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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 109 records · Page 6

Optics in engineering measurement; Proceedings of the Meeting, Cannes, France, December 3-6, 1985

The present conference on optical measurement systems considers topics in the fields of holographic interferometry, speckle techniques, moire fringe and grating methods, optical surface gaging, laser- and fiber-optics-based measurement systems, and optics for engineering data evaluation. Specific attention is given to holographic NDE for aerospace composites, holographic interferometry of rotating components, new developments in computer-aided holography, electronic speckle pattern interferometry, mass transfer measurements using projected fringes, nuclear reactor photogrammetric inspection, a laser Doppler vibrometer, and optoelectronic measurements of the yaw angle of projectiles.

Fagan, William F.↗

Displaying Data As Movies

NMSB Movie computer program displays large sets of data (more than million individual values). Presentation dynamic, rapidly displaying sequential image "frames" in main "movie" window. Any sequence of two-dimensional sets of data scaled between 0 and 255 (1-byte resolution) displayed as movie. Time- or slice-wise progression of data illustrated. Originally written to present data from three-dimensional ultrasonic scans of damaged aerospace composite materials, illustrates data acquired by thermal-analysis systems measuring rates of heating and cooling of various materials. Developed on Macintosh IIx computer with 8-bit color display adapter and 8 megabytes of memory using Symantec Corporation's Think C, version 4.0.

Moore, Judith G.↗

Ceramic susceptor for induction bonding of metals, ceramics, and plastics

A thin (.005) flexible ceramic susceptor (carbon) was discovered. It was developed to join ceramics, plastics, metals, and combinations of these materials using a unique induction heating process. Bonding times for laboratory specimens comparing state of the art technology to induction bonding were cut by a factor of 10 to 100 times. This novel type of carbon susceptor allows for applying heat directly and only to the bondline without heating the entire structure, supports, and fixtures of a bonding assembly. The ceramic (carbon film) susceptor produces molten adhesive or matrix material at the bond interface. This molten material flows through the perforated susceptor producing a fusion between the two parts to be joined, which in many instances has proven to be stronger than the parent material. Bonding can be accomplished in 2 minutes on areas submitted to the inductive heating. Because a carbon susceptor is used in bonding carbon fiber reinforced plastics and ceramics, there is no radar signature or return making it an ideal process for joining advanced aerospace composite structures.

Fox, Robert L.↗

Effects of thermal and moisture cycling on the internal structure of stitched RTM laminates

Conventional aerospace composites are strong and stiff in the directions parallel to the carbon fibers, but they are prone to delaminations and damage in the through-the-thickness directions. Recent research has shown that substantial improvements in damage tolerance are obtained from textile composites with Z-direction reinforcement provided by stitching, weaving, or braiding. Because of the mismatch in thermal and moisture expansion properties of the various material components, there is a potential for microcracks to develop in the resin matrix. These cracks can form to relieve the mechanical stresses that are generated during curing or in-service temperature cycles.

Walker, Jeff↗

Innovations in Aircraft Design

The Boeing 777 carries with it basic and applied research, technology, and aerodynamic knowledge honed at several NASA field centers. Several Langley Research Center innovations instrumental to the development of the aircraft include knowledge of how to reduce engine and other noise for passengers and terminal residents, increased use of lightweight aerospace composite structures for increased fuel efficiency and range, and wind tunnel tests confirming the structural integrity of 777 wing-airframe integration. Test results from Marshall Space Flight Center aimed at improving the performance of the Space Shuttle engines led to improvements in the airplane's new, more efficient jet engines. Finally, fostered by Ames Research Center, the Boeing 777 blankets that protect areas of the plane from high temperatures and fire have a lineage to Advanced Flexible Reusable Surface Insulation used on certain areas of the Space Shuttle. According to Boeing Company estimates, the 777 has captured three-quarters of new orders for airplanes in its class since the program was launched.

