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Various aspects of the application of composite materials to aircraft structures are considered. Failure prediction techniques, buckling and postbuckling research, laminate fatigue analysis, damage tolerance, high temperature resin matrix composites and electrical hazards of carbon fiber composites are among the topics discussed.
The satellite surface potential monitor (SSPM) has been developed for the P78-2 SCATHA (Spacecraft Charging At The High Altitudes) satellite to determine the response of selected spacecraft materials to charged-particle environmental fluxes. Since the monitor infers total surface voltages from a single point on the interior side of insulators, a ground simulation program was undertaken to develop analytical techniques to model the monitors and to obtain an experimental calibration of the relationship between the flight measurement techniques and actual measurements. The experimental testing was conducted using monoenergetic electron beams irradiating samples in the dark. An analytical computer model was developed in the NASCAP (NASA Charging Analyzer Program) code. The analytical model material properties for Kapton that controlled backscatter and secondary yield were adjusted to obtain a single set of values that produced reasonable fits for both voltages and currents. The analytical techniques developed in the ground technology investigation have been applied to space flight conditions. Predictions were compared with limited flight data. The agreement is very good indicating that the technique, and NASCAP, can be used to predict spacecraft material charging behavior. Details of the testing, the analytical modelling technique and flight data comparisons are presented.
The analyses, designs, fabrication, and cold-flow acceptance testing of LOX/RP-1 preburner components required for a high-pressure staged-combustion rocket engine are discussed. Separate designs of injectors, combustion chambers, turbine simulators, and hot-gas mixing devices are provided for fuel-rich and oxidizer-rich operation. The fuel-rich design addresses the problem of non-equilibrium LOX/RP-1 combustion. The development and use of a pseudo-kinetic combustion model for predicting operating efficiency, physical properties of the combustion products, and the potential for generating solid carbon is presented. The oxygen-rich design addresses the design criteria for the prevention of metal ignition. This is accomplished by the selection of materials and the generation of well-mixed gases. The combining of unique propellant injector element designs with secondary mixing devices is predicted to be the best approach.
Analytical results indicate that a careful selection of materials and truss design, combined with accurate manufacturing techniques, can result in very accurate surfaces for large space antennas. The purpose of this paper is to examine these relationships for various types of structural configurations. Comparisons are made of the accuracy achievable by truss- and dome-type structures for a wide range of diameter and focal length of the antenna and wavelength of the radiated signal.
The requisite methodology to solve linear and nonlinear problems associated with the static and dynamic analysis of rotating machinery, their static and dynamic behavior, and the interaction between the rotating and nonrotating parts of an engine is developed. Linear and nonlinear structural engine problems are investigated by developing solution strategies and interactive computational methods whereby the man and computer can communicate directly in making analysis decisions. Representative examples include modifying structural models, changing material, parameters, selecting analysis options and coupling with interactive graphical display for pre- and postprocessing capability.
A low cost wind turbine blade based on a stainless steel fiberglass foam Budd blade design concept, was evaluated for its principle characteristics, low cost features, and its advantages and disadvantages. A blade structure was designed and construction methods and materials were selected. A complete blade tooling concepts, various technical and economic analysis, and evaluations of the blade design were performed. A comprehensive fatigue test program is conducted to provide data to verify the design stress allowables.
The development and evaluation of a low cost blade concept based on the NASA-Lewis specifications is discussed. A blade structure was designed and construction methods and materials were selected. Complete blade tooling concepts, various technical and economic analysis, and evaluations of the blade design were performed. A comprehensive fatigue test program was conducted to provide data and to verify the design. A test specimen of the spar assembly, including the root end attachment, was fabricated. This is a full-scale specimen of the root end configuration, 20 ft long. A blade design for the Mod '0' system was completed.
The mid-deck lockers of the STS and the requirements for operating an experiment in this region are described. The design of the surface tension induced convection and the free surface phenomenon experiments use a two locker volume with an experiment unique structure as a housing. A manual mode is developed for the Surface Tension Induced Convection experiment. The fluid is maintained in an accumulator pre-flight. To begin the experiment, a pressurized gas drives the fluid into the experiment container. The fluid is an inert silicone oil and the container material is selected to be comparable. A wound wire heater, located axisymmetrically above the fluid can deliver three wattages to a spot on the fluid surface. These wattages vary from 1-15 watts. Fluid flow is observed through the motion of particles in the fluid. A 5 mw He/Ne laser illuminates the container. Scattered light is recorded by a 35mm camera. The free surface phenomena experiment consists of a trapezoidal cell which is filled from the bottom. The fluid is photographed at high speed using a 35mm camera which incorporated the entire cell length in the field of view. The assembly can incorporate four cells in one flight. For each experiment, an electronics block diagram is provided. A control panel concept is given for the surface induced convection. Both experiments are within the mid-deck locker weight and c-g limits.
Friction and wear induced mechanical failures may be controlled to extend the life of tribological components through the interposition of selected solid materials between contacting surfaces. Thin solid films of soft and hard materials are appropriate to lower friction and enhance the wear resistance of precision tribo-elements. Thin film coating technologies that have been developed may be used to interpose thin solid layers between contacting surfaces to reduce friction or to extend wear life. Film deposition technologies developed include chemical vapor deposition (CVD) and physical vapor deposition (PVD). Sputter coating is a PVD process for thin film deposition. It allows close control of coating thickness and composition and is well-suited for the deposition of tribological coatings. In this paper, the utility of magnetron sputtering for the deposition of tribological coatings is examined. Experimental results obtained when coated bodies are tested under a number of tribological operating conditions are presented. It is shown that when film adhesion problems are resolved, sputtering can be an effective means of depositing tribological coatings.
