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NASA NTRS2019

Testing and Analysis Correlation of Composite Sandwich Longitudinal Bonded Joints for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project has been developing and demonstrating critical composite technologies with a focus on joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA expertise and capabilities. The CTE project has focused on the development of composite longitudinal bonded joint technologies for conical structures such as the SLS Payload Attach Fitting (PAF) due to challenging joint geometries and loads compared to cylindrical jointed structures. The CTE team selected and designed a double-lap composite bonded joint as the most advantageous longitudinal joint to advance for the CTE project. This paper reports on the longitudinal bonded joint sub-element test articles that were fabricated and tested for several loading conditions to test the capability of the bonded joint design. Test and analysis correlation to the sub-element test articles are presented in the paper.

Sleight, David W.↗

NASA NTRSDate not supplied

Modal Correlation of Complex Aerospace Joints Using Automated Variable Substitution

A critical task involved with being able to predict flight loads accurately in aerospace finite element models (FEMs) is the prior verification of the FEMs by conducting modal survey testing (MST). Experience comparing dynamic response of initial FEMs to MST data tends to demonstrate that FEMs can have unacceptable accuracy even when best modeling practices are followed. One inherent source of inaccuracy in linear dynamic FEMs is the modeling of nonlinear joints with mechanisms such as spherical bearings. These joints are usually designed to freely translate or rotate under the high levels of loading experienced in flight. Engineers who create linear FEMs conventionally model these joints without any stiffness in the mechanism degrees of freedom to meet this design intent. However, inaccuracy is observed during test validation of these FEMs, which usually relies on low-level force excitation orders of magnitude below flight load levels. This low-level modal test rarely overcomes the joint friction that is present, and thus the mechanism joints are able to react loads. This divide between the test results and the FEM creates a significant challenge to the engineer who is performing the correlation, in that the engineer has no basis for what stiffness value should be used to make the FEM match the test results. A compounding challenge is that complicated built-up aerospace structures commonly have multiple joints through a load path where each joint will “stick” and “slip” at different levels of force input. Explicitly matching the dynamics of a system containing these nonlinear mechanisms would require a nonlinear FEM, which is prohibitively costly for dynamic simulations of most aerospace systems. The objective of this paper is to present a workflow that can efficiently cycle through many iterations of a FEM, allowing a Monte Carlo style examination of the design space to identify candidate stiffness values for nonlinear mechanism joints. The outlined approach is specific to MSC Nastran and utilizes MSC Nastran’s symbolic substitution capabilities, coupled with the IMAT™ and Attune™ software packages developed by ATA Engineering, Inc. (ATA). The workflow is demonstrated with a case study from the correlation effort for The Boeing Company’s Crew Space Transportation (CST)-100 Starliner FEM. Keywords: Correlation, MSC Nastran, IMAT™, Attune™, Finite Element Model, Modal Testing

Correlation↗

DOE OSTI2021

Mitigation of Galvanic Corrosion in Bolted Joint of AZ31B and Carbon Fiber-Reinforced Composite Using Polymer Insulation

The use of polymer insulation to mitigate galvanic corrosion was examined for bolted joints of AZ31B Mg alloy and carbon fiber-reinforced composite. To assess the corrosion behaviors of bolted joints with and without polymer insulation, solution immersion and salt spray exposure (ASTM B117) tests were conducted, and the corrosion depths and volumes were determined for the joint specimens after the tests. The polymer-insulated bolted joints exhibited much lower corrosion depths and volumes, highlighting the effective mitigation of galvanic corrosion. The reductions of joint strength in the post-corrosion joint specimens were relatively small (up to ~10%) in the polymer-insulated group but greater (up to 90%) in the group with no insulation. Cross-sectional characterization of post-corrosion joints with polymer insulation revealed local pits developed on AZ31B under galvanic influence, indicating that limited galvanic attack (that did not decrease the joining integrity significantly) could still occur during a long salt spray exposure (~1264 h) owing to the permeation of an aqueous corrosive medium.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Effect of die design on microstructure and mechanical joint strength in friction self-piercing riveted AA7055-T76 and AA7055-T76