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Non-Destructive Evaluation of Materials via Ultraviolet Spectroscopy

A document discusses the use of ultraviolet spectroscopy and imaging for the non-destructive evaluation of the degree of cure, aging, and other properties of resin-based composite materials. This method can be used in air, and is portable for field use. This method operates in reflectance, absorbance, and luminescence modes. The ultraviolet source is used to illuminate a composite surface of interest. In reflectance mode, the reflected response is acquired via the imaging system or via the spectrometer. The spectra are analyzed for organic compounds (conjugated organics) and inorganic compounds (semiconducting band-edge states; luminescing defect states such as silicates, used as adhesives for composite aerospace applications; and metal oxides commonly used as thermal coating paints on a wide range of spacecraft). The spectra are compared with a database for variation in conjugation, substitution, or length of molecule (in the case of organics) or band edge position (in the case of inorganics). This approach is useful in the understanding of material quality. It lacks the precision in defining the exact chemical structure that is found in other materials analysis techniques, but it is advantageous over methods such as nuclear magnetic resonance, infrared spectroscopy, and chromatography in that it can be used in the field to assess significant changes in chemical structure that may be linked to concerns associated with weaknesses or variations in structural integrity, without disassembly of or destruction to the structure of interest.

Pugel, Betsy↗

Micromechanics and Piezo Enhancements of HyperSizer

The commercial HyperSizer aerospace-composite-material-structure-sizing software has been enhanced by incorporating capabilities for representing coupled thermal, piezoelectric, and piezomagnetic effects on the levels of plies, laminates, and stiffened panels. This enhancement is based on a formulation similar to that of the pre-existing HyperSizer capability for representing thermal effects. As a result of this enhancement, the electric and/or magnetic response of a material or structure to a mechanical or thermal load, or its mechanical response to an applied electric or magnetic field can be predicted. In another major enhancement, a capability for representing micromechanical effects has been added by establishment of a linkage between HyperSizer and Glenn Research Center s Micromechanics Analysis Code With Generalized Method of Cells (MAC/GMC) computer program, which was described in several prior NASA Tech Briefs articles. The linkage enables Hyper- Sizer to localize to the fiber and matrix level rather than only to the ply level, making it possible to predict local failures and to predict properties of plies from those of the component fiber and matrix materials. Advanced graphical user interfaces and database structures have been developed to support the new HyperSizer micromechanics capabilities.

Arnold, Steven M.↗

NASA Tech Briefs, January 2012

Contents of this issue are: (1) Energy-Based Tetrahedron Sensor for High-Temperature, High-Pressure Environments (2) Handheld Universal Diagnostic Sensor (3) Large-Area Vacuum Ultraviolet Sensors (4) Fiber Bragg Grating Sensor System for Monitoring Smart Composite Aerospace Structures (5) Health-Enabled Smart Sensor Fusion Technology (6) Extended-Range Passive RFID and Sensor Tags (7) Hybrid Collaborative Learning for Classification and Clustering in Sensor Networks (8) Self-Healing, Inflatable, Rigidizable Shelter (9) Improvements in Cold-Plate Fabrication (10) Technique for Radiometer and Antenna Array Calibration - TRAAC (11) Real-Time Cognitive Computing Architecture for Data Fusion in a Dynamic Environment (12) Programmable Digital Controller (13) Use of CCSDS Packets Over SpaceWire to Control Hardware (14) Key Decision Record Creation and Approval Module (15) Enhanced Graphics for Extended Scale Range (16) Debris Examination Using Ballistic and Radar Integrated Software (17) Data Distribution System (DDS) and Solar Dynamic Observatory Ground Station (SDOGS) (18) Integration Manager (19) Eclipse-Free-Time Assessment Tool for IRIS (20) Automated and Manual Rocket Crater Measurement Software (21) MATLAB Stability and Control Toolbox Trim and Static Stability Module (22) Patched Conic Trajectory Code (23) Ring Image Analyzer (24) SureTrak Probability of Impact Display (25) Implementation of a Non-Metallic Barrier in an Electric Motor (26) Multi-Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover (27) Uniform Dust Distributor for Testing Radiative Emittance of Dust-Coated Surfaces (28) MicroProbe Small Unmanned Aerial System (29) Highly Stable and Active Catalyst for Sabatier Reactions (30) Better Proton-Conducting Polymers for Fuel-Cell Membranes (31) CCD Camera Lens Interface for Real-Time Theodolite Alignment (32) Peregrine 100-km Sounding Rocket Project (33) SOFIA Closed- and Open-Door Aerodynamic Analyses (34) Sonic Thermometer for High-Altitude Balloons (35) Near-Infrared Photon-Counting Camera for High-Sensitivity Observations (36) Integrated Optics Achromatic Nuller for Stellar Interferometry (37) High-Speed Digital Interferometry (38) Ultra-Miniature Lidar Scanner for Launch Range Data Collection (39) Shape and Color Features for Object Recognition Search (40) Explanation Capabilities for Behavior-Based Robot Control (41) A DNA-Inspired Encryption Methodology for Secure, Mobile Ad Hoc Networks (42) Quality Control Method for a Micro-Nano-Channel Microfabricated Device (43) Corner-Cube Retroreflector Instrument for Advanced Lunar Laser Ranging (44) Electrospray Collection of Lunar Dust (45) Fabrication of a Kilopixel Array of Superconducting Microcalorimeters with Microstripline Wiring Spacecraft Attitude Tracking and Maneuver Using Combined Magnetic Actuators (46) Coherent Detector for Near-Angle Scattering and Polarization Characterization of Telescope Mirror Coatings