The NASA Aircraft Energy Efficiency (ACEE) Composite Primary Aircraft Structures Program was designed to develop technology for advanced composites in commercial aircraft. Research on composite materials, aircraft structures, and aircraft design is presented herein. The following parameters of composite materials were addressed: residual strength, damage tolerance, toughness, tensile strength, impact resistance, buckling, and noise transmission within composite materials structures.
A screening program to determine the effects of high pressure hydrogen on selected candidate materials for advanced single crystal turbine blade applications is examined. The alloys chosen for the investigation are CM SX-2, CM SX-4C, Rene N-4, and PWA1480. Testing is carried out in hydrogen and helium at 34 MPa and room temperature, with both notched and unnotched single crystal specimens. Results show a significant variation in susceptibility to Hydrogen Environment Embrittlement (HEE) among the four alloys and a marked difference in fracture topography between hydrogen and helium environment specimens.
The similarities in siderophile abundances strongly suggest that the Moon was derived from the Earth's mantle after the Earth's core had formed. The energy required to remove material from the Earth's mantle and place it into geocentric orbit can be supplied most readily by impact processes during accretion of the Earth. Impacts of late-accreting, high-velocity planetismals would evaporate many times their masses of mantle material. These gases would be accompanied by a massive spray of shock-melted silicate droplets. It is suggested that the gases produced from such near-equatorial impacts were rapidly spun out into equatorial geocentric orbit. The evaporated material was selectively recondensed, and, accompanied by the shock melted, devolatilized silicate droplets, accreted to form a sediment ring of Earth-orbiting planetismals. This sediment ring also captured a significant proportion of Earth-bound planetismals. The Moon was formed by accretion from planetismals comprising the sediment ring.
A screening program to determine the effects of high pressure hydrogen on selected candidate materials for advanced single crystal turbine blade applications is examined. The alloys chosen for the investigation are CM SX-2, CM SX-4C, Rene N-4, and PWA1480. Testing is carried out in hydrogen and helium at 34 MPa and room temperature, with both notched and unnotched single crystal specimens. Results show a significant variation in susceptibility to Hydrogen Environment Embrittlement (HEE) among the four alloys and a marked difference in fracture topography between hydrogen and helium environment specimens.
The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life was experienced. The objective is to identify bearing materials and/or materials processing techniques offering signficant potential for extending HPOTP bearing performance life. Interactive thermomechanical analysis of the HPOTP bearing-shaft system was performed with the SHABERTH computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures and circumferential stress in the inner rings were quantified as functions of radial load, thrust load and ball-race contact friction. Criteria established from the output of this analysis are being used for material candidate selection.
A computer model is developed in order to calculate fluence for a generalized spacecraft in orbital flight based on mass spectrometer and incoherent scatter (MSIS) measurements of ambient density. The calculations are used to identify criteria for the selection of materials for the construction of an LEO Space Station. The model is generalized such that the surfaces for study can be oriented in any direction with respect to: a body coordinate system fixed to the spacecraft (E surfaces); and a solar inertial coordinate system. A parametric study was performed in order to evaluate the effects of altitude, inclination, and solar activity on atomic oxygen fluence. Values are obtained for samples of Mylar, Kevlar, Kapton, Tedlar, Teflon and sulfone, as well as for some ethylene polymers. The range of values for material reactivities is from 360 microns for ram-facing surfaces to 200 microns for solar power surfaces during each cycle of solar activity. The possibility of improving reactivity by employing certain chemical coatings is also discussed.
In his third State of the Union address, President Reagan told NASA to develop a permanent manned space station in 10 years. The President also ordered the Department of Transportation to help private firms launch rockets, thus introducing the commercialization of space. There were five space shuttle and six expendable vehicle launches in 1984. Materials were selected from a number of published sources. The document records KSC events of interest to historians and other researchers. Arrangement is by month; items are by date of the published sources. Actual date of the event may be indicated in parenthesis, when the article itself does not make that information explicit.
Solar thermodynamics research and technology is reported. Comments on current program activity and future plans with regard to satisfying potential space station electric power generation requirements are provided. The proceedings contain a brief synopsis of the presentations to the panel, including panel comments, and a summary of the panel's observations. Selected presentation material is appended. Onboard maintainability and repair in space research and technology plan, solar thermodynamic research, program performance, onboard U.S. ground based mission control, and technology development rad maps from 10 C to the growth station are addressed.
An experimental and analytical study was conducted to delineate the compression failure mechanisms of composite structures. The present report summarizes further results on kink band formation in unidirectional composites. In order to assess the compressive strengths and failure modes of fibers them selves, a fiber bundle was embedded in epoxy casting and tested in compression. A total of six different fibers were used together with two resins of different stiffnesses. The failure of highly anisotropic fibers such as Kevlar 49 and P-75 graphite was due to kinking of fibrils. However, the remaining fibers--T300 and T700 graphite, E-glass, and alumina--failed by localized microbuckling. Compressive strengths of the latter group of fibers were not fully utilized in their respective composite. In addition, acoustic emission monitoring revealed that fiber-matrix debonding did not occur gradually but suddenly at final failure. The kink band formation in unidirectional composites under compression was studied analytically and through microscopy. The material combinations selected include seven graphite/epoxy composites, two graphite/thermoplastic resin composites, one Kevlar 49/epoxy composite and one S-glass/epoxy composite.