas crystallize alkali feldspar, and andesite to dacite magmas likely form plagioclase. Therefore, at least two starting magmas at distinct melting degrees, which could easily come from a single mantle source, are necessary to explain the whole compositional range of feldspar and pyroxene analyzed within Bradbury rocks. Conclusion: Because rocks from the Bradbury formation are likely originating from the same magmatic source with minimal weathering as supported by several studies using different approaches, igneous mineral chemistry analyzed by CheMin and ChemCam allows us to back out reasonable magmatic pathways that could have crystallized them. Fractional crystallization of at least two starting magmas originating from distinct melting degrees of a single mantle source can explain the whole range of feldspar and pyroxene composition. Both alkaline and sub-alkaline liquids can be produced, with compositions corresponding to those of the igneous rocks analyzed by ChemCam within the Bradbury formation, highlighting the complexity of Mars magmatism.

Payre, V.↗

A model of early lunar differentiation

The presence of anorthosites and the scarcity of complementary mafic rocks in the lunar crust suggest a body of melt with depth of the order of the depth of the crust itself (about 60 km). This depth is consistent with geophysical and geochemical models which call for a depth of melting of the order of 200-500 km. The major and minor element compositions of the ancient pristine rocks require complex igneous processes if the moon accreted homogeneously and has chondritic interelement ratios among the refractory elements. Anorthosites crystallized from magmas that had assimilated plagioclase and a light REE-enriched component. KREEP as well as most of the troctolites and norites formed from relatively primitive magmas that were mixed with a LIL-enriched, Sc-Ti depleted component. Assimilation and mixing processes inferred for pristine rocks are consistent with crystallization from a convecting magma ocean which initially developed a floating anorthosite crust with a plagioclase-saturated boundary layer beneath it, transitional in temperature and composition to the main body of the magma beneath it.

Longhi, J.↗

Tailored Fiber Placement for Complex Preforms

Tailored Fiber Placement (TFP) offers a novel approach to optimize fiber architecture for the fabrication of complex, structural parts not traditionally suitable for advanced composites. This technology not only offers new routes for weight reduction via metal substitution, it also offers cost reduction through minimization of material scrap and reduced labor. This reduction in component weight leads to increased fuel efficiency, and reduced production energy consumption, thereby, helping to achieve the stated IACMI technical goals. This technology leverages centuries of manufacturing development in support of the textile and embroidery industry. One major drawback to this technology is the lack of commercial or non- proprietary structural performance data and robust analytical tools used to optimize fiber architecture and predict performance. This project was structured to utilize common sub-element features to validate analytical performance tools, generate performance data, and gather cost and performance data on components of interest. This project was designed to give industry sponsors the confidence and ability to take full advantage of TFP to fabricate primary, highly loaded structure and integrate features such as metallic fasteners. The project focused principally on the use of high strength carbon fiber, such as T700, and the use of aerospace epoxy resin matrix to primarily support development of new composite applications in vehicle, aerospace, and industrial markets. This project applied previously developed analytical tools to predict the performance of TFP produced parts. This work focused on developing the pipeline to characterize material in order to accurately predict component performance when modifying the TFP print paths and stitch density. This focused on experimental characterization via standardized ASTM testing, alongside experimental testing of more representative service components by testing curved beam strength, beam shear performance, a large scale TFP lug, and ultimately designing a fully TFP clip bracket that reduced weight and cost compared to a traditional metallic component. The new knowledge gained from this program included: 1) development and demonstration of novel analytical tools applied to analysis of TFP preforms; 2) development and demonstration of a building block approach using coupons and sub-elements to optimize the design of a more complex component; 3) demonstration that optimized fiber orientation using TFP can exceed performance of conventional textile composite materials and can open new applications currently limited to metallic components; 4) Demonstration of performance and cost benefits of the TFP process as compared to metallic and conventional textile composites. Recommendations for follow-on work include development of design allowables to assess the impact of high temperature/moisture exposure or saturation during loading, tracking the impact of stitching needle wear on the performance of parts and ability to stitch thicker preforms, using TFP preforms as local reinforcement at areas of bearing or complex loading, and topology optimization of components by tow steering. The expertise developed during the course of this project can be leveraged to provide commercial engineering design and fabrication services using TFP. UDRI is in the process of formalizing their partnership with Spintech, who will serve as the commercialization partner for this technology and provide molding services and deliver finished components to the end user. UDRI will continue to produce the preforms until the economics allow Spintech to procure its own TFP equipment or lease UDRI equipment, at which point UDRI will step away from manufacture and serve as the engineering and design lead on product development.

36 MATERIALS SCIENCE↗

Thermostructural tailoring of fiber composite structures

A significant area of interest in design of complex structures involves the study of multidisciplined problems. The coordination of several different intricate areas of study to obtain a particular design of a structure is a new and pressing area of research. In the past, each discipline would perform its task consecutively using the appropriate inputs from the other disciplines. This process usually required several time-consuming iterations to obtain a satisfactory design. The alternative pursued here is combining various participating disciplines and specified design requirements into a formal structural computer code. The main focus of this research is to develop a multidiscipline structural tailoring method for select composite structures and to demonstrate its application to specific areas. The development of an integrated computer program involves the coupling of three independent computer programs using an excutive module. This module will be the foundation for integrating a structural optimizer, a composites analyzer and a thermal analyzer. With the completion of the executive module, the first step was taken toward the evolution of multidiscipline software in the field of composite mechanics. Through the use of an array of cases involving a variety of objective functions/constraints and thermal-mechanical load conditions, it became evident that simple composite structures can be designed to a combined loads environment.

Acquaviva, Thomas H.↗