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Guided Wave Delamination Detection and Quantification With Wavefield Data Analysis

Unexpected damage can occur in aerospace composites due to impact events or material stress during off-nominal loading events. In particular, laminated composites are susceptible to delamination damage due to weak transverse tensile and inter-laminar shear strengths. Developments of reliable and quantitative techniques to detect delamination damage in laminated composites are imperative for safe and functional optimally-designed next-generation composite structures. In this paper, we investigate guided wave interactions with delamination damage and develop quantification algorithms by using wavefield data analysis. The trapped guided waves in the delamination region are observed from the wavefield data and further quantitatively interpreted by using different wavenumber analysis methods. The frequency-wavenumber representation of the wavefield shows that new wavenumbers are present and correlate to trapped waves in the damage region. These new wavenumbers are used to detect and quantify the delamination damage through the wavenumber analysis, which can show how the wavenumber changes as a function of wave propagation distance. The location and spatial duration of the new wavenumbers can be identified, providing a useful means not only for detecting the presence of delamination damage but also allowing for estimation of the delamination size. Our method has been applied to detect and quantify real delamination damage with complex geometry (grown using a quasi-static indentation technique). The detection and quantification results show the location, size, and shape of the delamination damage.

Tian, Zhenhua↗

In Situ Thermal Inspection of Automated Fiber Placement Operations for Tow and Ply Defect Detection

The advent of Automated Fiber Placement (AFP) systems have aided the rapid manufacturing of composite aerospace structures. One of the challenges that AFP systems pose is the uniformity of the deposited prepreg tape layers, which complicates detection of laps, gaps, overlaps and twists. The current detection method used in industry involves halting fabrication and performing a time consuming, visual inspection of each tape layer. Typical AFP systems use a quartz lamp to heat the base layer to make the surface tacky as it deposits another tape layer. The innovation proposed in this paper is to use the preheated base layer as a through-transmission heat source for inspecting the newly added tape layer in situ using a thermographic camera mounted on to the AFP hardware. Such a system would not only increase manufacturing throughput by reducing inspection times, but it would also aid in process development for new structural designs or material systems by providing data on as-built parts. To this end, a small thermal camera was mounted onto an AFP robotic research platform at NASA, and thermal data was collected during typical and experimental layup operations. The data was post processed to reveal defects such as tow overlap/gap, wrinkling, and peel-up. Defects that would have been impossible to detect visually were also discovered in the data, such as poor/loss of adhesion between plies and the effects of vacuum debulking. This paper will cover the results of our experiments, and the plans for future versions of this inspection system.

Juarez, Peter D.↗

Thermomechanical Property Prediction of Amorphous and Crystal PEKK via Molecular Dynamics

Traditionally, advanced aerospace composites have been manufactured using thermoset resins. However, recently, thermoplastics have been investigated for use in the manufacturing of composite materials due to their unique manufacturing characteristics. Thermoplastic resins can be reshaped and formed, along with the added benefit of being recyclable, which thermoset resin cannot. Thermoplastic materials undergo a crystallization process during manufacturing which affects the percent crystallinity of the material. The crystallization needs to be understood better to maximize the potential of thermoplastic resins. PEKK is a thermoplastic material with good chemical, thermal, and mechanical loading resistance. PEKK is also a material NASA is interested in for developing new bonded joint technology. The crystalline microstructure of PEKK is at the micrometer length scale, and it is of interest to model the effects of the crystallinity structure on PEKK’s bulk properties. Molecular dynamics (MD) is a simulation tool that allows for property-structure relationships between atomistic structure and nanometer-length portions of a material. This makes MD a useful tool for developing the structure-property relationship of PEKK. However, the micrometer length scale of PEKK’s crystal structure is too large for MD. Thus, a hybrid approach to modeling PEKK’s microstructure is proposed in this work where MD models are built of both the amorphous and crystalline phases of PEKK. The engineering material properties can be obtained using MD at the nanometer length scale. A micromechanics approach can then generate the micrometer length scale of the crystallinity and the effective properties can be homogenized. The objective of this paper is to show the MD model workflow and the MD-predicted properties of PEKK. The properties can then be homogenized with different crystalline percentages to build design graphs that can be used to tailor PEKK for specific composite applications.