In the present study, a unique friction self-piercing riveting (F-SPR) was applied to join high-strength, low-ductility aluminum alloy (AA) 7055-T76 and AA7055-T76 to mitigate a cracking issue. Also, the effect of die design on both joint formation and the mechanical joint performance were investigated. A crack-free joint was achieved when joining AA7055-T76 and AA7055-T76 by F-SPR. As the bottom diameter of the die increased, the mechanical interlocking distance initially increased then became almost saturated. At the same time, the solid-state bonding gradually disappeared, and the lap-shear fracture changed from bottom aluminum fracture to rivet pull-out with partial bottom aluminum fracture. The average maximum lap-shear joint strength of 11.57 kN and cross tension of 5.65 kN were achieved from the D2 die design owing to the combined contributions from high mechanical interlocking distance and good solid-state bonding at the joint interface. Ultrafine grain refinement was observed at the region next to the rivet shank outer surface and along the materials flow line between the top and bottom aluminum sheet in the rivet cavity. Further, because of the same joint-process parameters, the hardness profile at the joints made by different dies did not show obvious differences. As the distance from the base metal to the rivet outer surface decreased, frictional heat caused the hardness to initially decrease from 190 to 150 HV in the heat-affected zone. Hardness increased up to 175 HV in the thermomechanical affected zone (TMAZ-I) owing to large plastic deformation.

36 MATERIALS SCIENCE↗

NASA NTRS2024

Pull-off Behavior of Stitched Composite T-Joints

T-joints are key structural elements that connect opposing surfaces, thereby providing the load path between flat or curved panels (i.e., upper and lower wing skins) and transverse components (i.e., stiffeners). Due to the low interlaminar strength of polymer matrix composites and their geometrical discontinuities, these joints are vulnerable to pull-off loads. To address these issues, through-thickness reinforcements can be employed to enhance the interlaminar capability of these type of joints. In this study, T-joints were manufactured using through-thickness stitching in dry carbon preforms and cured using the vacuum-assisted resin transfer molding (VARTM) process. Stitched and unstitched T-joints were tested under pull-off loading conditions, and surface strain fields were obtained using a 3D digital image correlation system. The ultimate load, displacement, and absorbed energy of the stitched T-joints were greater than their unstitched counterparts by approximately 16%, 34%, and 58%, respectively. Failure mechanisms were identified by examining fracture surfaces using optical microscopy. Results demonstrate that through-thickness stitching significantly improves the damage tolerance of T-joints, which highlights the effectiveness of stitching to enhance the structural integrity of large aerospace components.

VARTM↗

DOE OSTI2024

Testing and modeling of CLT-to-CLT joints made using hardwood dowels and screws with varying spacing

With the increasing popularity of mass timber, utilizing large-diameter wood screws and hardwood dowels can offer an easy and cost-efficient way to join structural elements. However, the existing research on hardwood dowels is limited to single fastener joints under monotonic loading. No research is available on the group effects of joints with multiple hardwood dowels. Here, this paper presents the results of 96 monotonic and cyclic single-shear plane CLT-to-CLT joint tests with hardwood dowels (Red Oak and Yellow Birch, 25.4 mm diameter) and self-tapping wood screws (8 mm diameter) in Grand-Fir CLT, where screws were inserted both perpendicular and at a 45-degree angle to the grain for comparison to hardwood dowels. The study evaluated the mechanical properties of the joints by changing fastener spacing. Mechanical properties such as yielding and peak strength, displacement, elastic and yielding stiffness, and ductility were evaluated. The results showed equal strength and stiffness properties for hardwood dowels comparable with large-diameter screws. Additionally, the hardwood dowel joints demonstrated moderate ductility properties. The strength and stiffness of the tested joints were compared with analytical equations found in the literature by considering the group action factor of the fasteners. Lastly, a nonlinear force-displacement model was presented and compared to the experimental results and analytical calculations, which gives the possibility to predict and optimize the mechanical behavior of hardwood dowel and screw joints with varying numbers and spacing between fasteners.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Characterization and qualification of neutron radiation effects – Summary of Japan-USA Joint Projects for 40 years