poly ether ketone ketone↗

Multiscale Modeling of Thermoplastics Using Atomistic-informed Micromechanics

A multiscale model was developed for predicting the thermoelastic behavior of semi-crystalline thermoplastic materials for composite aerospace applications. At the highest scale containing the semi-crystalline spherulite in an amorphous matrix, the generalized method of cells, or high fidelity method of cells, was used to perform the homogenization calculations to obtain the effective properties. Models were developed assuming a cubic, or spherical shape, for the spherulite to understand if the morphology of the spherulite affects the effective thermoelastic properties. The generalized method of cells was used to model at the repeating unit cells at the subscales of the microstructure including the lamellae stacks and granular crystal blocks. The scales are integrated using the multiscale micromechanics method in the NASA Multiscale Analysis Tool. Data from molecular dynamics simulations were used as inputs for the amorphous and crystalline constituents. Convergence studies were performed to determine the best level of discretization for the repeating unit cell at the highest scale. Effective Young’s modulus, shear modulus, Poisson’s ratio, coefficient of thermal expansion, and thermal conductivity were predicted for polyether ether ketone and polyether ketone ketone, and very good agreement between the model utilizing the cubic spherulite and the experimental data, where available, was observed for polyether ketone ketone. Normalization of the data for the bulk polyether ketone ketone, against amorphous data, improved the predictions as compared to experimental data. Overall, the high fidelity method of cells predicted a stiffer response then the generalized method of cells as the crystallinity was increased. The shape of the spherulite had a minimal effect on the predicted bulk properties of the polymers.

thermoplastics↗

The Inspectability Metric: A Formalized System Of Measurement Enabling The Design For Inspection Framework

Nondestructive evaluation (NDE) engineers are often confronted with structural design choices that present challenges to meeting inspection requirements. These challenges, at best, increase the resources needed to design an inspection solution and, at worst, require resource intensive redesign of the structure. If the inspectability of the structure can be determined early in the design cycle, these challenging inspection scenarios can be avoided. The emergence of additive manufacturing has further compounded this problem by enabling the creation of highly optimized structures with no regard to inspection constraints. Design for inspection (DFI) offers a framework to integrate nondestructive evaluation (NDE) into the design process to alleviate the mechanisms that produce uninspectable designs. DFI is the concept of including inspectability in a multi-objective optimization framework so that it can be considered in parallel to other metrics such as mass and manufacturability. This allows rapid evaluation of the trade-off between design metrics to find solutions that meet the inspection needs of a particular material system, structural concept, or vehicle program. To enable DFI, there must be a system by which the inspectability of a structure can be measured. This system must be agile to produce results quickly, it must be versatile to work with the type of incomplete information one would encounter early in the design process (such as lack of inspection requirements), and it must be delivered in a form that is easily understood by designers. To meet this need, this presentation introduces the novel inspectability metric as a system to measure inspectability. The inspectability metric is a standardized, automation friendly procedure that uses simulations to determine inspectability. Along with guidelines to properly process designs and integrate with existing workflows, the inspectability metric provides a suite of simulation tests to interrogate the ability to find defects and the sensitivity to variability. The testing rubric is designed to maximize the coverage of the parameter space while minimizing the number of simulations needed. The inspectability metric has been in development in collaboration with industry partners to ensure compatibility with modern simulation tools and aerospace design workflows. In this study, we will demonstrate how the inspectability metric is able to determine the inspectability of multiple types of structures, including aerospace composites and additively manufactured parts. We will then show how the inspectability score can be plugged into existing design optimization tasks, such as structural sizing algorithms or design for manufacturing (DFM) frameworks.

Design for inspection↗

Multiscale Modeling of Thermoplastics Using Atomistic-informed Micromechanics

A multiscale repeating unit cell model of a single spherulite containing four disparate length scales was developed to predict the thermoelastic behavior of semicrystalline thermoplastic materials for composite aerospace applications. The continuum level scales were fully coupled and modeled using the generalized method of cells and the high fidelity generalized method of cells micromechanics theories. Data from molecular dynamics simulations were used as inputs for the amorphous and crystalline constituents in the multiscale continuum models. Effective Young’s modulus, shear modulus, Poisson’s ratio, coefficient of thermal expansion, and thermal conductivity were predicted for polyether ether ketone and polyether ketone ketone, showing good agreement with the available experimental data from the open literature. Moreover, it is shown that predicted properties are fairly insensitive to the fidelity of the micromechanics model used at the highest continuum scale or the assumed shape of the spherulite.

thermoplastics↗

Computational composite mechanics for aerospace propulsion structures

Specialty methods are presented for the computational simulation of specific composite behavior. These methods encompass all aspects of composite mechanics, impact, progressive fracture and component specific simulation. Some of these methods are structured to computationally simulate, in parallel, the composite behavior and history from the initial fabrication through several missions and even to fracture. Select methods and typical results obtained from such simulations are described in detail in order to demonstrate the effectiveness of computationally simulating (1) complex composite structural behavior in general and (2) specific aerospace propulsion structural components in particular.

Chamis, C. C.↗

Computational composite mechanics for aerospace propulsion structures

Specialty methods are presented for the computational simulation of specific composite behavior. These methods encompass all aspects of composite mechanics, impact, progressive fracture and component specific simulation. Some of these methods are structured to computationally simulate, in parallel, the composite behavior and history from the initial frabrication through several missions and even to fracture. Select methods and typical results obtained from such simulations are described in detail in order to demonstrate the effectiveness of computationally simulating: (1) complex composite structural behavior in general, and (2) specific aerospace propulsion structural components in particular.

Chamis, Christos C.↗

Impact Simulation of Composite Panels for Aerospace Applications

The aerospace research community has been working towards the development of a comprehensive framework for the design of composite structures at the component, subassembly, assembly, and system levels. Such a framework requires accurate, efficient and easy-to-use mathematical and computational models that are in sync with physical reality. The research work in this paper is designed to help an aerospace structural engineer move towards this goal by simulating dynamic impact to composite panels. First, the existing orthotropic visco-elastic visco-plastic material model in LS-DYNA commercial finite element program, MAT_COMPOSITE_TABULATED_PLASTICITY_DAMAGE (MAT_213) is enhanced with the development and use of rate-dependent damage data. Using state-of-the-art experimental procedures, impact validation test data are created. Second, the versatility of the constitutive model is examined by its ability to simulate a low velocity (27 ft/s, 8 m/s) impact test, and two high velocity impact tests (385–417 ft/s, 117–127 m/s) that straddle the ballistic limit of the projectile and the composite panels. Third, these impact events are modeled using three different finite element types – under-integrated and fully-integrated solid elements, and fully-integrated thin shell elements. Insight into accuracy versus numerical efficiency is gained by comparing the performance of solid versus thin shell elements. The numerical results show that accurate predictions of these impact events can be obtained with reasonable effort and care.

Simulations↗

Custom Machines Advance Composite Manufacturing

Here is a brief list of materials that NASA will not be using to construct spacecraft: wood, adobe, fiberglass, bone. While it might be obvious why these materials would not make for safe space travel, they do share a common characteristic with materials that may well be the future foundation of spacecraft design: They all are composites. Formed of two or more unlike materials - such as cellulose and lignin in the case of wood, or glass fibers and plastic resin in the case of fiberglass-composites provide enhanced mechanical and physical properties through the combination of their constituent materials. For this reason, composites are used in everything from buildings, bathtubs, and countertops to boats, racecars, and sports equipment. NASA continually works to develop new materials to enable future space missions - lighter, less expensive materials that can still withstand the extreme demands of space travel. Composites such as carbon fiber materials offer promising solutions in this regard, providing strength and stiffness comparable to metals like aluminum but with less weight, allowing for benefits like better fuel efficiency and simpler propulsion system design. Composites can also be made fatigue tolerant and thermally stable - useful in space where temperatures can swing hundreds of degrees. NASA has recently explored the use of composites for aerospace applications through projects like the Composite Crew Module (CCM), a composite-constructed version of the aluminum-lithium Multipurpose Crew Capsule. The CCM was designed to give NASA engineers a chance to gain valuable experience developing and testing composite aerospace structures.

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