The Joint Projects under the Japan-USA Fusion Cooperation Program started in 1981 and has continued for more than 40 years. In the Joint Projects, although a wide range of fusion materials and engineering issues were covered, neutron radiation effects on fusion reactor materials have always been the major research emphases, and the neutron irradiation facilities in the US were jointly used by Japanese and US researchers. Japanese test facilities including neutron and charged particle irradiation facilities were complementarily used. Here, the initial focus of the Joint Projects was on fundamental fusion neutron radiation effects and irradiation correlation. Systematic comparison of fission and fusion radiation effects in comparable damage levels and the effects of transmutation-induced helium were investigated. The collaboration was then focused on the effect of dynamic irradiation effects in variable conditions. In addition to the relatively fundamental studies, the Joint Projects contributed largely to development of candidate materials such as RAFM steels, vanadium alloys, SiC/SiC composites, and tungsten alloys, through a mechanism-oriented approach. The Joint Projects also covered issues specific to materials application to fusion blankets and plasma-facing components, including neutron radiation effects such as tritium retention and permeation of neutron-irradiated plasma-facing materials. Various irradiation technologies were developed and applied to the irradiation experiments, including those for in-situ testing.Considering that high energy neutron sources, such as A-FNS and IFMIF-DONES, now have high viability, the research supporting the neutron source programs is essential. The knowledge obtained through the Joint Projects is valuable and should be advanced for this purpose. To this end, it is of urgent necessity to launch an international scientific program accumulating knowledge of fusion neutron radiation effects, including their fundamental aspects.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Control of wetting and uniformity via ZrSi x formation in ceramic-to-metal joints fabricated using Ag-Zr brazes

The deposition of a 2.0 µm SiO 2 film on the alumina surface in Kovar TM /94% alumina joints enables the formation of a silicide reaction layer on the alumina during brazing with 97Ag2Zr1Cu. Additionally, the average and standard deviation of joint thickness decrease from 50 to 15 and 29 to 4 µm, respectively compared to joints without added SiO 2 . Finally, the average failure stress of these braze joints was 45 MPa, while that of similar joints without added SiO 2 was 90 MPa. Sessile drop experiments of 98Ag2Zr on SiO 2 and 99.6% Al 2 O 3 substrates show that the braze wets and spreads to 3x its original area on SiO 2 with a wetting angle near 0°, but remains the same area on 99.6% Al 2 O 3 with a wetting angle of 106.6°. Focused-ion-beam scanning electron microscopy analysis of a cross-section of the 98Ag2Zr sessile drop on the SiO 2 substrate has shown that Zr reacts with SiO 2 to form Zr oxide and silicide layers. Scanning transmission electron microscopy diffraction and energy dispersive X-ray spectroscopy analysis indicate this silicide layer contains tetragonal Zr 5 Si 4 . In conclusion, analysis shows the silicide layer enhances wetting and joint uniformity while unreacted SiO 2 embrittles the joint and degrades strength.

alumina↗

NASA NTRS1982

Experimental data on single-bolt joints in quasi isotropic graphite/polyimide laminates

Sixteen ply, quasi-isotropic laminates of Celanese Celion 6000/PMR-15 and Celion 6000/LARC-160 with a fiber orientation of (0/45/90/-45) sub 2S were evaluated. Tensile and open hole specimens were tested at room temperature to establish laminate tensile strength and net tensile strength at an unloaded bolt hole. Double lap joint specimens with a single 4.83-mm (0.19 in.) diameter bolt torqued to 1.7 N-m (15 lbf-in.) were tested in tension at temperatures of 116 K (-250F), 297 K (75F), and 589 K (600F). The joint ratios of w/d (specimen width to hole diameter) and e/d (edge distance to hole diameter) were varied from 4 to 6 and from 2 to 4, respectively. The effect of joint geometry and temperature on failure mode and joint stresses are shown. Joint stresses calculated at maximum load for each joint geometry and test temperature are reported. Joint strength in net tension, bearing, and shear out at 116 K (-250F), 297 K (75F), and 589 K (600F) are given for the Celion 6000/PMR-15 and Celion 6000/LARC-160 laminates.

Wichorek, G. R.↗

NASA NTRS1983

Design and fabrication of realistic adhesively bonded joints

Eighteen bonded joint test specimens representing three different designs of a composite wing chordwise bonded splice were designed and fabricated using current aircraft industry practices. Three types of joints (full wing laminate penetration, two side stepped; midthickness penetration, one side stepped; and partial penetration, scarfed) were analyzed using state of the art elastic joint analysis modified for plastic behavior of the adhesive. The static tensile fail load at room temperature was predicted to be: (1) 1026 kN/m (5860 1b/in) for the two side stepped joint; (2) 925 kN/m (5287 1b/in) for the one side stepped joint; and (3) 1330 kN/m (7600 1b/in) for the scarfed joint. All joints were designed to fail in the adhesive.

Shyprykevich, P.↗

NASA NTRS1985

Effects of load proportioning on the capacity of multiple-hole composite joints

This study addresses the issue of adjusting the proportion of load transmitted by each hole in a multiple-hole joint so that the joint capacity is a maximum. Specifically two-hole-in-series joints are examined. The results indicate that when each hole reacts 50% of the total load, the joint capacity is not a maximum. One hole generally is understressed at joint failure. The algorithm developed to determine the load proportion at each hole which results in maximum capacity is discussed. The algorithm includes two-dimensional finite-element stress analysis and failure criteria. The algorithm is used to study the effects of joint width, hole spacing, and hole to joint-end distance on load proportioning and capacity. To study hole size effects, two hole diameters are considered. Three laminates are considered: a quasi-isotropic laminate; a cross-ply laminate; and a 45 degree angle-ply laminate. By proportioning the load, capacity can be increased generally from 5 to 10%. In some cases a greater increase is possible.

Hyer, M. W.↗

NASA NTRS1987

Structural behavior of solid rocket motor field joints

Structural analysis studies conducted on three concepts for the Space Shuttle Solid Rocket Motor field joints are summarized. Deflections and stresses in the Challenger clevis-tang joint are compared with a proposed capture-tang replacement joint and with an alternate bolted joint design. Results indicate deflections and stresses are subsequently reduced in both the capture-tang and bolted joint concepts. The capture-tang and bolted joint designs are respectively 24 and 70 percent heavier than the baseline clevis-tang joint.

Card, Michael F.↗

NASA NTRS1989

Axisymmetric shell analysis of the Space Shuttle solid rocket booster field joint

The Space Shuttle Challenger (STS 51-L) accident led to an intense investigation of the structural behavior of the solid rocket booster (SRB) tang and clevis field joints. The presence of structural deformations between the clevis inner leg and the tang, substantial enough to prevent the O-ring seals from eliminating hot gas flow through the joints, has emerged as a likely cause of the vehicle failure. This paper presents results of axisymmetric shell analyses that parametrically assess the structural behavior of SRB field joints subjected to quasi-steady-state internal pressure loading for both the original joint flown on mission STS 51-L and the redesigned joint recently flown on the Space Shuttle Discovery. Discussion of axisymmetric shell modeling issues and details is presented and a generic method for simulating contact between adjacent shells of revolution is described. Results are presented that identify the performance trends of the joints for a wide range of joint parameters.

Nemeth, Michael P.↗

NASA NTRS1989

Qualification of improved joint heaters

Qualification testing of the Redesigned Solid Rocket Motor improved igniter-to-case joint and field joint heaters was conducted on the fired TEM-04 static test motor and was completed on 7 Sep. 1989. The purpose of the test was to certify the installation and performance of the improved joint heaters for use on flight motors. The changes incorporated in the improved heaters improve durability and should reduce handling damage. The igniter-to-case joint and field joint primary heater circuits were subjected to five 20-hr ON cycles. The heater redundant circuits were then subjected to one 20-hr ON cycle. Voltage, current, and temperature set point values were maintained within the specified limits for both heaters during each ON cycle. When testing was complete, both heaters were removed and inspected. No discolorations or any other anomalies were found on either of the heaters. Based on the successful completion of this test, it is recommended that the improved igniter-to-case joint and field joint heaters be used on future flight motors.

Cook, M.↗

NASA NTRS1989

Measurement of damping of graphite epoxy composite materials and structural joints

The damping capacity of graphite epoxy materials and structural joints was evaluated. The damping ratio of different composite specimens and bonded joints were systematically evaluated under normal atmospheric conditions and in a vacuum environment. Free and forced vibration test methods were employed for measuring the damping ratios. The effect of edge support conditions on the damping value of a composite tube specimen was studied by using a series of experiments performed on the specimen with different edge supports. It was found that simulating a free-free boundary conditions by having no constraints at the ends gives the lowest value of the material damping of the composite. The accuracy of the estimation of the damping ratio value was improved by using a curve-fitting technique on the response data obtained through measurement. The effect of outgassing (moisture desorption) on the damping capacity was determined by measuring the damping ratio of the tube specimen in a vacuum environment before and after outgassing had occurred. The effects of high and low temperatures on the damping was also investigated by using a series of experiments on tube and beam specimens. An analytical model to study the vibrations of a bonded lap joint system was formulated. Numerical results were generated for different overlap ratios of the system. These were compared with experimental results. In order to determine the influence of bonded joints on the material damping capacity, experiments were conducted on bonded lap-jointed and double-butt-jointed specimens. These experimental results were compared with simple beam specimens with no joints.

Crocker, Malcolm J.↗

NASA NTRS1991

Dynamic Analyses Including Joints Of Truss Structures

Method for mathematically modeling joints to assess influences of joints on dynamic response of truss structures developed in study. Only structures with low-frequency oscillations considered; only Coulomb friction and viscous damping included in analysis. Focus of effort to obtain finite-element mathematical models of joints exhibiting load-vs.-deflection behavior similar to measured load-vs.-deflection behavior of real joints. Experiments performed to determine stiffness and damping nonlinearities typical of joint hardware. Algorithm for computing coefficients of analytical joint models based on test data developed to enable study of linear and nonlinear effects of joints on global structural response. Besides intended application to large space structures, applications in nonaerospace community include ground-based antennas and earthquake-resistant steel-framed buildings.

Belvin, W. Keith↗

NASA NTRS1991

A finite element approach for the dynamic analysis of joint-dominated structures

A finite element method to model dynamic structural systems undergoing large rotations is presented. The dynamic systems are composed of rigid joint bodies and flexible beam elements. The configurations of these systems are subject to change due to the relative motion in the joints among interconnected elastic beams. A body fixed reference is defined for each joint body to describe the joint body's displacements. Using the finite element method and the kinematic relations between each flexible element and its corotational reference, the total displacement field of an element, which contains gross rigid as well as elastic effects, can be derived in terms of the translational and rotational displacements of the two end nodes. If one end of an element is hinged to a joint body, the joint body's displacements and the hinge degree of freedom at the end are used to represent the nodal displacements. This results in a highly coupled system of differential equations written in terms of hinge degrees of freedom as well as the rotational and translational displacements of joint bodies and element nodes.

Chang, Che-Wei↗

NASA NTRS1992

Pressure vessel flex joint

An airtight, flexible joint is disclosed for the interfacing of two pressure vessels such as between the Space Station docking tunnel and the Space Shuttle Orbiter bulkhead adapter. The joint provides for flexibility while still retaining a structural link between the two vessels required due to the loading created by the internal/external pressure differential. The joint design provides for limiting the axial load carried across the joint to a specific value, a function returned in the Orbiter/Station tunnel interface. The flex joint comprises a floating structural segment which is permanently attached to one of the pressure vessels through the use of an inflatable seal. The geometric configuration of the joint causes the tension between the vessels created by the internal gas pressure to compress the inflatable seal. The inflation pressure of the seal is kept at a value above the internal/external pressure differential of the vessels in order to maintain a controlled distance between the floating segment and pressure vessel. The inflatable seal consists of either a hollow torus-shaped flexible bladder or two rolling convoluted diaphragm seals which may be reinforced by a system of straps or fabric anchored to the hard structures. The joint acts as a flexible link to allow both angular motion and lateral displacement while it still contains the internal pressure and holds the axial tension between the vessels.

Kahn, Jon B.↗